Torre de Carga 2007 PDF

MAST REPAIRS
2 AND 3-STAGE MASTS

S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [G004]; H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005]; E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) [E098]; S6.0FT,
S7.0FT, (S135FT, S155FT) [D024]; H6.0FT,
H7.0FT, (H135FT, H155FT) [H006]
PART NO. 1627340 4000 SRM 1250

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Mast Repairs Table of Contents
TABLE OF CONTENTS
Safety Procedures When Working Near Mast.................................................................................................... 1

Fork Repair .......................................................................................................................................................... 3
Remove ............................................................................................................................................................. 3
Install ............................................................................................................................................................... 4
Checks .............................................................................................................................................................. 4
Carriage Replacement ......................................................................................................................................... 5
Remove ............................................................................................................................................................. 5
Install ............................................................................................................................................................... 5
Integral Sideshift Carriage Repair ................................................................................................................... 11
Remove, for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) ............................... 11
Disassemble ................................................................................................................................................... 11
Assemble ........................................................................................................................................................ 14
Install, for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) ............................... 14
Hang On Sideshift Carriage Repair.................................................................................................................. 14
Remove, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006) ............................................................................................................................ 14
Disassemble ................................................................................................................................................... 20
Cylinders, Disassemble ................................................................................................................................. 23
Sideshift Cylinder...................................................................................................................................... 23
Fork Positioner Cylinders ......................................................................................................................... 24
Clean and Inspect .......................................................................................................................................... 24
Cylinders, Assemble ...................................................................................................................................... 25
Fork Positioner Cylinders ......................................................................................................................... 25
Sideshift Cylinder...................................................................................................................................... 25
Assemble ........................................................................................................................................................ 26
Install ............................................................................................................................................................. 26
Two-Stage Mast With Limited Free-Lift Repair .............................................................................................. 27
Remove ........................................................................................................................................................... 27
Disassemble ................................................................................................................................................... 28
Assemble ........................................................................................................................................................ 39
Install, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) and
H6.0FT, H7.0FT (H135FT, H155FT) (H006) Lift Truck Models ................................................................. 40
Install, S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) Lift Trucks Models.............................................................................................................. 41
Header Hose Alignment ................................................................................................................................ 51
Two-Stage Mast With Full Free-Lift Repair..................................................................................................... 61
Remove ........................................................................................................................................................... 61
Disassemble ................................................................................................................................................... 61
Assemble ........................................................................................................................................................ 68
Install ............................................................................................................................................................. 70
Header Hose Installation and Adjustment .................................................................................................. 75
Installation ................................................................................................................................................ 75
Adjustment ................................................................................................................................................ 75
Three-Stage Mast With Full Free-Lift Repair.................................................................................................. 76
©2007 HYSTER COMPANY i

Table of Contents Mast Repairs
TABLE OF CONTENTS (Continued)

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

S120FTS; S120FTPRS) [G004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098];
S6.0FT, S7.0FT, (S135FT, S155FT) [D024];
H6.0FT, H7.0FT, (H135FT, H155FT) [H006]
ii
4000 SRM 1250 Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast

The following procedures MUST be used when in- • If parts of the mast must be in a raised po-
specting or working near the mast. Additional pre- sition, install a safety chain to restrain the
cautions and procedures can be required when removing parts of the mast. Connect moving
pairing or removing the mast. parts to a part that does not move. Follow
these procedures:
WARNING 1. Put mast in vertical position.
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury or 2. Raise mast to align bottom crossmember of mast
death can result if part of the body is hit by upright that moves in outer mast with crossmem-
parts of the mast or the carriage. ber on outer mast. On the two-stage mast, the
• Never put any part of the body into or under moving part is the inner mast. On the three-
the mast or carriage unless all parts are com- stage mast, it is the intermediate mast. See Fig-
pletely lowered or a safety chain is installed. ure 1.
Also make sure that the power is OFF and the
key is removed. Put a DO NOT OPERATE tag 3. Use a 3/8-inch minimum safety chain with a hook
in the operator’s compartment. Disconnect to fasten the crossmembers together so the mov-
the battery and put a tag or lock on the bat- able member cannot lower. Put hook on back side
tery connector. of mast. Make sure hook is completely engaged
• Be careful of the forks. When the mast is with a link in the chain. Make sure safety chain
raised, the forks can be at a height to cause does not touch lift chains or chain sheaves, tubes,
an injury. hoses, fittings, or other parts on the mast.
• DO NOT climb on the mast or lift truck at any 4. Lower mast until there is tension in safety chain
time. Use a ladder or personnel lift to work and free-lift cylinder (full free-lift models) is com-
on the mast. pletely retracted.
• Mast repairs require disassembly and re-
moval of parts and can require removal of NOTE: Apply the parking brake. After lowering or
the mast or carriage. Follow the repair pro- restraining the mast, shut off the power, and remove
cedures in this section. key. Put a DO NOT OPERATE tag in the operator’s
compartment. Disconnect battery and put a tag or
WHEN WORKING NEAR THE MAST ALWAYS: lock on battery connector.
• Lower the mast and carriage completely:
Turn the key switch to the ON position and 5. Install another safety chain (9.5 mm (3/8 in.)
push the lift/lower control lever forward un- minimum) between the top or bottom bar of the
til there is no movement in the mast. Make carriage (6) and a crossmember on the outer
sure that all parts of the mast that move are mast as a secondary safety device. Install a DO
fully lowered. NOT REMOVE tag on the safety chain(s).
OR
1
Safety Procedures When Working Near Mast 4000 SRM 1250
A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST

1. OUTER MAST 4. HOOK 7. CROSSMEMBER
2. INNER MAST 5. FREE-LIFT CYLINDER
3. INTERMEDIATE MAST 6. CARRIAGE BAR
Figure 1. Safety Chaining the Mast
2
4000 SRM 1250 Fork Repair
Fork Repair
The forks are held on the carriage by hooks. The carriage further so the top hook of the fork is disen-
forks are kept in position by pins that fit through the gaged from the top carriage bar. Move the carriage
top fork hooks and into slots in the top bar carriage. away from the fork or use a lifting device to move the
Always check that the pins for the forks keep the fork away from the carriage.
forks in position on the carriage. Replace damaged
fork pin parts. The forks can be removed from the
carriage by aligning the forks with the fork removal
notch. The fork removal notch is in the bottom bar of
the carriage.
REMOVE
WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 66 to 183 kg (145 to 403 lb).
A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Slide the fork 1. CARRIAGE BARS 3. BLOCKS
to the fork removal notch in the bottom bar of the car- 2. HOOK FORK
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through Figure 2. Hook Fork Removal
the fork removal notch. See Figure 3. Lower the
1. LOAD BACKREST 6. WEDGE

2. CARRIAGE 7. WASHER
3. FORKS 8. SPRING
4. FORK 9. PIN
5. KNOB 10. FORK REMOVAL NOTCH
Figure 3. Carriage and Forks
3
Fork Repair 4000 SRM 1250
INSTALL Some applications may require closer alignment. If

the forks do not meet specification, they both must
Move the fork and carriage so the top hook on the be replaced. Check that the bottom of each fork is
fork can engage the upper carriage bar. Raise the not excessively worn. Check for smooth and proper
carriage to move the lower hook through the fork re- operation of the fork lock pins. Repair or replace any
moval notch. Slide the fork on the carriage so both damaged or broken fork lock pins or components and
upper and lower hooks engage the carriage bars. En- lubricate, as necessary. See Figure 3.
gage the latch pin with a notch in the upper carriage
bar.
CHECKS
WARNING
Never repair damaged forks by heating or
welding. Forks are made of tempered steel
using special procedures. Always replace dam-
aged forks as a pair.
Inspect the forks for cracks and wear. Check the

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

A. HEEL OF FORK (MUST BE 90% OF
Standard Fork Maximum Fork Tip DIMENSION B)
Lengths Difference 1 B. ORIGINAL FORK THICKNESS (DIMENSION B)
mm (in.) mm (in.) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
914 (36) 27 (1.08) 2. CRACKS
1067 (42) 32 (1.26) 3. MAXIMUM ANGLE 93
4. FORK REMOVAL NOTCH
1219 (48) 37 (1.44) 5. CARRIAGE
1372 (54) 41 (1.62) Figure 4. Fork Check

1524 (60) 46 (1.80)
1829 (72) 55 (2.16)
1Difference of alignment between fork tips must

be no more than 3% of the total fork length.
4
4000 SRM 1250 Carriage Replacement
Carriage Replacement
REMOVE 6. If any of the load rollers must be replaced, make
a note of the arrangement of the shims.
WARNING
Do not work under a raised carriage. Lower
INSTALL
the carriage or use a chain or blocks to prevent 1. Connect a lifting device to the carriage. Install
the carriage and inner mast from lowering. load backrest and forks on the carriage. Move
lift truck up to the carriage. Make sure carriage
NOTE: If the mast is equipped with a sideshift car-
is stable.
riage, see the paragraphs under Sideshift Carriage
Repair. 2. Use lift cylinders to raise inner mast until it is
above the load rollers of the carriage, and care-
1. Tilt forks forward so carriage has stability and
fully lower the inner mast onto the carriage.
will not fall when it is disconnected from the
mast. 3. For lift trucks E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) and S4.0, 4.5, 5.5FT,
2. Lower carriage and forks on blocks so lift chains
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
become loose.
S120FTS; S120FTPRS) (G004) equipped with
two and three stage full free lift mast. The snap
WARNING rings must be installed into chain anchor into
When disconnecting the lift chains, keep con- back of carriage.
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast. 4. For lift trucks H4.0FT5/FT6; H4.5FTS5,
This procedure will prevent the lift chains H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
from falling and causing an injury or damage. (N005) equipped with two and three stage full
free lift mast. The snap rings must be installed
3. Remove chain anchor pin from each chain an- into chain anchor into front of carriage.
chor at the carriage. Disconnect lift chains from
carriage. Check chain anchors and anchor pins NOTE: Install chain anchor pins so that heads of pins
for wear and serviceability. Discard worn or un- face inside and center of mast. Both legs of cotter pin
serviceable chain anchors and chain anchor pins. must be bent against chain anchor pin.
Discard cotter pin. See Figure 5, Figure 6. Fig-
5. Replace worn or unserviceable chain anchor pins
ure 7, and Figure 8.
and chain anchors on the carriage with new ones.
Connect lift chains to the chain anchors on the
WARNING carriage. Figure 5, Figure 6. Figure 7, and Fig-
Make sure the carriage is stable and will not ure 8.
fall over when the inner mast is raised above
the load rollers of the carriage. 6. Tighten chain anchor nuts to:
• For lift truck models E3.50-5.50XL, E4.50XLS
4. Use lift cylinders to raise inner mast until it is (E70-120Z, E100ZS) (E098), S4.0, 4.5,
above the load rollers of the carriage. If the hy- 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
draulic system cannot be used, connect a lifting 100FTBCS; S120FTS; S120FTPRS) (G004),
device to the top of the inner mast. Carefully and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
raise inner mast until it is above the load rollers H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
of the carriage. tighten to 210 N•m (155 lbf ft).
• For lift truck models S6.0FT, S7.0FT,
5. Move lift truck from carriage. Connect a lifting (S135FT,S155FT) (D024) and H6.0FT, H7.0FT
device to the carriage. Make sure carriage is sta- (H135FT, H155FT) (H006), tighten to 370 N•m
ble. Remove load backrest and forks. Put car- (273 lbf ft).
riage on floor so that load rollers are up.
5
Carriage Replacement 4000 SRM 1250
1. CARRIAGE 7. CHAIN ANCHOR POSITION (THREE STAGE

2. LOAD ROLLER FULL FREE-LIFT MAST)
3. SHIMS 8. PIN
4. SNAP RING 9. COTTER PIN
5. SIDE ROLLER (OPTIONAL) 10. CHAIN ANCHOR PIN
6. CHAIN ANCHOR POSITION (TWO STAGE 11. GUARD (RH)
LIMITED FREE-LIFT MAST) 12. LUBE FITTING
Figure 5. Carriage for Lift Truck Models S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT,
H7.0FT (H135FT, H155FT) (H006)
Legend for Figure 6

A. THREE STAGE FULL FREE-LIFT MAST B. TWO STAGE LIMITED FREE-LIFT MAST
1. PIN 10. COTTER PIN
2. PIN ASSEMBLY 11. CHAIN ANCHOR PIN
3. CARRIAGE 12. CHAIN ANCHOR
4. CAPSCREW 13. SNAP RING
5. WASHER 14. SHIM
6. LOAD ROLLER 15. WASHER
7. SNAP RING (EXTERNAL) 16. LUBE FITTINGS
8. SPACER 17. SIDE ROLLERS
9. NUT
6
Figure 6. Pin-Type Carriage for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)
7
Figure 7. Carriage for Lift truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098) and
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
8
Legend for Figure 7

A. TWO STAGE LIMITED FREE-LIFT B. TWO AND THREE STAGE FULL FREE-LIFT
1. LOAD ROLLER 9. PIN
2. SHIM 10. SNAP RING (EXTERNAL)
3. SNAP RING 11. GUARD (RH)
4. SPACER 12. CAPSCREW
5. GUARD (LH) 13. WASHER
6. CHAIN ANCHOR PIN 14. NUT
7. COTTER PIN 15. CARRIAGE
8. CHAIN ANCHOR 16. LUBE FITTINGS
9
Figure 8. Carriage for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005)
10
4000 SRM 1250 Integral Sideshift Carriage Repair
Legend for Figure 8

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

REMOVE, FOR LIFT TRUCK MODELS WARNING
E3.50-5.50XL, E4.50XLS (E70-120Z, Make sure the carriage is stable and will not
E100ZS) (E098), S4.0, 4.5, 5.5FT, S5.5FTS, fall over when the inner mast is raised above
(S80, 100, 120FT; S80, 100FTBCS; the load rollers of the carriage.
S120FTS; S120FTPRS) (G004), AND 6. Use lift cylinders to raise inner mast until it is
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; above the load rollers of the carriage. If the hy-
H5.0-5.5FT (H80, 90, 100, 110, 120FT) draulic system cannot be used, connect a lifting
(N005) device to the top of the inner mast. Carefully
raise inner mast until it is above the load rollers
1. Relieve hydraulic pressure to the sideshift cylin- of the carriage.
der by moving sideshift lever in both directions
several times. 7. Move lift truck away from carriage. Connect a
lifting device to the carriage. Make sure carriage
NOTE: Tag hydraulic lines and fittings prior to dis- is stable. Remove load backrest and forks. Put
connecting to aid in connecting during installation. carriage on floor so that load rollers are up.
2. Disconnect hydraulic lines from sideshift cylin- 8. If any of the load rollers must be replaced, make
der. Put caps and plugs on open lines and cylin- a note of the arrangement of the shims.
der ports.
DISASSEMBLE
3. Tilt forks forward so carriage is stable and will
not fall when it is disconnected from the mast. 1. Remove capscrews from lower hooks and remove
the lower hooks. See Figure 9.
4. Lower carriage and forks on blocks so lift chains
become loose. See Figure 2. 2. Lift the mobile frame from the bottom and rotate
it forward to free it from the fixed frame.
WARNING 3. Remove upper and lower bearings from the fixed
When disconnecting the lift chains, keep con- frame.
connect the ends of the lift chains to the mast. 4. If damaged, remove grease fittings from the fixed
This procedure will prevent the lift chains frame. See Figure 10.
from falling and causing an injury or damage.
5. Remove sideshift cylinder rods from each end of
5. Remove pin from each chain anchor at the car- the cylinder body.
riage. Disconnect lift chains from carriage.
Check chain anchors and anchor pins for wear 6. Remove snap rings from each end of the cylinder
and serviceability. Discard worn or unser- body and remove rod scrapers, rod bushings, and
viceable chain anchors and chain anchor pins. seals from cylinder body.
Discard cotter pin. See Figure 5.
11
Integral Sideshift Carriage Repair 4000 SRM 1250
1. CAPSCREWS 12. FIXED FRAME

2. LOWER HOOK 13. CYLINDER BODY
3. MOBILE FRAME 14. SHIM
4. LOWER BEARINGS 15. SIDE ROLLER
5. UPPER BEARINGS 16. BRACKET
6. GREASE FITTINGS 17. PIN
7. CYLINDER ROD 18. SPACER
8. SNAP RING 19. GUARD (RH)
9. ROD SCRAPER 20. LOCKWASHER
10. ROD BUSHING 21. LUBE FITTING
11. SEAL
Figure 9. Integral Sideshift Carriage
12
4000 SRM 1250 Integral Sideshift Carriage Repair
1. SIDE LOAD ROLLERS 3. *LUBE FITTINGS

2. LUBE FITTING 4. FITTINGS
* LUBE FITTING NOT USED ON E3.50-4.00XL, E4.50XLS (E70-80Z, E100ZS) (E098) LIFT TRUCKS EQUIPPED
WITH INTEGRAL SIDESHIFT.
Figure 10. Integral Sideshift Carriage, Side Roller and Lube Fitting Location
13
Hang On Sideshift Carriage Repair 4000 SRM 1250
ASSEMBLE H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT)
1. Lubricate with clean hydraulic oil and install
seals, rod bushings, and rod scrapers into the (N005)
cylinder body and secure with snap rings. See 1. Connect a lifting device to the carriage. Install
Figure 9. load backrest and forks on the carriage. Move
2. Install cylinder rods into each end of the cylinder lift truck up to the carriage. Make sure carriage
body. is stable.
3. Install grease fittings into the fixed frame if re- 2. Use lift cylinders to raise inner mast until it is
moved. See Figure 10. above the load rollers of the carriage, and care-
4. Install upper and lower bearings onto the fixed
frame. NOTE: Install new chain anchor pins so that heads
of pins face inside and center of mast. Both legs of
5. Install the mobile frame onto the fixed frame by cotter pin must be bent against chain anchor pin.
hooking it at the top of the fixed frame first and
lowering it to the bottom. 3. Replace worn or unserviceable chain anchor pins
and chain anchors on the carriage with new ones
6. Install lower hooks and capscrews. Tighten the and install new cotter pin. Connect lift chains
capscrews to 78 N•m (58 lbf ft). to the chain anchors on the carriage. See Fig-
ure 5. Tighten chain anchor nuts to 210 N•m
INSTALL, FOR LIFT TRUCK MODELS (155 lbf ft).
E3.50-5.50XL, E4.50XLS (E70-120Z,
4. Remove protective caps and plugs from hydraulic
E100ZS) (E098), S4.0, 4.5, 5.5FT, S5.5FTS, lines and cylinder ports. Connect lines to the
(S80, 100, 120FT; S80, 100FTBCS; sideshift cylinder as tagged during removal.
S120FTS; S120FTPRS) (G004), AND
Hang On Sideshift Carriage Repair

REMOVE, LIFT TRUCK MODELS S6.0FT, frame) and the hang on sideshift assembly. When
S7.0FT (S135FT, S155FT) (D024) AND the word carriage is used in procedures below, it
H6.0FT, H7.0FT (H135FT, H155FT) (H006) refers to the complete hang on sideshift carriage
assembly; either with the fork positioner or without
NOTE: The hang on sideshift carriage assembly is the fork positioner.
made up of either two or three other assemblies.
If the lift truck is equipped with a fork positioner, 1. Move lift truck to a flat surface. Apply the park-
the hang on sideshift carriage assembly consists of ing brake.
the standard carriage (fixed frame), the hang on 2. Position the carriage in the center of the truck.
sideshift assembly and the fork positioner assembly.
See Figure 11. If the lift truck is not equipped with 3. Lower carriage and forks on blocks to loosen the
a fork positioner, the hang on sideshift carriage lift chains. See Figure 12.
assembly is made up of the standard carriage (fixed
14
4000 SRM 1250 Hang On Sideshift Carriage Repair
NOTE: FORKS REMOVED FOR CLARITY.

1. FORK POSITIONER ASSEMBLY 7. SIDESHIFT CYLINDER HYDRAULIC
2. FORK POSITIONER CYLINDERS CONNECTION
3. HYDRAULIC HOSES 8. SIDESHIFT CYLINDER
4. FORK POSITIONERS 9. GREASE FITTING
5. HANG ON SIDESHIFT ASSEMBLY 10. STANDARD CARRIAGE (FIXED FRAME)
6. LOWER MOUNTING HOOKS 11. VALVE BODY HYDRAULIC CONNECTIONS
Figure 11. Hang On Sideshift Carriage With Fork Positioner
15
6. If lift truck is equipped with a E-Hydraulic con-

trol valve, turn key to the ON position, if lift
truck is equipped with a key start option, or
press the power ON/OFF button if lift truck is
equipped with a keyless start option. See the
Operating Manual. Disconnect the non-pres-
surized hose and put caps and plugs on the open
lines and cylinder ports. Move the sideshift
mini-lever in both directions several times to re-
lieve hydraulic pressure to the sideshift cylinder.
Disconnect the pressurized hose and put caps
and plugs on the open lines and cylinder ports.
1. CARRIAGE BARS 3. BLOCKS WARNING

2. HOOK FORK When disconnecting the lift chains, keep con-
Figure 12. Place Carriage On Blocks
connect the ends of the lift chains to the mast.
NOTE: Make sure the lifting device has a capacity of This procedure will prevent the lift chains
1450 kg (3200 lb). from falling and causing an injury or damage
to the lift truck.
4. Connect a lifting device to the carriage assembly.
Slowly raise lifting device until chain is taut to 7. Disconnect the lift chains by removing the pins
provide carriage with stability. from each chain anchor at the carriage. See Fig-
ure 13.
WARNING 8. If lift truck is not equipped with a fork positioner,

Before disconnecting the hydraulic hoses, re- remove hang on sideshift carriage assembly from
lieve the pressure in the hydraulic system. the lift truck as follows:
Serious injury can occur if pressure is not
relieved from hydraulic system prior to dis- a. Remove the forks. See Figure 14 and the
connecting hydraulic hoses. section Fork Repair for the procedures.
5. If lift truck is equipped with manual hydraulic b. Remove capscrews that secure load backrest
control valve, turn key to the ON position, if to standard carriage and remove the load
lift truck is equipped with a key start option, or backrest from carriage.
press the power ON/OFF button, if lift truck is
NOTE: If engine is not operational, connect a lifting
equipped with a keyless start option. See the Op-
device to the inner mast and raise the inner mast
erating Manual. Relieve hydraulic pressure to
until it is above the load rollers of the carriage.
the sideshift cylinder by moving manual sideshift
lever in both directions several times. c. Make sure carriage is stable and connected
to lifting device. Start the engine and use the
NOTE: Tag hydraulic lines and fittings prior to re-
lift cylinders and raise the inner mast until it
moval to aid in connecting during installation.
is above the load rollers of the carriage. Move
Disconnect hydraulic lines from sideshift cylin- lift truck away from carriage.
der (see Figure 11). Put caps and plugs on open
d. Lift carriage assembly, using the lifting de-
lines and cylinder ports.
vice, and place carriage assembly on a pallet
NOTE: Tag hydraulic lines and fittings prior to re- or blocks so that the load rollers are up. Re-
moval to aid in connecting during installation. move lifting device from carriage assembly.
16
1. CARRIAGE 7. CHAIN ANCHOR POSITION (THREE STAGE

2. LOAD ROLLER FULL FREE-LIFT MAST)
3. SHIMS 8. PIN
4. SNAP RING 9. COTTER PIN
5. SIDE ROLLER (OPTIONAL) 10. CHAIN ANCHOR PIN
6. CHAIN ANCHOR POSITION (TWO STAGE 11. GUARD (RH)
LIMITED FREE-LIFT MAST) 12. GREASE FITTING
Figure 13. Carriage (Fixed Frame) for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024)
and H6.0FT, H7.0FT (H135FT, H155FT) (H006)
17
1. LOAD BACKREST 6. WEDGE

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

2. MOUNTING CAPSCREW 6. FORK CARRIERS
3. WASHER 7. FORK POSITIONER FRAME
4. FORKS
Figure 15. Fork Positioner Removal
19
f. Go to Step 8 and perform the procedures de- 5. Remove the locknut and lug from cylinder rod
scribed there. Do not do Step b. end anchors.
10. If any of the load rollers must be replaced, make 6. Remove two nuts (see Figure 17) that attach the
a note of the arrangement of the shims. fork positioner cylinders to fork positioner frame.
DISASSEMBLE 7. Disengage the cylinders from fork positioner

frame by moving both cylinders inward into the
1. Remove capscrews from lower hooks and remove center plate. To disassemble the fork positioner
the lower hooks from hang on sideshift assembly. cylinders, see Cylinders, Disassemble.
See Figure 16.
NOTE: Make note of the number of shims removed.
NOTE: Make sure the lifting device has a capacity of
450 kg (1000 lb). 8. Remove the capscrews, washers, and shims from
the center plate.
2. Attach a lifting device to the hang on sideshift
assembly (see Figure 16) and remove hang on 9. Remove the cylinders, center plate, and fork
sideshift assembly from standard (fixed frame) carriers as an assembly from the fork positioner
carriage assembly (see Figure 13). frame.
3. If damaged, remove grease fittings from stan- 10. Slide the fork carriers off of the cylinders and
dard carriage and hang on sideshift carriage. See disengage the cylinders from the center plate.
Figure 13 and Figure 11. To disassemble the fork positioner cylinders, see
Cylinders, Disassemble.
4. Remove the two cotter pins and clevis pins and
remove the sideshift cylinder from hang on
sideshift frame. To disassemble the sideshift
cylinder, see Cylinders, Disassemble.
20
1. GREASE FITTING 6. O-RING 11. NUT

2. BEARING STRIP 7. CLEVIS PIN 12. LOWER HOOK
3. ANCHOR BRACKET 8. COTTER PIN 13. CAPSCREW
4. SIDESHIFT CYLINDER 9. RESTRICTOR WASHER 14. WASHER
5. FITTING 10. LOWER BEARING 15. FACEPLATE
Figure 16. Hang On Sideshift Assembly
21
1. NUT 8. SNAP RING

2. HYDRAULIC LINES 9. BUSHING
3. CAPSCREW 10. FORK CARRIERS
4. WASHER 11. CENTER PLATE
5. VALVE BODY 12. SHIMS
6. FORK POSITIONER FRAME 13. LUG
7. FORK POSITION CYLINDERS 14. LOCKNUT
Figure 17. Fork Positioner Assembly
22
CYLINDERS, DISASSEMBLE 4. Remove rod assembly and retainer from the

cylinder.
Sideshift Cylinder
5. Remove retainer from rod.
To disassemble the sideshift cylinder, perform the fol-
lowing steps (see Figure 18): CAUTION
1. Position the cylinder rod in the fully extended To prevent damage to sealing surfaces, use
position and remove the snap ring from the re- brass tools when removing seals and O-rings
tainer.
6. Remove and discard wiper, seal, backup ring, and
2. Push cylinder retainer into the shell approxi- O-ring from the retainer.
mately 50 mm (2 in.) until the retainer ring is
7. Remove lock nut from the rod and remove piston.
exposed.
8. Remove and discard seal and backup ring from
3. Remove the retainer ring.
the piston.
1. SNAP RING 6. WIPER 11. PISTON

2. RETAINER RING 7. SEAL 12. SEAL
3. ROD 8. BACKUP RING 13. BACKUP RING
4. RETAINER 9. O-RING
5. CYLINDER SHELL 10. LOCK NUT
Figure 18. Hang On Sideshift Cylinder
23
Fork Positioner Cylinders CLEAN AND INSPECT

Disassemble the fork positioner cylinders as follows
(see Figure 19):
WARNING
Cleaning solvents can be flammable and toxic,
1. Unscrew and remove the cylinder rod retainer. and can cause skin irritation. When using
cleaning solvents, always follow the recom-
2. Remove the piston, rod, and cylinder rod retainer mendations of the manufacturer.
as an assembly from cylinder shell.
WARNING
CAUTION Compressed air can move particles so that they
To prevent damage to sealing surfaces, use cause injury to the user or to other personnel.
brass tools when removing seals and O-rings Make sure that the path of the compressed air
is away from all personnel. Wear protective
3. Slide the cylinder rod retainer from the cylinder goggles or a face shield to prevent injury to the
rod. Remove all seals, O-rings, and backup rings eyes.
from cylinder rod.
CAUTION
CAUTION DO NOT use steam to clean the side rollers and
To prevent damage to the cylinder, DO NOT load rollers. Steam will cause corrosion and
clamp on the cylinder rod sealing surface. damage to rollers and roller parts.
4. Place cylinder in a soft-jawed vise and remove 1. Use steam or solvent to clean the metal parts of
the piston nut and piston. the carriage. Dry with compressed air.
2. Inspect the carriage weldments and rollers for

CAUTION wear or damage. Inspect the welds for cracks.
To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings 3. Inspect chain anchors and anchor pins for wear
and serviceability. Discard worn or unservice-
5. Remove all seals, O-rings, and backup rings from able chain anchors and chain anchor pins. See
piston. the Parts Manual for part numbers.
1. CYLINDER ROD 5. BACKUP RING 9. PISTON

2. ROD SEAL 6. O-RING 10. PISTON SEAL
3. ROD WIPER 7. SPACER 11. PISTON NUT
4. CYLINDER ROD RETAINER 8. CYLINDER SHELL
Figure 19. Fork Positioner Cylinders
24
4. Check the load rollers to make sure they are not 3. Lubricate with clean hydraulic oil and install a
broken or worn. new piston seal on the piston.
4. Slide the cylinder rod retainer onto the cylinder

WARNING rod.
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using 5. Apply an antiseize compound to the retainer
cleaning solvents, always follow the recom- threads and screw the retainer into the shell.
mendations of the manufacturer. Tighten the retainer to 75 N•m (55 lbf ft).
WARNING Sideshift Cylinder

Compressed air can move particles so that they Assemble the sideshift cylinder as follows (see Fig-
cause injury to the user or to other personnel. ure 18):
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the CAUTION
eyes. To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings
5. Clean all parts of the sideshift cylinder and fork
positioner cylinders in solvent or steam. Dry 1. Lubricate with clean hydraulic oil and install
with compressed air. new seal and backup ring on the piston.
6. Inspect the cylinder shell bores, pistons, rods,

bushings, and retainers for scratches or grooves. CAUTION
If parts are worn or damaged, replace the part. To prevent damage to the cylinder, DO NOT
See the Parts Manual for part numbers. clamp on the cylinder rod sealing surface.
CYLINDERS, ASSEMBLE 2. Place cylinder in a soft-jawed vise, and install

piston on the rod.
Fork Positioner Cylinders 3. Install and tighten lock nut on rod to 135 to
Assemble the fork positioner cylinders as follows (see 163 N•m (100 to 120 lbf ft).
Figure 19):
4. Install rod and piston in the shell.
CAUTION CAUTION
1. Lubricate new seals and O-rings with clean
5. Install new O-ring and backup ring in the groove
hydraulic oil and install new cylinder rod seal,
of the retainer.
wiper seal, O-rings and backup rings onto the
cylinder rod retainer. 6. Push the retainer into the cylinder shell until the
retainer ring groove is exposed.
CAUTION 7. Install retainer ring into groove in the shell.
To prevent damage to the cylinder, DO NOT
clamp on the cylinder rod sealing surface. 8. Pull rod and piston out of shell until the retainer
stops on the retainer ring and the snap ring
2. Place cylinder in a soft-jawed vise, and install groove is exposed.
piston on the rod. Apply Loctite® 242 (Blue) to
threads of piston nut and tighten nut to 75 N•m 9. Install the snap ring on the retainer.
(55 lbf ft).
25
ASSEMBLE INSTALL
NOTE: Be sure to assemble the fork positioner cylin- NOTE: Make sure the lifting device has a capacity of
ders and sideshift cylinder before starting this sec- 1450 kg (3200 lb).
tion. See Cylinders, Assemble for procedures to as-
semble the cylinders. 1. If lift truck is not equipped with a fork positioner:
1. Slide the fork carriers onto the cylinders. Install a. Connect a lifting device to the carriage as-
the cylinders into the holes in the center plate. sembly and install load backrest to carriage
assembly. Tighten nuts to 70 to 80 N•m (56
2. Install the cylinders, fork carriers, and center to 60 lbf ft).
plate into holes in fork positioner frame. See Fig-
ure 17. b. Install the forks to carriage assembly. See
the section Fork Repair for the procedures.
3. Install the shims, noted during removal, to the Make sure carriage is stable and move lift
center plate with two capscrews and washers. truck up to the carriage assembly.
Tighten the capscrews to 44 N•m (30 lbf ft).
2. If lift truck is equipped with a fork positioner:
4. Install lugs to cylinder rod end anchors with lock-
nuts. Tighten locknuts to 220 N•m (160 lbf ft). a. Install the forks onto hang on sideshift car-
riage. See the section Fork Repair for the
5. Secure the fork positioner cylinders, fork car- procedures.
riers, and center plate to fork positioner frame
with two nuts. Tighten the nuts to 220 N•m b. Connect a lifting device to fork positioner
(160 lbf ft). frame and lift frame up and align the fork
carriers with the top of the forks. See Fig-
6. Install assembled sideshift cylinder to sideshift ure 17.
assembly frame using two cotter and clevis pins.
See Figure 16. c. Secure the fork positioner frame to hang on
sideshift frame using four capscrews and
7. If grease fittings were removed due to damage, washers. Tighten capscrews to 145 N•m
install new grease fittings into standard carriage (110 lbf ft) Make sure carriage is stable and
and hang on sideshift carriage. move lift truck up to the carriage assembly.
NOTE: Make sure the lifting device has a capacity of 3. Remove protective caps and plugs from hydraulic
450 kg (1000 lb). lines and cylinder ports. Connect lines to the
sideshift cylinder, fork positioner cylinders, and
8. Using a lifting device, lift the hang on sideshift fork positioner valve body as tagged during re-
assembly (see Figure 11) up and place it onto the moval. See Figure 11 and Figure 17.
standard carriage (fixed frame) by hanging the
anchor bracket over the standard carriage. See NOTE: Install new chain anchor pins so that the
Figure 13. heads of pins face inside and center of mast. Both
legs of cotter pin must be bent against chain anchor
9. Install the lower hooks onto hang on sideshift as- pin.
sembly using capscrews and washers. Tighten
capscrews to 155 to 170 N•m (115 to 125 lbf ft). 4. Replace worn or unserviceable chain anchor pins
and chain anchors on the carriage with new ones
NOTE: Make sure the lifting device has a capacity of and install new cotter pin.
450 kg (1000 lb).
5. Connect lift chains to the chain anchors on the
10. Using a lifting device, install the fork positioner carriage. See Figure 13. Tighten chain anchor
assembly (see Figure 17) onto hang on sideshift nuts to 210 N•m (155 lbf ft).
assembly (see Figure 16) using four capscrews
and washers. Tighten capscrews to 155 to 6. Use lift cylinders to raise inner mast until it is
170 N•m (115 to 125 lbf ft). above the load rollers of the carriage, and care-
26
4000 SRM 1250 Two-Stage Mast With Limited Free-Lift Repair
7. Operate the carriage assembly through several fittings and cylinder rod ends and to force any
complete cycles and check for any leaks at the air in the system to the hydraulic tank.
Two-Stage Mast With Limited Free-Lift Repair

REMOVE
1. Fully lower inner mast. If mast must be disas-
sembled, remove forks and carriage as described
in sections Fork Repair and Carriage Replace-
ment.
2. Connect a lifting device to all top crossmembers

of the mast weldments (see Figure 1). Make sure
lifting device will hold the weight of the mast.
Raise lifting device so the mast has stability.
3. Remove lift and tilt cylinders following proce-

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

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
model lift trucks. Remove the capscrews that
hold the mast pivot pins to the J-hook mounts
on the drive axle. Check that the pins fit snug
in the outer mast. If pins can be moved up and
down a minimum of 4 mm (0.157 in.), replace
bushings in outer mast and/or mast pivot pins
as required. See Figure 21 and Figure 22. 1. MAST HANGER BUSHING
2. LUBE FITTINGS
5. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; 3. MAST BUSHING PLUGS
S80, 100FTBCS; S120FTS; S120FTPRS) (G004), 4. CAPSCREW
S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and 5. WASHER
6. MAST MOUNTING CAP
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098) model lift trucks. Remove the four cap- Figure 20. Mast Mounts Removal for Lift Truck
screws holding the left and right mast mounting Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
hangers to the drive axle. See Figure 20. 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) Shown
6. Remove the mast from lift truck. Put mast in a
position so the crossmembers are on the floor.
27
Two-Stage Mast With Limited Free-Lift Repair 4000 SRM 1250
assembly procedures. See Figure 27 for S4.0,

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

mast. Connect a crane to the center of inner
mast. See Figure 24. Slide inner mast out of the
outer mast until stub shafts are in the notches of
the outer mast. Remove inner mast from outer
mast.
3. Using a brass drift, remove tilt rod bushing from

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

brication from the bearings in the load rollers.
Water in the bearings of the sheaves and the
link pins of chains can also shorten the service
life of these parts.
1. Inspect sheaves and load rollers for wear or

damage. DO NOT use steam to clean lift chains,
sheaves, or load rollers. The bearings in the
sheaves and load rollers are sealed and lubri-
cated.
2. Inspect chain anchors and anchor pins for dam-

age. If damaged, replace.
WARNING
1. INNER MAST
2. OUTER MAST Commercial cleaning solvents may be
flammable and toxic and can cause severe skin
Figure 24. Inner Mast irritation. When using commercial cleaning
solvents, always comply with solvent manu-
facturer’s recommended safety precautions.
WARNING
Never replace just the worn section of a chain.
Replace the complete chain. Never replace just
one chain of a chain pair. Replace both chains.
3. Clean lift chains with solvent. Inspect lift chains

for wear or damage. See Figure 26. A lift chain
becomes longer when it is worn. If a section of
chain is 3% longer than a similar section of new
chain, the chain is worn and must be replaced.
If a chain scale is available, check lift chains as
shown in Figure 26. If a chain scale is not avail-
able measure 20 links of chain. Measure from
the center of a pin to the center of another pin 20
pitches away. Compare the length with the chart
1. TILT ROD BUSHING in Figure 26. Replace chain if the length of 20
links of the worn section is more than the maxi-
Figure 25. Mast Bushing Location mum wear limit. Lubricate chains with SAE 30
engine oil. The best procedure is to remove lift
CLEAN AND INSPECT chains from lift truck and soak them in SAE 30
engine oil.
CAUTION
DO NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam
30
NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE.
Pitch
Total Length of Wear Limit
20 Links (Pitch) The Maximum Length of
of New Chain 20 Links
25.4 mm (1.00 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

31.8 mm (1.25 in.) 635.0 mm (25.0 in.) 654.1 mm (25.8 in.)
1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE
Figure 26. Lift Chains Check
31
Figure 27. Two-Stage Mast With Limited Free-Lift for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) Shown
32

A. INNER MAST C. OUTER MAST WITH MAIN LIFT CYLINDERS
B. OUTER MAST
1. INNER MAST 14. BRACKET
2. SNAP RING 15. LOCKWASHER
3. MAIN LIFT CYLINDER 16. CAPSCREW
4. LIFT CHAIN 17. FITTING
5. HOSES 18. NUT
6. WASHER 19. SPACER
7. SHIMS 20. CONTROL VALVE HOUSING
8. LOAD ROLLER 21. LOWERING CONTROL VALVE
9. BEARING STRIP 22. CLAMP
10. O-RING 23. COTTER PIN
11. OUTER MAST 24. CHAIN ANCHOR
12. CHAIN SHEAVE 25. PIN
13. BEARING 26. VELOCITY FUSE
33
Figure 28. Two-Stage Mast With Limited Free-Lift for Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
34

A. INNER MAST C. OUTER MAST WITH MAIN LIFT CYLINDERS
B. OUTER MAST
1. STUB SHAFT 18. HOUSING
2. SNAP RING 19. LOWERING CONTROL VALVE
3. SHIMS 20. CLAMP
4. BEARING STRIP 21. HOSE (RH)
5. O-RING 22. STRAP CLAMP
6. OUTER MAST 23. CLAMP
7. BUSHING 24. VELOCITY FUSE
8. LOAD ROLLER 25. HOSE
9. INNER MAST 26. HOSE (LH)
10. CAPSCREW 27. HOSE
11. LOCKWASHER 28. NUT
12. WASHER 29. CHAIN ANCHOR
13. BRACKET 30. COTTER PIN
14. CHAIN SHEAVE 31. ANCHOR PIN
15. SPACER 32. CHAIN
16. FITTING 33. HOSE
17. NUT
35
Figure 29. Two-Stage Mast With Limited Free-Lift for Lift Truck Models S6.0FT, S7.0FT,
(S135FT,S155FT) (D024)
36

A. INNER MAST C. MAIN LIFT CYLINDERS
B. OUTER MAST
1. INNER MAST 16. CLAMP
2. STUB SHAFT 17. HOSE
3. LOAD ROLLER 18. STRAP CLAMP
4. SHIMS 19. HOSE CLAMP
5. SNAP RING 20. SPRING
6. CHAIN SHEAVE 21. WASHER
7. BEARING STRIP 22. HOUSING
8. BEARING STRIP SHIMS 23. LOWERING CONTROL VALVE
9. OUTER MAST 24. NUT
10. LUBE FITTING 25. LIFT CHAIN
11. BUSHING 26. LIFT CYLINDER
12. WASHER 27. CHAIN ANCHOR
13. CAPSCREW 28. PIN
14. CAP 29. COTTER PIN
15. FITTING
37
Figure 30. Two-Stage Mast With Limited Free-Lift for Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006)
38

A. INNER MAST C. MAIN LIFT CYLINDERS
B. OUTER MAST
1. INNER MAST 15. FITTING
2. STUB SHAFT 16. CLAMP
4. SHIMS 18. STRAP CLAMP
5. SNAP RING 19. HOSE CLAMP
6. CHAIN SHEAVE 20. SPRING
7. BEARING STRIP 21. WASHER
8. BEARING STRIP SHIMS 22. HOUSING
9. OUTER MAST 23. LOWERING CONTROL VALVE
10. SNAP RING 24. NUT
11. BUSHING 25. LIFT CHAIN
12. WASHER 26. LIFT CYLINDER
13. CAPSCREW 27. CHAIN ANCHOR
14. COTTER PIN 28. PIN
ASSEMBLE
NOTE: The shims for the load rollers keep the weld-
ments parallel and provide correct clearance. Dur-
ing assembly, the location of the shims will be ap-
proximately the same as they were before disassem-
bly. Check clearance and adjust shims for wear or
changes because of repairs. Strip bearings are also
adjusted by using shims. See Mast Adjustments in
this section for the instructions to make the neces-
sary adjustments.
1. Connect a lifting device to the center of inner

mast (see Figure 24). Put stub shafts through
notches in the outer mast. Slide inner mast into
the outer mast so stub shafts are seen at the top
and bottom of the weldments.
2. Install strip bearings, new O-rings, and shims,

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

Figure 32.
39

(S135FT,S155FT) (D024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006) tighten capscrew to
33 N•m (24 lbf ft).
8. Connect hydraulic lines and fittings between

lowering control valve and lift cylinders. See
Figure 27, Figure 28, Figure 29, and Figure 30.
9. Install chain anchor and nut.

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

ers. Raise the mast assembly to a vertical posi-
tion. Place mast mounting hangers on the drive
41
Figure 33. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
42

1. HOSES 10. FITTING
2. CLAMP 11. TUBE
3. SPACER 12. PLATE
4. STUB SHAFT 13. WASHER
5. SHEAVE 14. NUT
6. CAPSCREW 15. STRAIN RELIEF
7. LOCKWASHER 16. BRACKET
8. GROMMET 17. HOSE REEL (OPTIONAL)
9. NUT
43
Figure 34. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)
44

1. HOSES 10. FITTING
2. CLAMP 11. TUBE
3. SPACER 12. PLATE
5. SHEAVE 14. NUT
6. CAPSCREW 15. STRAIN RELIEF
7. LOCKWASHER 16. BRACKET
8. GROMMET 17. HOSE REEL (OPTIONAL)
9. NUT 18. JUNCTION BOX
45
Figure 35. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
46

1. HOSES 8. GROMMET
2. CLAMP 9. NUT
3. SPACER 10. FITTING
4. STUB SHAFT 11. TUBE
5. SHEAVE 12. WASHER
6. CAPSCREW 13. NUT
7. LOCKWASHER
47
Figure 36. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models S6.0FT,
S7.0FT, (S135FT,S155FT) (D024)
48

1. STUBSHAFT 10. JAM NUT
2. SHEAVE 11. BRACKET
3. BUSHING 12. TUBE
4. NUT 13. HOSE
5. CLAMP 14. BRACKET
6. CAPSCREW 15. WASHER
7. FITTING 16. PLATE
8. CHECK VALVE 17. STRAIN RELIEF
9. O-RING 18. HOSE REEL
49
Figure 37. Two-Stage Mast With Limited Free-Lift Header Hoses for Lift Truck Models H6.0FT,
H7.0FT (H135FT, H155FT) (H006)
50

1. STUBSHAFT 9. O-RING
2. SHEAVE 10. JAM NUT
3. BUSHING 11. BRACKET
4. NUT 12. TUBE
5. CLAMP 13. HOSE
6. CAPSCREW 14. BRACKET
7. FITTING 15. WASHER
8. CHECK VALVE
HEADER HOSE ALIGNMENT NOTE: The carriage height must be correct before the
header hoses can be adjusted. See Lift Chains Ad-
Before installing the header hoses, make sure you justment for the carriage adjustment procedure.
know the lift height of the mast. The tension on the
header hoses is adjusted according to lift height. The 1. Mark each hose with a single letter: A, B, C,
lift height is on the Nameplate of the lift truck and and D. See Figure 38, for lift truck models
on the right-hand side of the outer mast. E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), Figure 39, for lift truck models S4.0, 4.5,
Some lift trucks are equipped with auxiliary hy- 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
draulic functions that are fastened to the carriage. BCS; S120FTS; S120FTPRS) (G004), Figure 40,
Examples of these auxiliary functions are sideshift for lift truck models H4.0FT5/FT6; H4.5FTS5,
carriages or roll clamps. These auxiliary functions H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
require header hoses for their operation. (N005), Figure 41, for lift truck models S6.0FT,
S7.0FT, (S135FT,S155FT) (D024), and Figure 42,
WARNING for lift truck models H6.0FT, H7.0FT (H135FT,
Before working on or near the mast, see Safety H155FT) (H006).
Procedures When Working Near Mast in this
section.
NOTE: This procedure is for the four-function option.

The three-function option will have hoses A and B
only.
51
A. HOSE (THREE FUNCTION) D. HOSE (FOUR FUNCTION)

B. HOSE (THREE FUNCTION) E. HOSE (FIVE FUNCTION)
C. HOSE (FOUR FUNCTION)
Figure 38. Header Hose Alignment for Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
52
Figure 39. Header Hose Alignment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
53

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

Figure 40. Header Hose Alignment for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
54
Figure 41. Header Hose Alignment for Lift Truck Models S6.0FT, S7.0FT, (S135FT,S155FT) (D024)
55

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

Figure 42. Header Hose Alignment for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)
56
NOTE: The fifth function hose does not require ten- S155FT) (D024), and Figure 37, for lift truck
sion marks. models H6.0FT, H7.0FT (H135FT, H155FT)
(H006).
2. Dimension E is determined by the height of
the outer mast channel from the ground and 6. Place the hoses at the location of the hose
the length of the outer mast channel. See sheave(s). The sheave(s) and stub shafts must
dimensions Y and Z in Figure 43. To deter- be assembled, and the hose(s) must be routed
mine E, use Table 2 for lift truck models S4.0, onto the sheave(s) before the hose(s) are attached
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, to the mast. Refer to Figure 33. Tighten the hose
100FTBCS; S120FTS; S120FTPRS) (G004), clamp hardware to 8 N•m (71 lbf in) and the
Table 3 for lift truck models H4.0FT5/FT6; sheave assembly capscrews to 66 N•m (49 lbf ft).
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), Table 4 for lift truck models 7. Put the clamps over the hoses and attach the
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) clamps to the upper brackets. DO NOT tighten
(E098), Table 5 for lift truck models S6.0-7.0FT the hardware.
(S135, 155FT) (D024), and Table 6 for lift truck
NOTE: To make the alignment of dimension E eas-
models H6.0-7.0FT (H135-155FT) (H006) to de-
ier, use a crane with a capacity of at least 907.2 kg
termine pre-calculated tension mark locations.
(2000 lb) to raise the carriage high enough to install
3. Clamp the end of the hose (the smaller fitting) a safety chain. See Figure 1.
that attaches to the carriage in a vise (do NOT
8. Align dimension mark E, which is determined
clamp on the threads), and pull on the other end
using Figure 43, at the bottom of the clamps.
until the hose is straight. Do NOT apply enough
Tighten the hardware to 8 N•m (71 lbf in). Refer
force to stretch the hose. See Figure 43.
to Figure 39 or Figure 41.
NOTE: This mark will be used to pretension the
9. Connect the header hoses to the cowl hoses.
header hoses during installation.
10. Use the rubber clamps and hose clamps to attach
4. Place a mark on all the hoses at dimension E (all
the hoses to the main lift cylinders. Make sure
measurements are made from the carriage end of
the hoses do NOT stretch or fold while tilting the
the hose [the smaller fitting]).
mast fully forward and backward.
5. Attach the hoses as shown in Figure 33, for
11. With no load on the forks, check the header hose
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
adjustment by operating the mast through the
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
full lift cycle two times. When properly adjusted,
S120FTPRS) (G004) and, Figure 34, for lift truck
the hoses will not be so tight that they compress
models E3.50-5.50XL, E4.50XLS (E70-120Z,
when they pass over the sheaves nor will they be
E100ZS) (E098), Figure 35, for lift truck models
so loose that they touch the load backrest or any
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
crossmember that is next to a sheave. If neces-
(H80, 90, 100, 110, 120FT) (N005), Figure 36,
sary, repeat until hoses are properly adjusted.
for lift truck models S6.0FT, S7.0FT, (S135FT,
57
1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE
Figure 43. Header Hose Measurement
58
Table 2. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck Models S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
Tension Marker from

Channel Length
Lift Height Carriage End
(Reference)
Dimension "E"
mm in. mm in. mm in.
2740 107.9 2025 79.7
2020 79.5
3000 118.1 2054 80.8
3340 131.5 2316 91.1
2320 91.3
3600 141.7 2345 92.3
3940 155.1 2607 102.6
2620 103.1
4200 165.4 2636 103.7
Table 3. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck Models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
Tension Marker from

Channel Length
(Reference)
Dimension "E"
2740 107.9
2020 79.5 2473 97.3
3000 118.1
3340 131.5
2320 91.3 2768 108.9
3600 141.7
3940 155.1
2620 103.1 3061 120.5
4200 165.4
4640 182.7
3070 120.8 3503 137.9
4900 192.9
5240 206.3
3470 136.6 3896 153.3
5500 216.5
5840 229.9
3870 152.3 4289 168.8
6100 240.2
59
Table 4. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck
Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
Tension Marker from

Channel Length
(Reference)
Dimension "E"
2790 109.8 2025 79.7
2020 79.5
3050 120.1 2060 81.1
3390 133.5 2316 91.1
2320 91.3
3650 143.7 2351 92.5
3990 157.1 2607 102.6
2620 103.1
4250 167.3 2642 104.0
4690 184.6 3044 119.8
3070 120.8
4950 194.9 3079 121.2
5290 208.3 3432 135.1
3470 136.6
5550 218.5 3467 136.4
5840 231.9 3820 150.3
3870 152.3
6150 242.1 3855 151.7
Table 5. Standard Mast Height; Header Hose Tension Mark Location for Lift
Truck Models S6.0-7.0FT (S135, 155FT) (D024)
Tension Marker from

Channel Length
(Reference)
Dimension "E"
2340 92.1 1862 73.3
2084 82.0
3340 131.5 2584 101.7 2352 92.6

4340 170.9 3084 121.4 2842 111.9
Table 6. Standard Mast Height; Header Hose Tension Mark Location for Lift
Truck Models H6.0-7.0FT (H135-155FT) (H006)
Tension Marker from

Channel Length
(Reference)
Dimension "E"
2940 115.7
2384 93.9 2156 84.9
3340 131.5 2584 101.7 2352 92.6
60
4000 SRM 1250 Two-Stage Mast With Full Free-Lift Repair
Table 6. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck
Models H6.0-7.0FT (H135-155FT) (H006) (Continued)
Tension Marker from

Channel Length
(Reference)
Dimension "E"
4340 170.9 3084 121.4 2842 111.9
5340 210.2 3584 141.4 3332 131.1

5940 233.9 4009 157.8 3748 147.6
Two-Stage Mast With Full Free-Lift Repair

REMOVE 100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), and Figure 47 for lift truck models
1. Fully lower inner mast. If mast must be disas- H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
sembled, remove forks and carriage as described (H80, 90, 100, 110, 120FT) (N005).
ment. 2. Slide inner mast from the bottom of the outer
mast approximately 30 cm (12 in.). Remove strip
2. Connect a lifting device to all top crossmembers bearings. See Figure 31. Remove load rollers
of the mast weldments (see Figure 1). Make sure from both weldments. Make a note of the shim
lifting device will hold the weight of the mast. arrangement. Shim arrangement will be approx-
Raise lifting device so the mast has stability. imately the same during assembly procedures.
3. For H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- 3. Using a brass drift, remove tilt rod bushing from
5.5FT (H80, 90, 100, 110, 120FT) (N005) model outer mast. Discard tilt rod bushing. See Fig-
lift trucks. Remove the capscrews that hold the ure 44.
mast pivot pins to the J-hooks mounts on the
drive axle. See Figure 21.
4. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,

120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) model lift trucks. Remove the
four capscrews and washers holding the left and
right mast mounting caps to the drive axle. Use
a lifting device to move mast from lift truck. Put
mast in a position so the crossmembers are on
the floor. See Figure 20.
DISASSEMBLE
1. Clean area around the hydraulic fittings for the
lift cylinders. Disconnect fittings at the lift cylin-
ders and put caps on open lines. See Figure 45
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), Figure 46 for lift 1. TILT ROD BUSHING
truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
Figure 44. Mast Bushing Location
61
Two-Stage Mast With Full Free-Lift Repair 4000 SRM 1250
4. Slide inner mast halfway out of the top of the S120FTPRS) (G004) and E3.50-5.50XL,
outer mast. Connect a lifting device to the center E4.50XLS (E70-120Z, E100ZS) (E098). Re-
of inner mast. See Figure 24. Slide inner mast move bushings and plugs from mast mounting
out of the outer mast until stub shafts are in the hangers. See Figure 20.
notches of the outer mast. Remove inner mast
from the outer mast. 7. Remove and disassemble sheaves and load
rollers as necessary for cleaning and repair. See
5. For lift truck models H4.0FT5/FT6; H4.5FTS5, Figure 45 for lift truck models E3.50-5.50XL,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) E4.50XLS (E70-120Z, E100ZS) (E098), Figure 46
(N005). Check that the pins fit snug in the outer for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
mast. If pins can be moved up and down a min- (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
imum of 4 mm (0.157 in.), replace bushings in S120FTPRS) (G004), and Figure 47 for lift truck
outer mast and/or mast pivot pins as required. models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
See Figure 21. H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005).
6. For lift trucks models S4.0, 4.5, 5.5FT, S5.5FTS,

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

A. INNER MAST AND FREE LIFT B. OUTER MAST AND MAIN LIFT
1. OUTER MAST 16. NUT
2. LOAD ROLLER 17. LOCKWASHER
3. SNAP RING 18. HOSE
4. SHIM 19. CLAMP
5. O-RING 20. PIN
6. TUBE 21. CHAIN GUARD
7. MAIN LIFT CYLINDER (RH) 22. CROSSHEAD
8. MAIN LIFT CYLINDER (LH) 23. FREE-LIFT CYLINDER
9. WASHER 24. LIFT CHAIN (LH SIDE SHOWN FOR CLARITY)
10. STRIP BEARING 25. CHAIN SHEAVES
11. FITTING 26. COTTER PIN
12. CAPSCREW 27. CHAIN ANCHOR
13. BRACKET 28. INNER MAST
14. LOWERING CONTROL VALVE HOUSING 29. VELOCITY FUSE
15. LOWERING CONTROL VALVE 30. STUB SHAFT
62
Figure 45. Two-Stage Mast With Full Free-Lift Repair for Lift Truck Models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
63
Figure 46. Two-Stage Mast With Full Free-Lift Repair for Lift Truck Models S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
64

A. INNER MAST AND FREE-LIFT B. OUTER MAST AND MAIN LIFT
1. OUTER MAST 17. LOCKWASHER
3. SNAP RING 19. CLAMP
4. SHIM 20. PIN
5. O-RING 21. CHAIN GUARD
6. TUBE 22. CROSSHEAD
7. MAIN LIFT CYLINDER (RH) 23. FREE-LIFT CYLINDER
8. MAIN LIFT CYLINDER (LH) 24. LIFT CHAIN (LH SIDE SHOWN FOR CLARITY)
9. WASHER 25. CHAIN SHEAVES
10. STRIP BEARING 26. COTTER PIN
11. FITTING 27. CHAIN ANCHOR
12. CAPSCREW 28. INNER MAST
13. BRACKET 29. VELOCITY FUSE
14. LOWERING CONTROL VALVE HOUSING 30. TIE DOWN CLAMP
15. LOWERING CONTROL VALVE 31. STUB SHAFT
16. NUT
65
Figure 47. Two-Stage Mast With Full Free-Lift Repair for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
66

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

CAUTION facturer’s recommended safety precautions.
clean the load rollers or the lift chains. Steam WARNING
and high-pressure water can remove the lu- Never replace just the worn section of a chain.
brication from the bearings in the load rollers. Replace the complete chain. Never replace just
Water in the bearings of the sheaves and the one chain of a chain pair. Replace both chains.
life of these parts. 4. Clean lift chains with solvent. Inspect lift chains
for wear or damage. See Figure 48. A lift chain
1. Inspect sheaves and load rollers for wear or becomes longer when it is worn. If a section of
damage. DO NOT use steam to clean lift chains, chain is 3% longer than a similar section of new
sheaves, or load rollers. The bearings in the chain, the chain is worn and must be replaced.
sheaves and load rollers are sealed and lubri- If a chain scale is available, check lift chains as
cated. shown in Figure 48. If a chain scale is not avail-
able measure 20 links of chain. Measure from
2. Inspect tilt cylinder bushing in mast. If dam- the center of a pin to the center of another pin 20
aged, replace. pitches away. Compare the length with the chart
in Figure 48. Replace chain if the length of 20
3. Inspect chain anchors and chain anchor pins. If
links of the worn section is more than the maxi-
damaged, replace.
mum wear limit. Lubricate chains with SAE 30
engine oil. The best procedure is to remove lift
WARNING chains from lift truck and soak them in SAE 30
Commercial cleaning solvents may be engine oil.
67
Pitch
25.4 mm (1.00 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

31.8 mm (1.25 in.) 635.0 mm (25.0 in.) 654.1 mm (25.8 in.)

ASSEMBLE in the outer mast. Slide inner mast into the outer
mast so stub shafts are seen at the top and bot-
NOTE: Shims for the load rollers keep the weldments tom of the weldments. See Figure 24.
parallel and provide correct clearance. During as-
sembly, the location of the shims will be approxi- 2. Install strip bearings, O-rings and the shims on
mately the same as they were before disassembly. the outer mast. Apply grease to bearing surface.
See Figure 31.
Check clearance and adjust shims for wear or
changes because of repairs. Strip bearings are also 3. Install load rollers and shims on both weldments.
adjusted by using shims. See the Mast Adjustments Check clearance of the load rollers and strip bear-
in this section for instructions to make the necessary ings as described in Mast Adjustments and Car-
adjustments. riage Adjustments.
1. Connect a lifting device to the center of the inner 4. Install new tilt rod bushing into outer mast. See
mast and insert stub shafts through the notches Figure 49.
68
S120FTPRS) (G004), and Figure 47 for lift truck

models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005).
Tighten capscrews to:
(E70-120Z, E100ZS) (E098) tighten capscrews
to 210 N•m (13 lbf ft).
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) tighten capscrews to
175 N•m (129 lbf ft).
• For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005) tighten capscrews to 175 N•m
(129 lbf ft).
8. Install lift cylinders. Make sure spacers, when

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

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

1. HYDRAULIC HOSES 11. CAPSCREW
2. CHANNEL 12. PAD
3. BRACKET 13. LOCKWASHER
4. CLAMP 14. FITTING
5. WASHER 15. NUT
6. HOSE SHEAVE 16. STRAIN RELIEF
7. SNAP RING 17. HOSE REEL (OPTIONAL)
8. WASHER 18. FITTING AND O-RING
9. TUBE 19. PLATE
10. STRAP CLAMP
70
Figure 50. Two-Stage Mast With Full Free-Lift Header Hoses for Lift Truck ModelsS4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
71
Figure 51. Two-Stage Mast With Full Free-Lift Header Hoses for Lift Truck ModelsE3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)
72

1. HYDRAULIC HOSES 11. CAPSCREW
2. CHANNEL 12. PAD
3. BRACKET 13. LOCKWASHER
4. CLAMP 14. FITTING
5. WASHER 15. NUT
6. HOSE SHEAVE 16. STRAIN RELIEF
8. WASHER 18. FITTING AND O-RING
9. TUBE 19. PLATE
10. STRAP CLAMP
73
Figure 52. Two-Stage Mast With Full Free-Lift Header Hoses for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
74

1. BRACKET (RH) 8. CAPSCREW
2. BRACKET (LH) 9. FITTING
3. PIN 10. LOCK NUT
4. HOSE SHEAVE 11. CAP
5. WASHER 12. CHANNEL
6. SNAP RING 13. HYDRAULIC HOSE
7. CLAMP
HEADER HOSE INSTALLATION AND 6. Ensure hoses routed between truck cowl and the
ADJUSTMENT main lift cylinder are able to move freely during
forward/back tilt without kinking or stressing fit-
Installation tings at cowl.
7. Cycle mast several times to ensure proper rout-

WARNING ing of hoses. Hoses should not bulge out over the
Before working on or near the mast, see Safety sheaves and should not rub up against adjacent
Procedures When Working Near Mast in this crossmembers.
section.
Adjustment
NOTE: This procedure is for the three and four-func-
tion option.
WARNING
The carriage height must be correct before the header Before working on or near the mast, see Safety
hoses can be installed. See Lift Chains Adjustment Procedures When Working Near Mast in this
for the carriage adjustment procedure. section.
1. Route hoses between channels, such that natural NOTE: This procedure is for the three and four-func-
curve of hose loop is between channels. Attach tion option.
hoses to the tube assemblies. See Figure 50, for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, The carriage height must be correct before the header
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- hoses can be adjusted. See Lift Chains Adjustment
PRS) (G004), Figure 51, for lift truck models for the carriage adjustment procedure.
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098), and Figure 52, for lift truck models 1. Loosen hardware at clamp located behind the
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT free-lift cylinder. See Figure 50, for lift truck
(H80, 90, 100, 110, 120FT) (N005). models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FT-
2. Install clamp 108 mm (4.25 in.) below the hose PRS) (G004), Figure 51, for lift truck models
fittings, to the bracket on channel. Tighten cap- E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
screw to 10.8 N•m (96 lbf in). (E098), and Figure 52, for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
3. Connect hoses on sheaves and slide hose sheave (H80, 90, 100, 110, 120FT) (N005).
assembly over stub shaft on bracket. Install
washer and snap ring to retain sheave assembly. 2. Pull on hoses so that hoses move by half the
clamp width or 15 mm (0.6 in.). Tighten hard-
4. Install fitting at the carriage and attach hoses ware.
to fittings with the natural curve of the hoses
routed over the top of sheaves. Attach hoses to 3. Repeat hose adjustment until hoses route
fittings on the hose assembly. smoothly through the mast. Hoses should
not bulge over the sheaves and should not rub
5. Install clamps at the top of channel to retain against adjacent crossmembers.
hoses.
75
Three-Stage Mast With Full Free-Lift Repair 4000 SRM 1250
Three-Stage Mast With Full Free-Lift Repair

REMOVE S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
1. Fully lower inner mast. If mast must be disas- (N005), and E3.50-5.50XL, E4.50XLS (E70-120Z,
sembled, remove forks and carriage as described E100ZS) (E098).
ment. 6. For H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
2. Connect a lifting device to all top crossmembers or H6.0FT, H7.0FT (H135FT, H155FT) (H006)
of the mast weldments (see Figure 1). Make sure model lift trucks. Remove the capscrews that
lifting device will hold the weight of the mast. hold the mast pivot pins to the J-hooks mounts
Raise lifting device so the mast has stability. on the drive axle. Check that the pins fit snug
in the outer mast. If pins can be moved up and
3. Remove tilt cylinders. See Cylinder Repair
down a minimum of 4 mm (0.157 in.), replace
2100 SRM 1328 for lift truck models H6.0FT,
bushings in outer mast and/or mast pivot pins
H7.0FT (H135FT, H155FT) (H006), S6.0FT,
as required. See Figure 21.
S7.0FT, (S135FT, S155FT) (D024) or Cylinder
Repair 2100 SRM 1139 for lift truck models 7. For S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
S80, 100FTBCS; S120FTS; S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (E098), and S6.0FT, S7.0FT, (S135FT,S155FT)
(H80, 90, 100, 110, 120FT) (N005), and (D024) model lift trucks. Remove the four cap-
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) screws holding the left and right mast mounting
E098. caps to the mast. Use a lifting device to move
mast from lift truck. Put mast in a position so the
4. Remove Lift Cylinders. See Cylinder Re-
crossmembers are on the floor. See Figure 20.
pair 2100 SRM 1328 for lift truck models
H6.0FT, H7.0FT (H135FT, H155FT) (H006)
DISASSEMBLE
and S6.0FT, S7.0FT, (S135FT, S155FT) (D024)
or Cylinder Repair 2100 SRM 1139 for 1. Clean area around the hydraulic fittings for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS, the lift cylinders. Disconnect hoses at the lift
(S80, 100, 120FT; S80, 100FTBCS; S120FTS; cylinders and put caps on open lines. See Fig-
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5, ure 53, for lift truck models S4.0, 4.5, 5.5FT,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
(N005), and E3.50-5.50XL, E4.50XLS (E70-120Z, S120FTS; S120FTPRS) (G004), Figure 54, for
E100ZS) (E098). lift truck models, E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), Figure 55, for
5. Remove Free Lift Cylinder. See Cylinder
lift truck models, H4.0FT5/FT6; H4.5FTS5,
Repair 2100 SRM 1328 for lift truck models
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
H6.0FT, H7.0FT (H135FT, H155FT) (H006),
(N005), Figure 56, for lift truck models, S6.0FT,
S6.0FT, S7.0FT, (S135FT, S155FT) (D024)
S7.0FT, (S135FT,S155FT) (D024), and Figure 57
or Cylinder Repair 2100 SRM 1139 for
for lift truck models, H6.0FT, H7.0FT (H135FT,
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
H155FT) (H006).
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
76
4000 SRM 1250 Three-Stage Mast With Full Free-Lift Repair
NOTE: OUTER MAST ASSEMBLY SHOWN.

1. OUTER MAST 13. MAIN LIFT CYLINDERS
2. STUB SHAFT 14. VELOCITY FUSE
3. LOAD ROLLER 15. FITTING
4. SHIM 16. WASHER
5. SNAP RING 17. BRACKET
6. BEARING STRIP 18. LOCKWASHER
7. O-RING 19. CAPSCREW
8. CHAIN ANCHOR 20. CLAMP
9. PIN 21. HOSES
10. COTTER PIN 22. LOWERING CONTROL VALVE HOUSING
11. NUT 23. LOWERING CONTROL VALVE
12. LIFT CHAIN
Figure 53. Main Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
77

1. OUTER MAST 13. MAIN LIFT CYLINDERS
2. STUB SHAFT 14. VELOCITY FUSE
3. LOAD ROLLER 15. FITTING
4. SHIM 16. WASHER
5. SNAP RING 17. BRACKET
6. BEARING STRIP 18. LOCKWASHER
7. O-RING 19. CAPSCREW
8. CHAIN ANCHOR 20. CLAMP
9. PIN 21. HOSES
10. COTTER PIN 22. LOWERING CONTROL VALVE HOUSING
11. NUT 23. LOWERING CONTROL VALVE
12. LIFT CHAIN
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
78

1. OUTER MAST 14. VELOCITY FUSE
2. STUB SHAFT 15. FITTING
3. LOAD ROLLER 16. WASHER
4. SHIM 17. BRACKET
6. BEARING STRIP 19. CAPSCREW
7. O-RING 20. CLAMP
8. CHAIN ANCHOR 21. HOSES
9. PIN 22. LOWERING CONTROL VALVE HOUSING
10. COTTER PIN 23. LOWERING CONTROL VALVE
11. NUT 24. SNAP RING
12. LIFT CHAIN 25. BUSHING
13. MAIN LIFT CYLINDERS
79
S6.0FT, S7.0FT, (S135FT,S155FT) (D024)
80

1. RIGHT HAND LIFT CYLINDERS 17. SHIM
2. STRAP CLAMP 18. LOAD ROLLER
3. FITTING 19. SNAP RING
4. CLAMP 20. LUBE FITTING
5. HOSE 21. BUSHING
6. CAPSCREW 22. PLUG
7. HOUSING 23. CAP
8. NUT 24. E-RING
9. WASHER 25. O-RING
10. LOWERING CONTROL VALVE 26. BEARING STRIP
11. TUBE 27. MAST SHIM
12. LEFT HAND LIFT CYLINDER 28. CHAIN ANCHOR
13. SPACER 29. SNAP RING
14. HOSE CLAMP 30. COTTER PIN
15. OUTER MAST 31. PIN
16. STUB SHAFT 32. CHAIN
81
H6.0FT, H7.0FT (H135FT, H155FT) (H006)
82

1. RIGHT HAND LIFT CYLINDER 16. STUB SHAFT
2. STRAP CLAMP 17. SHIM
3. FITTING 18. LOAD ROLLER
4. CLAMP 19. SNAP RING
5. HOSE 20. PIN
6. CAPSCREW 21. CHAIN
7. HOUSING 22. SNAP RING
8. NUT 23. BUSHING
9. WASHER 24. E-RING
10. LOWERING CONTROL VALVE 25. O-RING
11. TUBE 26. BEARING STRIP
12. LEFT HAND LIFT CYLINDER 27. MAST SHIM
13. SPACER 28. CHAIN ANCHOR
14. HOSE CLAMP 29. SNAP RING
15. OUTER MAST 30. COTTER PIN
83
Figure 58. Free-Lift Installation for Three-Stage Mast With Full Free-Lift for Lift Truck Models
SS4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and
84

A. INNER MAST B. INTERMEDIATE MAST
1. INTERMEDIATE MAST 16. VELOCITY FUSE
2. INNER MAST 17. WASHER
3. STUB SHAFT 18. CROSSHEAD
4. LOAD ROLLER 19. PIN
5. SHIM 20. CLAMP
6. SNAP RING 21. NUT
7. BEARING STRIP 22. HOSE
8. O-RING 23. CHAIN ANCHOR
9. SPACER 24. COTTER PIN
10. CHAIN SHEAVE 25. LIFT CHAIN
11. BRACKET 26. CHAIN GUARD
12. LOCKWASHER 27. TIE DOWN CLAMP
13. CAPSCREW 28. BALL BEARING
14. HOSE SHEAVE 29. COLLAR
15. FREE-LIFT CYLINDER
85
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
86

1. INTERMEDIATE MAST 15. FREE-LIFT CYLINDER
2. INNER MAST 16. VELOCITY FUSE
4. LOAD ROLLER 18. CROSSHEAD
5. SHIM 19. PIN
6. SNAP RING 20. CLAMP
7. BEARING STRIP 21. NUT
8. O-RING 22. HOSE
9. SPACER 23. CHAIN ANCHOR
10. CHAIN SHEAVE 24. COTTER PIN
11. BRACKET 25. LIFT CHAIN
12. LOCKWASHER 26. CHAIN GUARD
13. CAPSCREW 27. INSERT
14. HOSE SHEAVE 28. SHIM
87
S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006)
88

1. INNER MAST 11. FREE LIFT CYLINDER
2. CHAIN ANCHOR 12. LIFT CHAIN
3. WASHER 13. PIN
4. SPACER 14. BEARING
5. CAPSCREW 15. CHAIN SHEAVE
6. NUT 16. SET SCREW
7. STUB SHAFT 17. CROSS HEAD
8. LOAD ROLLER 18. GUARD
9. SHIM 19. INTERMEDIATE MAST
10. SNAP RING 20. BEARING STRIP
2. Remove the pins for the lift chains at the chain models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
anchors on the inner mast. Remove chain sheave 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
assembly from the free-lift cylinder. Disconnect (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
and cap all hydraulic lines for the free-lift cylin- H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
der. Remove capscrews and clamps that hold Figure 59, for lift truck models E3.50-5.50XL,
free-lift cylinder to the inner mast. Remove E4.50XLS (E70-120Z, E100ZS) (E098), and Fig-
free-lift cylinder. See Figure 58, for lift truck ure 60 for lift truck models, S6.0FT, S7.0FT,
models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, (S135FT,S155FT) (D024) and H6.0FT, H7.0FT
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (H135FT, H155FT) (H006).
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005), 6. Slide intermediate mast from the bottom of the
Figure 59, for lift truck models E3.50-5.50XL, outer mast approximately 30 cm (12 in.). Remove
E4.50XLS (E70-120Z, E100ZS) (E098), and Fig- strip bearings and load rollers. Make a note of
ure 60 for lift truck models, S6.0FT, S7.0FT, the shim arrangement. Shim arrangement will
(S135FT,S155FT) (D024) and H6.0FT, H7.0FT be approximately the same during assembly pro-
(H135FT, H155FT) (H006). cedures.
3. Disconnect and remove lift chains between the 7. Slide intermediate mast halfway out of the top of
outer mast and the inner mast. Slide inner mast the outer mast. Connect a lifting device to the
from the bottom of the intermediate mast ap- center of the intermediate mast. See Figure 24
proximately 30 cm (12 in.). Remove strip bear- Slide intermediate mast out of the outer mast
ings. Remove load rollers from the inner and in- until stub shafts are in the notches of the outer
termediate mast. Make a note of the shim ar- mast. Remove intermediate mast from the outer
rangement and remove shims. Shim arrange- mast.
ment will be approximately the same during as-
8. Using a brass drift, remove tilt rod bushing from
sembly procedures.
outer mast. Discard tilt rod bushing. See Fig-
4. Slide inner mast halfway out of the top of the ure 61.
intermediate mast. Connect a lifting device to
9. For lift trucks models S4.0, 5.0, 5.50FT
the center of inner mast. See Figure 24. Slide
([S80, 100, 120FT;] S80, 100, 120FTBCS;
the inner mast out of the intermediate mast.
S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS
5. Slide intermediate mast from the outer mast (E70-120Z, E100ZS) (E098), and S6.0FT, S7.0FT,
approximately 30 cm (12 in.) to disengage lift (S135FT,S155FT) (D024). Remove bushings and
cylinders from the intermediate mast. Remove plugs from mast mounting hangers. See Fig-
the lift cylinders from the mounts at the bottom ure 20.
of the outer mast. See Figure 58, for lift truck
89
and high-pressure water can remove the lu-

brication from the bearings in the load rollers.
Water in the bearings of the sheaves and the
life of these parts.
1. Inspect chain sheaves and load rollers for wear or

damage. DO NOT use steam to clean lift chains,
chain sheaves, or load rollers. The bearings in
the sheaves and load rollers are sealed and lu-
bricated.
2. Inspect chain anchors and anchor pins for dam-

age. If damaged, replace.
WARNING
Commercial cleaning solvents may be
1. TILT ROD BUSHING irritation. When using commercial cleaning
Figure 61. Mast Bushing Location facturer’s recommended safety precautions.
10. For lift trucks models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) WARNING
(N005) and H6.0FT, H7.0FT (H135FT, H155FT) Never replace just the worn section of a chain.
(H006). Remove mast mounting snap rings and Replace the complete chain. Never replace just
bushings from outer mast. See Figure 21. one chain of a chain pair. Replace both chains.
11. Remove and disassemble chain sheaves and 3. Clean lift chains with solvent. Inspect lift chains
load rollers as necessary for cleaning and re- for wear or damage. See Figure 62. A lift chain
pair. See Figure 58, for lift truck models S4.0, becomes longer when it is worn. If a section of
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, chain is 3% longer than a similar section of new
100FTBCS; S120FTS; S120FTPRS) (G004) and chain, the chain is worn and must be replaced.
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT If a chain scale is available, check lift chains as
(H80, 90, 100, 110, 120FT) (N005), Figure 59, shown in Figure 62. If a chain scale is not avail-
for lift truck models E3.50-5.50XL, E4.50XLS able measure 20 links of chain. Measure from
(E70-120Z, E100ZS) (E098), and Figure 60 for lift the center of a pin to the center of another pin 20
truck models, S6.0FT, S7.0FT, (S135FT,S155FT) pitches away. Compare the length with the chart
(D024) and H6.0FT, H7.0FT (H135FT, H155FT) in Figure 62. Replace chain if the length of 20
(H006). links of the worn section is more than the maxi-
mum wear limit. Lubricate chains with SAE 30
CLEAN AND INSPECT engine oil. The best procedure is to remove lift
chains from lift truck and soak them in SAE 30
CAUTION engine oil.
clean the load rollers or the lift chains. Steam
90
Pitch
25.4 mm (1.00 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

31.8 mm (1.25 in.) 635.0 mm (25.0 in.) 654.1 mm (25.8 in.)

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

NOTE: Shims for load rollers keep weldments paral- for lift truck models, H6.0FT, H7.0FT (H135FT,
lel and provide correct clearance. During assembly, H155FT) (H006), and Figure 58, for lift truck mod-
location of the shims will be approximately the same els S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
as they were before disassembly. Check clearance S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
and adjust shims for wear or changes because of and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
repairs. Strip bearings are also adjusted by us- (H80, 90, 100, 110, 120FT) (N005), Figure 59, for lift
ing shims. See Mast Adjustments procedure in truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
this section for instructions to make the necessary E100ZS) (E098), and Figure 60 for lift truck mod-
adjustments. See Figure 53, for lift truck models, S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and
els S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; H6.0FT, H7.0FT (H135FT, H155FT) (H006).
Figure 54, for lift truck models, E3.50-5.50XL, 1. Connect a lifting device to the center of the in-
E4.50XLS (E70-120Z, E100ZS) (E098), Figure 55, termediate mast (see Figure 24). Put stub shafts
for lift truck models, H4.0FT5/FT6; H4.5FTS5, through the notches in the outer mast. Slide in-
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) termediate mast into the outer mast so that stub
91
shafts are seen at the top and bottom of the weld- 6. For lift trucks models H4.0FT5/FT6; H4.5FTS5,
ments. H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and H6.0FT, H7.0FT (H135FT, H155FT)
2. Install strip bearings, O-rings and shims on the (H006). Install mast mounting snap rings and
intermediate mast. Apply grease to bearing sur- bushings into outer mast. See Figure 21.
face. See Figure 31.
7. Install main lift cylinders. Make sure the spac-
3. Install load rollers and shims on both weldments. ers, when installed, are in their original positions
Check the clearance of the load rollers and strip at the bottom mounts. Install capscrews, wash-
bearings as described in Mast Adjustments and ers, and brackets at the bottom of each cylinder.
Carriage Adjustments. Tighten capscrews to 38 N•m (28 lbf ft). Push
the inner mast to engage the rods of the lift
4. Install new tilt rod bushing into outer mast. See
cylinders. Install washers and snap rings at the
Figure 63.
top of the lift cylinders. If removed, install shims
as noted during disassembly. Install cylinder
clamps to the brackets at the top of the outer
mast. Tighten nuts to 18 N•m (159 lbf in).
See Figure 53 for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004), Figure 54,
for lift truck models, E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), Figure 55, for
lift truck models, H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), Figure 56, for lift truck models S6.0FT,
H155FT) (H006).
8. Install hose sheaves on the intermediate mast.
9. Connect lift chains to the chain anchors at the

bottom of the inner mast. Use wire to hold the
1. TILT ROD BUSHING other end of the lift chains to the top of the outer
mast.
Figure 63. Mast Bushing Location
10. Connect a lifting device to the center of the inner
5. For lift trucks models S4.0, 4.5, 5.5FT, S5.5FTS,
mast (see Figure 24). Put stub shafts through
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
the notches in the intermediate mast. Slide inner
S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS
mast into the intermediate mast so stub shafts
(E70-120Z, E100ZS) (E098), and S6.0FT, S7.0FT,
are seen at the top and bottom of the weldments.
(S135FT,S155FT) (D024). Install bushings and
plugs from mast mounting hangers. See Fig- 11. Install strip bearings, O-rings and shims on the
ure 20. outer mast. Apply grease to bearing surface. See
Figure 31.
NOTE: When installing mast mounting bushings,
ensure bores and snap ring grooves are clean and 12. Install load rollers and shims on both weldments.
free from any obstructions. Be sure to install the Check clearance of the load rollers and strip bear-
inner snap ring (nearest to truck center) first. Drive ings as described in Mast Adjustments and Car-
bushings until contact with inner snap ring is made. riage Adjustments.
Clean bushing material from outer snap ring grooves
and install outer snap ring.
92
13. Connect lift chains to the mounts at the top of the E100ZS) (E098), Figure 65, for lift truck models
outer mast. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
14. Install chain sheave assembly on the free-lift Figure 66, for lift truck models H4.0FT5/FT6;
cylinder. Install free-lift cylinder on the inner H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
mast. See Figure 58, for lift truck models S4.0, 110, 120FT) (N005), Figure 67, for lift truck mod-
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, els S6.0FT, S7.0FT, (S135FT,S155FT) (D024),
100FTBCS; S120FTS; S120FTPRS) (G004) and and Figure 68, for lift truck models H6.0FT,
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT H7.0FT (H135FT, H155FT) (H006).
(H80, 90, 100, 110, 120FT) (N005), Figure 59,
for lift truck models E3.50-5.50XL, E4.50XLS INSTALL
(E70-120Z, E100ZS) (E098), and Figure 60 for lift
truck models, S6.0FT, S7.0FT, (S135FT,S155FT) Install the three-stage mast using the procedures as
(D024) and H6.0FT, H7.0FT (H135FT, H155FT) described in Two-Stage Mast With Limited Free-Lift
(H006). Repair, Install, S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
15. Connect lift chains to the chain anchors at the (G004) S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and
mount on the inner mast. Attach wires between E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
the ends of the lift chains and the bottom cross- Lift Trucks Models. See Figure 53, for lift truck
member to control the lift chains during installa- models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
tion. S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
Figure 54, for lift truck models, E3.50-5.50XL,
16. Install lowering control valve on the outer mast.
E4.50XLS (E70-120Z, E100ZS) (E098), Figure 55,
for lift truck models, H4.0FT5/FT6; H4.5FTS5,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
S120FTPRS) (G004) and E3.50-5.50XL,
(N005), Figure 56, for lift truck models S6.0FT,
E4.50XLS (E70-120Z, E100ZS) (E098) tighten
• For lift truck models H4.0FT5/FT6; H4.5FTS5,
H155FT) (H006). Also, see arrangement of the
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
header hoses in Figure 64, for lift truck mod-
120FT) (N005) tighten capscrew to 38 N•m
els E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(28 lbf ft).
(E098), Figure 65, for lift truck models S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), Figure 66, for lift
(H135FT, H155FT) (H006) tighten capscrew to
truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
33 N•m (24 lbf ft).
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
17. Connect hydraulic lines and fittings between Figure 67, for lift truck models S6.0FT, S7.0FT,
the lowering control valve and lift cylinders and (S135FT,S155FT) (D024), and Figure 68, for lift
install header hose. See Figure 64, for lift truck truck models H6.0FT, H7.0FT (H135FT, H155FT)
models E3.50-5.50XL, E4.50XLS (E70-120Z, (H006).
93
Figure 64. Three-Stage Mast Header Hoses for Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
94

2. WASHER 10. FITTING
3. SHEAVE 11. HOSE REEL (OPTIONAL)
4. CLAMP 12. PLATE
5. CAPSCREW 13. PIN
6. HYDRAULIC HOSE 14. JUNCTION BOX
7. NUT 15. SPACER
8. BRACKET
95
Figure 65. Three-Stage Mast Header Hoses for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
96

1. HYDRAULIC HOSES 9. LOCKWASHER
2. NUT 10. PIN
3. BRACKET 11. FITTING
4. HOSE SHEAVE 12. SPACER
5. WASHER 13. STRAIN RELIEF
7. CLAMP 15. PLATE
8. CAPSCREW
97
1. HYDRAULIC HOSE 7. CLAMP

2. WASHER 8. CAPSCREW
3. NUT 9. BRACKET (RH)
4. BRACKET 10. PIN
5. SHEAVE 11. FITTING
6. SNAP RING 12. BRACKET (LH)
Figure 66. Three-Stage Mast Header Hoses for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
98
Figure 67. Three-Stage Mast Header Hoses for Lift Truck Models S6.0FT, S7.0FT, (S135FT,S155FT)
(D024)
99

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

1. TUBE 13. CAP
2. HYDRAULIC HOSE (THREE FUNCTION) 14. WASHER
3. HYDRAULIC HOSE (FOUR FUNCTION) 15. STRAIN RELIEF
4. HOSE CLAMP 16. BRACKET
5. CLAMP 17. HOSE REEL
6. FITTING 18. PLATE
7. CAPSCREW 19. NUT
8. HOSE SHEAVE 20. BRACKET (LH)
9. MOUNTING BRACKET 21. CLAMP (INSULATED)
10. SHAFT 22. BALL VALVE
11. SNAP RING 23. O-RING
12. SHIM
100
Figure 68. Three-Stage Mast Header Hoses for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006)
101
HEADER HOSE ALIGNMENT FOR S4.0, (E098) use Table 9 for pre-calculated tension
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; mark locations.
S80, 100FTBCS; S120FTS; S120FTPRS) 3. Clamp the end of the hose (the smaller fitting)
(G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; that attaches to the carriage in a vise (DO NOT
H5.0-5.5FT (H80, 90, 100, 110, 120FT) clamp on the threads), and pull on the other end
(N005) AND E3.50-5.50XL, E4.50XLS until the hose is straight. Do NOT apply enough
force to stretch the hose.
(E70-120Z, E100ZS) (E098)
NOTE: These marks will be used to pretension the
WARNING header hose during installation.
Before working on or near the mast, see Safety
4. Place a mark on all the hoses at dimensions F
and G (all measurements are made from the
section.
carriage end of the hose [the smaller fitting]).
NOTE: This procedure is for the four-function option. See Figure 65 and Table 7 for lift trucks models
The three-function option is identified with hoses A S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
and B and fifth function is identified with hose E. S80, 100FTBCS; S120FTS; S120FTPRS) (G004).
Table 8 for lift truck models H4.0FT5/FT6;
NOTE: The carriage height must be correct before the H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
header hoses can be adjusted. See Lift Chains Ad- 110, 120FT) (N005) and Table 9 for lift truck
justment for the carriage adjustment procedure. models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098).
1. Mark each hose with a single letter: A, B, C, D
or E. See Figure 69. 5. Attach the hoses to the carriage bracket with
clamps. Apply spray lubricant to the surface of
2. Dimensions F, G and H are determined by the the hose guide that contacts the hoses.
height of the outer mast channel from the ground
and the length of the outer mast channel. See 6. Place the hoses over the top of the free-lift chains
dimensions Y and Z in Figure 70. To determine and under the hose guides. Attach the hose
F, G and H for lift truck models S4.0, 4.5, 5.5FT, guides to the lower crossmember and tighten
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; the mounting hardware to 33 N•m (24 lbf ft).
S120FTS; S120FTPRS) (G004) use Table 7. To Make sure the bracket is between the crossmem-
determine F, G and H for lift truck models ber and the hose guide. Put the clamps over
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT the hoses and attach the clamps to the free-lift
(H80, 90, 100, 110, 120FT) (N005) use Table 8. bracket. (DO NOT tighten the hardware.). See
To determine F, G and H for lift truck models Figure 69.
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
102
Figure 69. Header Hose Alignment for Lift Truck Models S4.0, 5.0, 5.50FT ([S80, 100, 120FT;] S80,
100, 120FTBCS; S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) (Sheet 1 of 2)
103
Figure 69. Header Hose Alignment for Lift Truck Models S4.0, 5.0, 5.50FT ([S80, 100, 120FT;] S80,
100, 120FTBCS; S120FTPRS) (G004), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) (Sheet 2 of 2)
104

A. HOSE A (THREE FUNCTION) G. ALIGN TENSION MARK "G" AT THE TOP OF
B. HOSE B (THREE FUNCTION) CLAMP.
C. HOSE C (FOUR FUNCTION) H. ALIGN TENSION MARK "H" AT THE BOTTOM
D. HOSE D (FOUR FUNCTION) OF CLAMP.
E. HOSE E (FIVE FUNCTION) I. TOP VIEW
F. ALIGN TENSION MARK "F" AT THE TOP OF J. MIDDLE VIEW
CLAMP. K. BOTTOM VIEW
105
1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE
Figure 70. Header Hose Measurement
106
Table 7. Standard Mast Height; Header Hose Tension Mark Location for Lift Truck Models S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
Tension Marker
Tension Marker from Tension Marker
Channel from Carriage
Carriage End from Carriage End
Lift Height Length End
Dimension "F" Dimension "G"
(Reference) Dimension "H"
(Bottom) (Middle)
(Top)
mm in. mm in. mm in. mm in. mm in.
4087 160.9 2273 89.4 1619 63.7 4062 159.9
2020 79.5
4365 171.9 2418 95.1 1764 69.4 4207 165.6
4665 183.7 2120 83.4 2517 99.0 1814 71.4 4403 173.3
4640 182.7 2476 97.4 1722 67.7 4459 175.5
2220 87.4
4900 192.9 2615 102.9 1861 73.2 4598 181.0
5240 206.3 2673 105.2 1919 75.5 4850 190.9
2420 95.2
5500 216.5 2812 110.7 2058 81.0 4989 196.4
5950 234.3 2620 103.1 3009 118.4 2255 88.7 5380 211.8
Table 8. Standard Mast Height; Header Hose Tension Mark Location For lift truck models
Tension Tension
Tension Marker
Marker from Marker from
Channel Length from Carriage End
Lift Height Carriage End Carriage End
(Top)
(Bottom) (Middle)
4087 160.9 1619 63.7 2273 89.4 4062 159.9
2020 79.5
4365 171.9 1764 69.4 2418 95.1 4207 165.6
4387 172.7 1669 65.7 1669 65.7 4258 167.6
2120 83.4
4665 183.7 1814 71.4 2517 99.0 4403 173.3
4640 182.7 1722 67.7 1722 67.7 4459 175.5
2220 87.4
4900 192.9 1861 73.2 2615 102.9 4598 181.0
4940 194.5 1821 71.7 1821 71.6 4655 183.2
2320 91.3
5200 204.7 1960 77.1 2714 106.8 4794 188.7
5240 206.3 1919 75.5 1919 75.5 4850 190.9
2420 95.2
5500 216.5 2058 81.0 2812 110.7 4989 196.4
5950 234.3 2620 103.1 2255 88.7 2255 88.7 5380 211.8
107
Table 9. Standard Mast Height; Header Hose Tension Mark Location For lift truck
models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
Tension Tension
Tension Marker
Marker from Marker from
Channel Length from Carriage End
Lift Height Carriage End Carriage End
(Top)
(Bottom) (Middle)
4087 160.9 1525 60.0 2224 87.5 4024 158.4
2020 79.5
4365 171.9 1681 66.1 2380 93.7 4180 164.5
4387 172.7 1624 63.9 2323 91.4 4220 166.1
2120 83.4
4665 183.7 1779 70.0 2478 97.5 4375 172.2
4640 182.7 1728 68.0 2427 95.5 4421 174.0
2220 87.4
4900 192.9 1878 73.9 2577 101.4 4571 179.9
4940 194.5 1827 71.9 2526 99.4 4617 181.7
2320 91.3
5200 204.7 1976 77.7 2675 105.3 4766 187.6
5240 206.3 1925 75.7 2624 103.3 4812 189.4
2420 95.2
5500 216.5 2075 81.6 2774 109.2 4962 195.3
5950 234.3 2272 89.4 2971 116.9 5353 210.7
2620 103.1
5690 224.0 2122 83.5 2821 111.0 5203 204.8
NOTE: To make the alignment of dimension H eas- Tighten the hardware to 8 N•m (71 lbf in). See
ier, use a crane with a capacity of at least 907.2 kg Figure 69, Sheet 2.
(2000 lb) to raise the carriage high enough to attach
a safety chain. See Figure 1. 11. Install the clamps. See Figure 65 and Figure 69.
7. Align the mark for dimension H at the bottom 12. Connect the header hoses to the cowl hoses.
of the clamp to create the proper hose tension.
13. Use the rubber clamps and strap clamps to at-
Tighten the hardware to 8 N•m (71 lbf in).
tach the hoses to the main lift cylinders. Make
8. Position the hoses at the hose sheave. The sure the hoses do not stretch or fold while tilting
hose sheave and stub shaft must be installed on the mast fully forward and backward.
the hose before they are attached to the mast.
14. With no load on the forks, check the header hose
Tighten the hardware to 66 N•m (49 lbf ft).
adjustment by operating the mast through the
9. Put the clamps over the hoses and attach the full lift cycle two times. When properly adjusted,
clamps to the upper brackets. (DO NOT tighten the hoses will not be so tight that they compress
the hardware.) when they pass over the sheaves nor will they be
NOTE: To make the alignment of dimension F and crossmember that is next to a sheave. If neces-
G easier, use a crane to raise the inner channel high sary, repeat until hoses are properly adjusted.
enough to install a safety chain.
10. Align mark F and G on hoses A, B, C and D at

the top edge of clamp to create the proper tension.
108
HEADER HOSE ALIGNMENT FOR H6.0FT, 5. Install guides and snap rings onto the sheave.
H7.0FT (H135FT, H155FT) (H006) AND
6. Position the hoses on the hose sheave. The hose
S6.0FT, S7.0FT, (S135FT,S155FT) (D024) sheave must be installed on the hose before they
are attached to the mast. Install the sheave as-
WARNING sembly into the mast mount.
Before working on or near the mast, see Safety
7. Install the pin into the sheave assembly. Install
the socket head set screw.
section.
8. Put the clamps over the hoses and attach the
NOTE: This procedure is for the four-function option.
clamps to the upper brackets. (DO NOT tighten
The three-function option is identified with hoses A
the hardware.)
and B and fifth function is identified with hose D.
9. Install the clamps. See Figure 71.
NOTE: The carriage height must be correct before the
header hoses can be adjusted. See Lift Chains Ad- 10. Connect the header hoses to the cowl hoses.
justment for the carriage adjustment procedure.
11. Use the rubber clamps and strap clamps to at-
1. Mark each hose with a single letter: A, B, C, or tach the hoses to the main lift cylinders. Make
D. See Figure 71. sure the hoses do not stretch or fold while tilting
the mast fully forward and backward.
2. Attach hoses A and B to the carriage bracket
with clamps. Apply spray lubricant to the sur- 12. With no load on the forks, check the header hose
face of the hose guide that contacts the hoses. adjustment by operating the mast through the
full lift cycle two times. When properly adjusted,
3. Place hoses A and B over the top of the free-
the hoses will not be so tight that they compress
lift chains. Attach the hose guides to the guard
when they pass over the sheaves nor will they be
and tighten the mounting hardware to 31 N•m
(23 lbf ft). See Figure 71.
cross member that is next to a sheave. If neces-
4. Insert spacers into the sheave. See Figure 72 sary, repeat until hoses are properly adjusted.
109
Figure 71. Header Hose Alignment for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006) and S6.0FT, S7.0FT, (S135FT,S155FT) (D024) (Sheet 1 of 2)
110
A. HOSE A (THREE FUNCTION) C. HOSE C (FOUR FUNCTION)

B. HOSE B (THREE FUNCTION) D. HOSE D (FIVE FUNCTION)
Figure 71. Header Hose Alignment for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006) and S6.0FT, S7.0FT, (S135FT,S155FT) (D024) (Sheet 2 of 2)
111
Figure 72. Hose Sheave Installation
112
4000 SRM 1250 Tilt Cylinder Adjustment

1. INTERMEDIATE MAST SECTION 5. GUIDE
2. PIN 6. SPACER
3. SOCKET HEAD SET SCREW 7. SHEAVE
4. SNAP RING
Mast Operation Check

1. Check for leaks in the hydraulic system. Check
WARNING condition of hydraulic hoses and tubes.
Lower the lift mechanism completely. Never
allow anyone under a raised carriage. Do not NOTE: Some parts of the mast move at different
put any part of your body in or through the speeds during raising and lowering.
lift mechanism unless all parts of the mast
are completely lowered and the engine is 2. Slowly raise and lower the mast several times
STOPPED. without a load. Mast components must raise and
lower smoothly in correct sequence. Carriage
Before making any repairs, use blocks and raises first, then inner mast and intermediate
chains on the mast weldments and carriage so mast (three-stage masts only).
they cannot move. Make sure the moving parts
are attached to a part that does not move. 3. Inner mast and the carriage must lower com-
pletely.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components. 4. Check that controls for the attachment operate
Hydraulic oil can be injected into the body by the functions of the attachment. See symbols
pressure. by each of the controls. Make sure all hydraulic
lines are connected correctly and do not leak.
Tilt Cylinder Adjustment

Check tilt cylinder stroke by slowly tilting mast fully c. For lift truck models S4.0, 4.5, 5.5FT,
forward and backward several times. Both tilt cylin- S5.5FTS, (S80, 100, 120FT; S80, 100FT-
ders must stop their stroke at the same time. There BCS; S120FTS; S120FTPRS) (G004), E3.50-
must be no twist in the mast weldments. See Fig- 5.50XL, E4.50XLS (E70-120Z, E100ZS)
ure 73 and Figure 74. (E098), S6.0FT, S7.0FT, (S135FT,S155FT)
(D024) and H6.0FT, H7.0FT (H135FT,
1. Adjust the tilt cylinders as follows: H155FT) (H006) tighten capscrews on rod
end to 90 N•m (66 lbf ft) and tighten the
a. Tilt mast backward slowly until one rod is
anchor locking bolt to 68 N•m (50 lbf ft). For
against its stop. On the opposite cylinder,
lift truck models H4.0FT5/FT6; H4.5FTS5,
loosen capscrews on the rod end. Use a
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
wrench and turn the cylinder rod out until
120FT) (N005) tighten capscrews on rod end
both rods stop at the same time.
to 66 to 73 N•m (49 to 54 lbf ft) and tighten
b. Repeat procedure to make sure rods stop at the anchor locking bolt to 68 N•m (50 lbf ft).
same time within 1 mm (0.04 in.). Check the
tilt angles are correct as specified on Name-
plate of lift truck.
113
Tilt Cylinder Adjustment 4000 SRM 1250
1. MAST HANGER BUSHING 8. NUT

2. LUBE FITTINGS 9. WASHER
3. MAST BUSHING PLUGS 10. ROD END BUSHING
4. TILT PIN 11. TILT CYLINDER ASSEMBLY
5. ROD END 12. MAST MOUNTING CAP
6. ANCHOR PIN 13. LUBE FITTINGS*
7. CAPSCREW
* LUBE FITTINGS USED ONLY ON LIFT TRUCK MODELS S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004)
Figure 73. Tilt Cylinder Arrangement for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) Shown
114
4000 SRM 1250 Lift Chains Adjustment

1. TILT CYLINDER 7. CAPSCREW
2. MAST 8. LOCKWASHER
3. ROD END 9. NUT
4. BUSHING 10. PIVOT PIN
5. PIN 11. SNAP RING
6. RETAINER PIN 12. BUSHING
Figure 74. Tilt Cylinder Arrangement for

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

When the lift chains are correctly adjusted:
WARNING • The tension will be the same on each chain of the
When working on or near the mast, see Safety chain set. Check tension by pushing on both chains
Procedures When Working Near Mast in this at the same time.
section. • The chain length will be correct.
• The chains must travel freely through the complete
During test procedures for the hydraulic sys- cycle.
tem, fasten the load to the carriage with chains
to prevent it from falling. Keep all personnel NOTE: When the chain adjustments are complete,
away from the lift truck during the tests. make sure the threads on the nuts of the chain an-
chors are completely engaged. Make sure the chain
Never allow anyone under a raised carriage. anchors are not adjusted too tight. The chain anchors
DO NOT put any part of your body in or must be able to move on their mounting.
through the lift mechanism unless all parts
of the mast are completely lowered and the 1. When adjusting the lift chains on forklift trucks
engine is STOPPED. equipped with either pin or hook-type forks in-
stalled, go to Step 3. If the forklift truck is nor-
Never check for leaks by putting hands on mally equipped with a hook-type carriage and
hydraulic lines or components under pressure. has an attachment without forks, go to Step 4.
Hydraulic oil under pressure can be injected
into the skin.
115
Lift Chains Adjustment 4000 SRM 1250
NOTE: Install new cotter pins and chain anchor pins.

Both legs of cotter pin must be bent against chain
anchor pin.
2. Tighten chain anchor nuts to:

(E70-120Z, E100ZS) (E098), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004),
and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
tighten to 210 N•m (155 lbf ft).
(H135FT, H155FT) (H006), tighten to 370 N•m
(273 lbf ft).
NOTE: Prior to performing adjustment procedures, 1. MAST

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

riage, until the bottom of the lower carriage bar
is 82.5 ±3.0 mm (3.25 ±0.12 in.) above the floor
level. See Figure 76.
Table 10. Hook-Type Carriage Chain

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

Class IV 133.5 ±3.0 mm (5.26 ±0.12 in.)
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Figure 76. Lift Chain Adjustment, Hook-Type

Carriage
116
4000 SRM 1250 Mast Adjustments
Mast Adjustments
NOTE: Shims are installed on both sides of the load the clearance and adjust shims after repairs have
rollers. Do not add or remove shims from the stub been completed.
shafts. To change the position of the roller on the
stub shaft, move the shims from one side of the load 1. The load rollers control the alignment of the mast
roller to the other. uprights. See Figure 77. The alignment condi-
tions are given on a list below with the most im-
During assembly, the shim arrangement will be ap- portant condition first.
proximately the same as before disassembly. Check
NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO GIVE APPROXIMATELY EQUAL
SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO GIVE ZERO CLEARANCE AT POINT
OF TIGHTEST FIT.
A. TOP VIEW B. MAST FRONT VIEW C. CARRIAGE FRONT VIEW
1. CHANNEL 7. ZERO CLEARANCE AT POINT 10. PUT SPACER ON OUTSIDE OF
2. LOAD ROLLER OF TIGHTEST FIT TOP LOAD ROLLER, UNDER
3. STUB SHAFT 8. EQUAL SPACE ±1.5 mm SNAP RING
4. SNAP RING (0.060 in.) 11. SHIM FOR ZERO CLEARANCE
5. SHIMS 9. PARALLEL TO CHANNEL AT POINT OF TIGHTEST FIT
6. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
±1.5 mm (0.060 in.)
Figure 77. Mast Adjustments
117
Mast Adjustments 4000 SRM 1250
a. The mast uprights must be parallel to each b. Separate mast uprights and change shim ar-
other. rangements as required. Assemble uprights.
Slide upright all the way to the top and bot-
b. Use shims to adjust load rollers so there is tom to find the tightest fit.
zero clearance between load roller and chan-
nel at point of tightest fit. c. Repeat Step a and Step b until there is zero
clearance at the point of the tightest fit.
c. The number of shims under a load roller
must be approximately the same as the stub d. Measure distance between channels of mast
shaft in the opposite side of the upright. This uprights on top and bottom. Change shims
ensures the uprights will be approximately to keep distance equal between top and bot-
in the center. tom so mast uprights are parallel. Also make
sure the mast uprights are parallel within
2. Perform the following steps to adjust the mast 1.5 mm (0.060 in.).
load rollers:
3. Adjust strip bearings. See Figure 78. Insert
a. Use a crowbar to move mast uprights from shims under strip bearing. Adjust clearance un-
side to side to measure movement. Measure til there is less than 0.8 mm (0.030 in.) at the
movement in a minimum of three different tightest fit. See Figure 77.
positions of each mast upright.
1. STRIP BEARING 4. SHIMS

2. LOAD ROLLER 5. O-RING
3. MAST UPRIGHT
Figure 78. Strip Bearings Arrangement
118
4000 SRM 1250 Carriage Adjustments
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.
119
NOTES
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____________________________________________________________
____________________________________________________________
120
TECHNICAL PUBLICATIONS
4000 SRM 1250 7/07 (3/07)(11/06)(6/06)(3/06) Printed in U.S.A.

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MAST REPAIRS

2 AND 3-STAGE MASTS

PART NO. 1627340 4000 SRM 1250

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• 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.

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

©2007 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

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

Safety Procedures When Working Near Mast

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

Figure 1. Safety Chaining the Mast

A fork can be removed from the carriage for replace-

1. LOAD BACKREST 6. WEDGE

Figure 3. Carriage and Forks

INSTALL Some applications may require closer alignment. If

Inspect the forks for cracks and wear. Check the

Table 1. Fork Tip Alignment

Fork Tip Alignment Specifications

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

1Difference of alignment between fork tips must

1. CARRIAGE 7. CHAIN ANCHOR POSITION (THREE STAGE

Legend for Figure 6

Legend for Figure 7

Legend for Figure 8

Integral Sideshift Carriage Repair

1. CAPSCREWS 12. FIXED FRAME

Figure 9. Integral Sideshift Carriage

1. SIDE LOAD ROLLERS 3. *LUBE FITTINGS

ASSEMBLE H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

Hang On Sideshift Carriage Repair

NOTE: FORKS REMOVED FOR CLARITY.

Figure 11. Hang On Sideshift Carriage With Fork Positioner

6. If lift truck is equipped with a E-Hydraulic con-

1. CARRIAGE BARS 3. BLOCKS WARNING

WARNING 8. If lift truck is not equipped with a fork positioner,

1. CARRIAGE 7. CHAIN ANCHOR POSITION (THREE STAGE

1. LOAD BACKREST 6. WEDGE

Figure 14. Load Backrest and Forks

1. LIFTING DEVICE 5. SIDESHIFT CARRIAGE ASSEMBLY

Figure 15. Fork Positioner Removal

DISASSEMBLE 7. Disengage the cylinders from fork positioner

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

Figure 16. Hang On Sideshift Assembly

1. NUT 8. SNAP RING

Figure 17. Fork Positioner Assembly

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

1. SNAP RING 6. WIPER 11. PISTON

Figure 18. Hang On Sideshift Cylinder

Fork Positioner Cylinders CLEAN AND INSPECT

2. Inspect the carriage weldments and rollers for

1. CYLINDER ROD 5. BACKUP RING 9. PISTON

Figure 19. Fork Positioner Cylinders

4. Slide the cylinder rod retainer onto the cylinder