Hyster H/S/1.50-1.75XM Manual
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Hyster H/S/1.50-1.75XM Manual

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MAST
REPAIRS
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];
E1.50-1.75XM (E25-35XM, E25-35XM
) [D114];
2
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM
S) [D114];
2
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM
) [F108];
2
J2.00-3.20XM (J40-60XM, J40-60XM
) [A216];
2
J2.00-3.20XM (J40-60Z) [A416];
S/J2.00-3.00XL With Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177]; J30-40XMT
[H160];
2
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E40-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]
PART NO. 897507
4000 SRM 522

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  • Page 1 MAST REPAIRS H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001]; E1.50-1.75XM (E25-35XM, E25-35XM ) [D114]; H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001]; E2.00XMS (E40XMS, E40XM S) [D114]; H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187]; E2.00-3.20XM (E40-65XM, E40-65XM ) [F108]; J2.00-3.20XM (J40-60XM, J40-60XM ) [A216]; J2.00-3.20XM (J40-60Z) [A416];...
  • Page 2 • 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.

  • Page 3: Table Of Contents

    Three-Stage FFL Mast, New Hose Install ....................Three-Stage FFL Mast, Adjust Hoses After Install..................Lift and Tilt System Leak Check ........................Lift Cylinders Leak Check ..........................Tilt Cylinders Leak Check ..........................Tilt Cylinders Adjustment..........................Lift Chains Adjustment ............................. ©2003 HYSTER COMPANY...
  • Page 4 TABLE OF CONTENTS (Continued) Mast Adjustment ............................... Carriage Adjustment ............................Troubleshooting..............................This section is for the following models: H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001]; E1.50-1.75XM (E25-35XM, E25-35XM ) [D114]; H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001]; E2.00XMS (E40XMS, E40XM S) [D114];...

  • Page 5: General

    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.
  • Page 6 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...

  • Page 7: Forks Repair

    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.

  • Page 8: Carriages Repair

    Carriages Repair 4000 SRM 522 Legend for Figure 3 A. EARLIER MODELS B. LATER MODELS 1. FORKS 6. LEVER 2. CARRIAGE 7. WASHER 3. LOAD BACKREST EXTENSION 8. SPRING 4. FORK REMOVAL NOTCH 9. PIN 5. LATCH PIN ASSEMBLY 10. KNOB Carriages Repair STANDARD CARRIAGE, REMOVE 1.

  • Page 9: Hang-On Sideshift Carriage, Remove

    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.

  • Page 10: Standard Carriage And Hang-On Sideshift Carriage, Repair

    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.

  • Page 11: Hang-On Sideshift Carriage, Install

    4000 SRM 522 Carriages Repair weldment. Connect a crane [the capacity of the 6. Install the shim strips under the bottom bearing crane must be at least 681 kg (1501 lb)] to the top strip (be sure the shims are seated between the of the inner mast weldment.
  • Page 12 Carriages Repair 4000 SRM 522 NOTE: TWO AND THREE-STAGE FFL IS SHOWN. 1. INNER CARRIAGE 9. CLEVIS PIN 17. COTTER PIN 2. OUTER FRAME 10. HAIRPIN 18. LOAD ROLLER 3. SIDESHIFT CYLINDER 11. PIN 19. SHIMS 4. UPPER BEARING 12. LUBE FITTING 20.

  • Page 13: Clean And Inspect

    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.

  • Page 14: Install

    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.
  • Page 15 4000 SRM 522 Mast Repair NOTE: To perform the next two steps, the lift truck 5. On the H/S1.50-1.75XM, H/S2.00XMS (H/S25- must be raised. See the Operator Manual or Pe- 35XM, H/S40XMS), E1.50-1.75XM (E25-35XM, riodic Maintenance Manual for your lift truck for E25-35XM (D114), E2.00XMS...

  • Page 16: Two-Stage Lfl And Two-Stage Ffl Masts, Disassemble

    Mast Repair 4000 SRM 522 Legend for Figure 12 1. RETAINER CAP 6. NUT 2. LOCKWASHER 7. PIN 3. TILT CYLINDER 8. ROD END 4. OUTER MAST 9. WASHER WELDMENT 10. CAPSCREW 5. BUSHING WARNING The mast is heavy. The mast can weigh approx- imately 907.2 kg (2000 lb).
  • Page 17 4000 SRM 522 Mast Repair disengage the main lift cylinders from the inner WARNING mast weldment. Remove the main lift cylinders Be careful when removing or installing snap from the outer mast weldment. See Figure 13 rings. These snap rings can come loose dur- and Figure 14.
  • Page 18 Mast Repair 4000 SRM 522 Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)
  • Page 19 4000 SRM 522 Mast Repair Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 2 of 2)
  • Page 20 Mast Repair 4000 SRM 522 Legend for Figure 13 A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM ) (F108), E2.00-3.20XM (E40-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM ) (A216), J2.00-3.20XM (J40-60Z) (A416), AND S/E/J2.00-3.00XL (S/E/J40-60XL), SHOWN. B. MODELS H/S1.50-2.00XMS (H/S25-40XMS), E1.50-2.00XMS (E25-40XMS, E25-40XM S) (D114), E1.50-2.00XM (E25-35Z, E40ZS) (E114), AND J1.60-2.00XMT (J30-40XMT) SHOWN.
  • Page 21 4000 SRM 522 Mast Repair Figure 14. Two-Stage, Full Free-Lift Mast (Sheet 1 of 2)
  • Page 22 Mast Repair 4000 SRM 522 Figure 14. Two-Stage, Full Free-Lift Mast (Sheet 2 of 2)

  • Page 23: Three-Stage Ffl Mast

    4000 SRM 522 Mast Repair Legend for Figure 14 A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM ) (F108), E2.00-3.20XM (E40-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM ) (A216), J2.00-3.20XM (J40-60Z) (A416), AND S/E/J2.00-3.00XL (S/E/J40-60XL), SHOWN. B. MODELS H/S1.50-2.00XMS (H/S25-40XMS), E1.50-2.00XMS (E25-40XMS, E25-40XM S) (D114), E1.50-2.00XM (E25-35Z, E40ZS) (E114), AND J1.60-2.00XMT (J30-40XMT) SHOWN.
  • Page 24 Mast Repair 4000 SRM 522 8. Slide the intermediate mast weldment from the WARNING bottom of the outer mast weldment approxi- The mast is heavy. The mast can weigh ap- mately 30 cm (12 in.). Remove the strip bearings proximately 681 kg (1501 lb). Make sure all lift- at the top of the outer mast weldment.
  • Page 25 4000 SRM 522 Mast Repair Figure 16. Three-Stage, Full Free-Lift Mast (Sheet 1 of 2)
  • Page 26 Mast Repair 4000 SRM 522 A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM ) (F108), E2.00-3.20XM (E40-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM ) (A216), J2.00-3.20XM (J40-60Z) (A416), AND S/E/J2.00-3.00XL (S/E/J40-60XL), SHOWN. B. MODELS H/S1.50-2.00XMS (H/S25-40XMS), E1.50-2.00XMS (E25-40XMS, E25-40XM S) (D114), E1.50-2.00XM (E25-35Z, E40ZS) (E114), AND J1.60-2.00XMT (J30-40XMT) SHOWN. C.

  • Page 27: Mast And Chains, Clean And Inspect

    4000 SRM 522 Mast Repair Mast and Chains, Clean and Inspect 5. Clean the mast weldments with steam or solvent. 1. Inspect the chain sheaves and load rollers for wear or damage. Do NOT use steam to clean the lift chains, sheaves, or load rollers. The bearings in the sheaves and load rollers are sealed and lu- bricated.

  • Page 28: Two-Stage Lfl And Two-Stage Ffl Mast, Assemble

    Mast Repair 4000 SRM 522 TWO-STAGE LFL AND TWO-STAGE FFL 3. Install the load rollers and shims on both weld- ments. Check the clearance of the load rollers as MAST, ASSEMBLE described in Carriage Adjustment. WARNING 4. To install the main lift cylinders on the two-stage LFL mast, push the inner mast weldment to en- The mast is heavy.

  • Page 29: Three-Stage Ffl Mast, Assemble

    4000 SRM 522 Mast Repair Connect the hydraulic lines and fittings between weldment so the stub shafts are seen at the top the lowering control valve and the main lift cylin- and bottom of both weldments. ders. NOTE: The load rollers must be in place before strip 8.

  • Page 30: Install

    Mast Repair 4000 SRM 522 8. Connect a crane with a capacity of at least 681 kg them into the mounts on the mast. On the (1501 lb) to the center of the inner mast weld- J1.60-2.00XMT (J30-40ZT) lubricate the bush- ment.

  • Page 31: Lift Cylinders Repair

    4000 SRM 522 Lift Cylinders Repair caps. Tighten the capscrews to 34.8 N•m shown in Figure 19. Apply chassis lube only to (25.7 lbf ft). the surfaces indicated. NOTE: Lubricate the anchor pins with chassis grease before installation. 4. Connect the tilt cylinders to the mast. Install the anchor pins and/or cotter pins, washers, or capscrews.

  • Page 32: Free-Lift Cylinder, Remove

    Lift Cylinders Repair 4000 SRM 522 FREE-LIFT CYLINDER, REMOVE 4. Remove the crosshead from the cylinder rod. See Figure 20. Disassemble the crosshead as neces- 1. Remove the carriage as described in the proce- sary. dures for Carriages Repair. Lower the mast com- pletely.
  • Page 33 4000 SRM 522 Lift Cylinders Repair A. RIGHT-HAND CYLINDER B. LEFT-HAND CYLINDER 1. SHELL 7. O-RING 2. ROD AND PISTON 8. WEAR RING 3. WIPER 9. PISTON RING 4. ROD SEAL 10. SCREW* 5. RETAINER 11. SEALING WASHER* 6. BACKUP RING 12.
  • Page 34 Lift Cylinders Repair 4000 SRM 522 1. SHELL 9. BACKUP RING 2. SNAP RING 10. ROD 3. WASHER 11. SPACER 4. O-RING 12. O-RING 5. CHECK VALVE 13. WEAR RING 6. PISTON RING 14. RETAINER (THREE-STAGE 15. SEAL FFL ONLY) 16.

  • Page 35: Lift Cylinders, Assemble

    Figure 21 and Figure 24. 1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil or packing lubricant, Hyster Part No. 186061. Use new O-rings, seals, and wear rings. 2. Install the check valve and O-ring in the base of the piston.

  • Page 36: Main Lift Cylinders, Install

    Lift Cylinders Repair 4000 SRM 522 MAIN LIFT CYLINDERS, INSTALL a. Loosen the screws two turns to permit oil to flow around the threads of the screw. 1. Use a crane with a capacity of at least 1600 kg (3527 lb) to raise the mast until it is almost fully b.

  • Page 37: Header Hose Arrangements

    4000 SRM 522 Header Hose Arrangements Header Hose Arrangements NOTE: This is for H/S2.00-3.20XM (H/S40-65XM), 2. Use a calculator to calculate dimension E. See E2.00-3.20XM (E40-65XM, E40-65XM ) (F108), Figure 25. E2.00-3.20XM (E40-65Z) (G108), J2.00-3.20XM 3. Clamp the end of the hose (the smaller fitting) (J40-60XM, J40-60 ) (A216), J2.00-3.20XM (J40- that attaches to the carriage in a vise (do not...
  • Page 38 Header Hose Arrangements 4000 SRM 522 Figure 25. Header Hose Measurement, Two-Stage Limited Free-Lift Mast...
  • Page 39 4000 SRM 522 Header Hose Arrangements Legend for Figure 25 * Metric Formulas (All Dimensions are in Millimeters) @ Dimension E = (0.985 × Z) + (0.985 × Y) + 244 # Dimension E = (0.985 × Z) + (0.985 × Y) + 220 % Dimension E = (0.985 ×...
  • Page 40 Header Hose Arrangements 4000 SRM 522 Figure 26. Header Hoses, Two-Stage Limited Free-Lift Mast...
  • Page 41 4000 SRM 522 Header Hose Arrangements Legend for Figure 26 A. ALIGN MARK E AT BOTTOM OF THIS CLAMP 1. SPECIAL WASHER 7. COWL HOSES 2. HOSE SHEAVE 8. BOTTOM CLAMP 3. HOSE GUARD 9. HEADER HOSES 4. WASHER 10. BRACKET, UPPER 5.

  • Page 42: Two-Stage Lfl Mast, Adjust Hoses After Installation

    Header Hose Arrangements 4000 SRM 522 e. Lower the crane until there is tension in the WARNING safety chain. Make sure both hooks are prop- Mast parts are heavy and can move. Distances erly engaged before working on the mast. In- between parts are small.

  • Page 43: Two-Stage Ffl Mast, New Hose Install

    4000 SRM 522 Header Hose Arrangements TWO-STAGE FFL MAST, NEW HOSE 7. Put the clamps over the hoses and attach the clamps to the lower bracket (do NOT tighten the INSTALL hardware). WARNING NOTE: To make the alignment of dimension E easier, Before working on or near the mast, see Safety use a crane with a capacity of at least 908 kg (2002 lb) Procedures When Working Near Mast in this...
  • Page 44 Header Hose Arrangements 4000 SRM 522 Figure 28. Header Hose Measurement, Two-Stage Full Free-Lift Mast...
  • Page 45 4000 SRM 522 Header Hose Arrangements Legend for Figure 28 * Metric Formulas (All Dimensions are in Millimeters) Class II Mast Type Dimension E = (0.492 × Y) + (0.985 × Z) + 303 Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303 Step 1.
  • Page 46 Header Hose Arrangements 4000 SRM 522 Legend for Figure 28 (Continued) * Metric Formulas (All Dimensions are in Millimeters) Class III Mast Type 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.
  • Page 47 4000 SRM 522 Header Hose Arrangements NOTE: FOUR-FUNCTION MAST SHOWN. A. ALIGN MARK E AT BOTTOM OF THIS CLAMP 1. HOSE CHANNEL 8. TUBE 15. BOTTOM CLAMP 21. STUBSHAFT 2. COWL HOSES 9. FITTING 16. HOSE GUIDE 22. SHEAVE 3. HEADER HOSES 10.
  • Page 48 Header Hose Arrangements 4000 SRM 522 Figure 30. Header Hose Alignment, Two-Stage Full Free-Lift Mast...

  • Page 49: Two-Stage Ffl Mast, Adjust Hoses After Installation

    4000 SRM 522 Header Hose Arrangements 13. With no load on the forks, operate the mast NOTE: The carriage height must be correct before the through the full lift cycle two times. With the header hoses can be adjusted. See Lift Chains Ad- mast at full lift height, attach clamp at the bot- justment for the carriage adjustment procedure.
  • Page 50 Header Hose Arrangements 4000 SRM 522 Figure 31. Header Hose Measurement, Three-Stage Full Free-Lift Mast...
  • Page 51 4000 SRM 522 Header Hose Arrangements Legend for Figure 31 * Metric Formulas (All Dimensions are in Millimeters) Class II Mast Types Dimension E = (0.985 × Y) + (0.985 × Z) 350** Example: Dimension E = (0.985 × Y) + (0.985 × Z) Step 1.
  • Page 52 Header Hose Arrangements 4000 SRM 522 Legend for Figure 31 (Continued) * Metric Formulas (All Dimensions are in Millimeters) Class III Mast Type 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 II Mast - Metric Formula.
  • Page 53 4000 SRM 522 Header Hose Arrangements Figure 32. Header Hoses, Three-Stage Full Free-List Mast...
  • Page 54 Header Hose Arrangements 4000 SRM 522 Legend for Figure 32 NOTE: THREE-FUNCTION MAST SHOWN. 1. CAPSCREW 13. LOWER HOSE GUIDE 2. HOSE GUARD 14. NUT 3. SNAP RING 15. BOTTOM CLAMP 4. HOSE GUIDE 16. HEADER HOSES 5. FREE-LIFT CYLINDER CROSSHEAD 17.
  • Page 55 4000 SRM 522 Header Hose Arrangements Figure 33. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 1 of 3)
  • Page 56 Header Hose Arrangements 4000 SRM 522 Figure 33. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 2 of 3)
  • Page 57 4000 SRM 522 Header Hose Arrangements A. HOSE A F. FORKS B. HOSE B G. FRONT VIEW C. HOSE C H. LEFT-HAND CYLINDER D. HOSE D ALIGN MARK E AT BOTTOM OF THIS CLAMP. E. ALIGN MARK G ON HOSES A AND D AT J.
  • Page 58 Header Hose Arrangements 4000 SRM 522 8. SAFETY CHAIN INSTALLATION WHEN WARNING THE CARRIAGE IS RAISED: Mast parts are heavy and can move. Distances a. Put the mast in a vertical position. between parts are small. Serious injury or death can result if part of the body is hit by b.
  • Page 59 4000 SRM 522 Header Hose Arrangements 1. HOOK 2. SHACKLE Figure 34. Safety Chain Installation, Two-Stage Full Free-Lift and Three-Stage Full Free-Lift Mast (Sheet 2 of 2) 9. SAFETY CHAIN INSTALLATION WHEN e. Attach the other end of the chain around THE INNER CHANNEL IS RAISED: the lower crossmember of the inner channel.

  • Page 60: Three-Stage Ffl Mast, Adjust Hoses After Installation

    Header Hose Arrangements 4000 SRM 522 11. Position the hoses at the hose sheave. See Fig- any crossmember that is next to a sheave. If the ure 32 and Figure 33. The hose sheave and hose hoses require additional adjustment, see Three- guard must be installed on to the hose before they Stage FFL Mast, Adjust Hoses After Installation.

  • Page 61: Header Hose Arrangement

    4000 SRM 522 Header Hose Arrangement Header Hose Arrangement NOTE: This is the Header Hose Arrangement NOTE: This procedure is for the four-function option. for H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM, The three-function option will have hoses A and B H/S40XMS), E1.50-1.75XM (E25-35XM, E25- only.
  • Page 62 Header Hose Arrangement 4000 SRM 522 Figure 35. Header Hose Measurement, Two-Stage Limited Free-Lift Mast...
  • Page 63 4000 SRM 522 Header Hose Arrangement Legend for Figure 35 * 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.
  • Page 64 Header Hose Arrangement 4000 SRM 522 Figure 36. Header Hoses, Two-Stage Limited Free-Lift Mast...

  • Page 65: Two-Stage Lfl Mast, Adjust Hoses After Installation

    4000 SRM 522 Header Hose Arrangement Legend for Figure 36 A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE 1. HOSES, HEADER 12. NUT 2. CLAMP, STRAP 13. CAPSCREW 3. FITTINGS 14. CLAMP 4. CAPSCREW 15. WASHER 5.
  • Page 66 Header Hose Arrangement 4000 SRM 522 Figure 37. Header Hose Measurement, Two-Stage Full Free-Lift Mast...
  • Page 67 4000 SRM 522 Header Hose Arrangement Legend for Figure 37 * Metric Formulas (All Dimensions are in Millimeters) Class II Mast Type Dimension E = (0.492 × Y) + (0.985 × Z) + 303 Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303 Step 1.
  • Page 68 Header Hose Arrangement 4000 SRM 522 Legend for Figure 37 (Continued) * Metric Formulas (All Dimensions are in Millimeters) Class III Mast Type 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.
  • Page 69 4000 SRM 522 Header Hose Arrangement Figure 38. Header Hoses, Two-Stage Full Free-Lift Mast...

  • Page 70: Two-Stage Ffl Mast, Adjust Hoses After Installation

    Header Hose Arrangement 4000 SRM 522 Legend for Figure 38 NOTE: THREE-FUNCTION MAST SHOWN. A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE 1. CHANNEL 14. CARRIAGE BRACKET 2. COWEL HOSES 15. LOWER CLAMP 3. HEADER HOSES 16.
  • Page 71 4000 SRM 522 Header Hose Arrangement Figure 39. Header Hose Alignment, Two-Stage Full Free-Lift Mast...

  • Page 72: Three-Stage Ffl Mast, New Hose Install

    Header Hose Arrangement 4000 SRM 522 THREE-STAGE FFL MAST, NEW HOSE NOTE: To make the alignment of dimension E easier, use a crane with a capacity of at least 908 kg (2002 lb) INSTALL to raise the carriage high enough to attach a safety chain as shown in Figure 34.
  • Page 73 4000 SRM 522 Header Hose Arrangement Figure 40. Header Hose Measurement, Three-Stage Full Free-Lift Mast...
  • Page 74 Header Hose Arrangement 4000 SRM 522 Legend for Figure 40 * Metric Formulas (All Dimensions are in Millimeters) Class II Mast Type Dimension E = (0.985 × Y) + (0.985 × Z) 350** Example: Dimension E = (0.985 × Y) + (0.985 × Z) Step 1.
  • Page 75 4000 SRM 522 Header Hose Arrangement Legend for Figure 40 (Continued) * Metric Formulas (All Dimensions are in Millimeters) Class III Mast Type 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 II Mast - Metric Formula.
  • Page 76 Header Hose Arrangement 4000 SRM 522 Figure 41. Header Hoses, Three-Stage Full Free-Lift Mast...
  • Page 77 4000 SRM 522 Header Hose Arrangement Legend for Figure 41 NOTE: THREE-FUNCTION MAST SHOWN. A. OLD STYLE 1. CAPSCREW 14. NUT 2. HOSE GUARD 15. CLAMP 3. SNAP RING 16. HEADER HOSES 4. HOSE GUIDE 17. FREE-LIFT CHAINS 5. FREE-LIFT CYLINDER CROSSHEAD 18.
  • Page 78 Header Hose Arrangement 4000 SRM 522 Figure 42. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 1 of 3)
  • Page 79 4000 SRM 522 Header Hose Arrangement Figure 42. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 2 of 3)

  • Page 80: Three-Stage Ffl Mast, Adjust Hoses After Install

    Header Hose Arrangement 4000 SRM 522 A. HOSE A G. LEFT-HAND CYLINDER B. HOSE B H. ALIGN MARK E AT BOTTOM OF THIS CLAMP. C. HOSE C REAR VIEW D. HOSE D J. RIGHT-HAND CYLINDER E. FRONT VIEW K. FORKS F.

  • Page 81: Lift And Tilt System Leak Check

    4000 SRM 522 Lift and Tilt System Leak Check to 8 N•m (71 lbf in). See Figure 34, Figure 40, 3. With no load on the forks, check the header hose Figure 41, and Figure 42. adjustment by operating the mast through the full lift cycle two times.

  • Page 82: Tilt Cylinders Adjustment

    Tilt Cylinders Adjustment 4000 SRM 522 Tilt Cylinders Adjustment c. Slowly tilt the mast backward until one rod WARNING end just contacts the spacer. Add shims to When the tilt cylinders have tilt limit spacers, fill the gap at the opposite rod end until both make sure they are installed during installa- rod ends contact the spacers within 0.5 mm tion procedures.

  • Page 83: Lift Chains Adjustment

    4000 SRM 522 Lift Chains Adjustment 1. MAST 4. TILT LIMIT SPACER 1. MAST 3. TILT CYLINDER 2. ROD END 5. TILT CYLINDER 2. ROD ENDS 3. SHIMS Figure 45. Tilt Cylinder Adjustment Figure 44. Tilt Cylinder Adjustment J1.60-2.00XMT (J30-40ZT) H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM ) (F108), E2.00-3.20XM...
  • Page 84 Lift Chains Adjustment 4000 SRM 522 1. When adjusting the lift chains on forklift trucks carriage bar is above the floor level as shown in equipped with either pin- or hook-type forks in- Table 1. stalled, go to Step 2. If the forklift truck is nor- Table 1.
  • Page 85 4000 SRM 522 Mast Adjustment Legend for Figure 48 1. LOAD BACK REST 2. FORK PIN 3. DISTANCE FROM FORK PIN TO FLOOR Figure 48. Lift Chain Adjustment, Pin-Type Carriage Mast Adjustment NOTE: Shims are installed on both sides of the load b.
  • Page 86 Mast Adjustment 4000 SRM 522 b. Separate the mast weldments and change Change shims to keep the distance equal be- the shim arrangements as needed. Assemble tween the top and bottom of the mast weld- the mast weldments. Slide the mast weld- ments.
  • Page 87 4000 SRM 522 Troubleshooting Carriage Adjustment 1. Install the load rollers on the carriage. Install 3. Remove the carriage from the mast. Adjust the the shims for the rollers in the same sequence on shim arrangement for each load roller for clear- the stub shaft as before disassembly.
  • Page 88 Troubleshooting 4000 SRM 522 PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Rough movement of the mast There is air in the hydraulic system. Remove air. Check for loose connec- assembly. tions or breaks in lines. Lift cylinder(s) is damaged. Repair or install new lift cylinder. Mast weldments are damaged or not Align weldments.
  • Page 90 TECHNICAL PUBLICATIONS 4000 SRM 522 11/03 (3/03)(5/01)(5/96)(11/94)(7/94)(2/94)(11/93)(4/93) Printed in U.S.A.

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