Mastil Reparar

MAST
REPAIR
N35ZDR, N45ZR [C264];
N35ZDR2, N45ZR2 [D264];
N30ZDR, N35-40ZR [D470];
N35-40ZR2, N30ZDR2 [E470];
N30ZDRS, N35-40ZRS [A265];
N35-40ZRS2, N30ZDRS2 [B265]
PART NO. 1590956 4000 SRM 1195

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load
being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the
load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure
to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make
sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Load Backrest .................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 2
Forks ................................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 3
Checks ............................................................................................................................................................ 4
Sheaves ............................................................................................................................................................... 4
Hydraulic System............................................................................................................................................... 8
Hydraulic Oil ................................................................................................................................................. 10
Drain .......................................................................................................................................................... 10
Cylinder Identification .............................................................................................................................. 11
Fill .............................................................................................................................................................. 12
Main Lift Cylinders............................................................................................................................... 13
Free-Lift Cylinders................................................................................................................................ 13
Reach Carriage Assembly.................................................................................................................................. 14
Remove ........................................................................................................................................................... 14
Install ............................................................................................................................................................. 16
Load Rollers........................................................................................................................................................ 17
Mast................................................................................................................................................................ 17
Reach Assembly ............................................................................................................................................. 18
Load Rollers ............................................................................................................................................... 18
Side Rollers ................................................................................................................................................ 19
Mast .................................................................................................................................................................... 19
Remove ........................................................................................................................................................... 19
Disassemble ................................................................................................................................................... 20
Clean and Inspect .......................................................................................................................................... 22
Assemble ........................................................................................................................................................ 23
Install ............................................................................................................................................................. 24
Lift Cylinders ..................................................................................................................................................... 26
Main Lift Cylinders ....................................................................................................................................... 26
Remove....................................................................................................................................................... 26
Install ......................................................................................................................................................... 26
Free-Lift Cylinder.......................................................................................................................................... 30
Remove....................................................................................................................................................... 30
Install ......................................................................................................................................................... 30
Lift Chains.......................................................................................................................................................... 32
Clean and Inspect .......................................................................................................................................... 32
Mast Adjustments.............................................................................................................................................. 33
General ........................................................................................................................................................... 33
Mast Back Angle Adjustment ....................................................................................................................... 33
Load Rollers Adjustment............................................................................................................................... 34
Reach Carriage Assembly ......................................................................................................................... 34
Adjust Wear Plugs - Mast ............................................................................................................................. 35
Adjust Main-Lift Chains ............................................................................................................................... 36
Adjust Free-Lift Chain .................................................................................................................................. 37
Adjust Wear Strips ........................................................................................................................................ 38
Mast Racking ................................................................................................................................................. 40
Proximity Switches........................................................................................................................................ 41
©2013 HYSTER COMPANY i

Table of Contents Mast
TABLE OF CONTENTS (Continued)

Replace ....................................................................................................................................................... 41
Free-Lift Proximity Switch................................................................................................................... 41
Load Lowering Proximity Switch (Optional)....................................................................................... 42
Adjust ......................................................................................................................................................... 43
Mast Operation Check ....................................................................................................................................... 43
Lift System Leak Check .................................................................................................................................... 43
Lift Cylinder Leak Check .............................................................................................................................. 43
Tilt Cylinder Leak Check .............................................................................................................................. 44
This section is for the following models:
N35ZDR, N45ZR [C264];

N35ZDR2, N45ZR2 [D264];
N30ZDR, N35-40ZR [D470];
N35-40ZR2, N30ZDR2 [E470];
N30ZDRS, N35-40ZRS [A265];
N35-40ZRS2, N30ZDRS2 [B265]
ii
4000 SRM 1195 Safety Procedures When Working Near Mast
General
This section contains instructions for the removal, rollers take the forward and back stress loads during
installation, repair, and adjustment procedures on operation of the mast, and roll on sealed bearing
the three-stage, full free-lift (FFL) reach truck masts. assemblies.
Masts are available in a 5.5-in. configuration, 6.9-in.
configuration, as well as a 5.5 heavy-duty configura- WARNING
tion, which uses a 6.9-in. outer mast weldment with
The mast and carriage assemblies and their
5.5-in. inner and intermediate weldments. The de-
components are heavy. To help prevent dam-
scription and operation of these masts are outlined
age or an injury, a lifting device of suitable
in the section Mast, Description 4000 SRM 1194. A
capacity must be used during all service pro-
troubleshooting chart is listed at the end of this sec-
cedures.
tion. Repair procedures for the reach carriages are
presented in Reach Carriages 4500 SRM 1196. The mast assemblies must have the mast weldments
parallel with equal clearance on each side between
These mast assemblies and carriages have wear
all weldments. Correct operation also depends on
plugs and shims to allow for wear and adjustment.
periodic cleaning, lubrication, and adjustment. See
The wear plugs are housed in the stub shafts of
Mast Operation Check, Hydraulic System Leaks
the load rollers and slide against the center of the
Check, Lift Chains, Mast Adjustments, and Car-
weldment channels. A setscrew and jam nut secure
riage Adjustments at the end of this section.
each wear plug in the correct position. The load
Safety Procedures When Working Near Mast

The forks may be difficult to see when the mast is
WARNING raised. Be careful not to hit your head when working
All chains, ropes, and lifting equipment MUST around raised forks. Also, be careful not to trip over
be fully examined by qualified personnel at forks on or near the floor. If possible, remove forks
least once a year or more at frequent intervals from carriage before safety chaining the mast.
according to the local conditions of use.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely. Make
WARNING
sure there is no movement in the mast. Make sure
Mast parts are heavy and may shift. Distances all parts of the mast that can move are fully low-
between parts are small. Serious injury can re- ered.
sult if part of the body is hit by parts of the mast
or the carriage. OR
• Never put any part of the body into or under
the mast or carriage unless all parts are com- • If the mast must be in a raised position for re-
pletely lowered or a safety chain is installed. pairs, install a safety chain around the top or mid-
Also make sure the power is off and the key dle crossmember of the outer weldment and the
is removed. Attach a DO NOT OPERATE tag crossmember of the inner weldment to secure the
to the control handle. mast.
• DO NOT make repairs or adjustments unless
you have been properly trained and autho- WARNING
rized to do so. Repairs and adjustments must
Perform the following steps from the side of the
be performed by trained service technicians.
mast using a ladder. Never stand under the car-
• DO NOT climb on the mast or lift truck at any
riage until safety chains are installed.
time. Use a ladder or personnel lift to work
on the mast. 1. Remove forks from carriage if possible.
• Move the truck to a safe location with room to
raise the mast if necessary. Block the wheels 2. Raise mast to align the crossmembers of the in-
of the truck to prevent movement. termediate mast weldment with a crossmember
on outer weldment.
1
Load Backrest 4000 SRM 1195
3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum

size, around crossmembers of inner and outer
weldment. Secure it in place. See Figure 1.
4. Lower mast until safety chain stops mast. Lower

the mast until all components of the mast that
can move are completely lowered. Make sure
there is no movement of mast.
5. Turn key switch to the OFF position, disconnect

the battery, and attach a DO NOT OPERATE
tag to the control handle.
6. Wrap a second safety chain, 9.5 mm (3/8 in.) min-

imum size, around crossmembers of intermedi-
ate and outer weldments. Secure it in place as
an additional precaution.
NOTE: The mast operator guard MUST be removed

to install safety chain. Remove safety chain and in- 1. OUTER MAST WELDMENT
2. INNER MAST LOWER CROSSMEMBER
stall guard AFTER repairs are complete. 3. SAFETY CHAIN
4. CARRIAGE CROSSMEMBER
Figure 1. Safety Chain the Mast
Load Backrest
REMOVE INSTALL
1. Position the load backrest onto the tilting frame
WARNING using a lifting device. Align the holes on the load
The load backrest is heavy and can cause an backrest with the proper mounting holes on the
injury. DO NOT try to remove it without using tilting frame.
a lifting device.
2. Loosely install the four capscrews securing the
1. Attach a lifting device to steady the load back- load backrest to the carriage.
rest.
3. Tighten all four capscrews to 102 N•m (75 lbf ft).
2. Remove the four capscrews that fasten the load
backrest to the carriage.
3. Lift the load backrest from the tilting frame us-

ing the lifting device.
2
4000 SRM 1195 Forks
Forks
The forks are held on the carriage by hooks. The
forks are kept in position by pins that fit through the
top fork hooks and into slots in the top bar carriage.
If pin does not remain engaged in carriage slot, re-
place with new pin. Always check that the pins for
the forks keep the forks in position on the carriage.
Replace damaged fork pin parts. The forks can be re-
moved 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 1. CARRIAGE BARS 3. BLOCKS

DO NOT try to remove a fork without a lifting 2. HOOK FORK
device. Each hook fork for these lift trucks can
Figure 2. Hook Fork Removal
weigh 45 to 115 kg (99 to 254 lb).
A fork can be removed from the carriage for replace-

ment or other maintenance. Slide the fork to the fork
removal notch in the bottom bar of the carriage. See
Figure 2 and Figure 3. Lower the fork onto blocks so
the bottom hook of the fork moves through the fork
removal notch. See Figure 2. Lower the carriage fur-
ther so the top hook of the fork is disengaged from
the top carriage bar. Move the carriage away from
the fork or use a lifting device to move the fork away
from the carriage.
INSTALL
Move the fork and carriage so the top hook on the
fork can engage the upper carriage bar. Raise the 1. FORK 4. SPRING
carriage to move the lower hook through the fork re- 2. KNOB 5. PIN
moval notch. Slide the fork on the carriage so both 3. LOCK PIN
upper and lower hooks engage the carriage bars. En-
Figure 3. Forks and Lock Pin Assembly
gage the lock pin with a notch in the upper carriage
bar.
3
Sheaves 4000 SRM 1195
CHECKS be replaced. Check that the bottom of each fork is

not excessively worn. Check for smooth and proper
WARNING operation of the fork lock pins. Repair or replace any
damaged or broken fork lock pins or components and
Never repair damaged forks by heating or
lubricate, as necessary. See Figure 4.
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.
Table 1. Fork Tip Alignment
Fork Tip Alignment Specifications

Standard Fork Maximum Fork Tip
Lengths Difference 1
mm (in.) mm (in.)
914 (36) 27 (1.08)
1067 (42) 32 (1.26)
1219 (48) 37 (1.44) A. HEEL OF FORK (MUST BE 90% OF DIMENSION
B)
1372 (54) 41 (1.62) B. ORIGINAL FORK THICKNESS (DIMENSION B)
1524 (60) 46 (1.80) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
1829 (72) 55 (2.16) FORK LENGTH)
2. CRACKS
1Difference of alignment between fork tips must
3. MAXIMUM ANGLE 93°
be no more than 3% of the total fork length. 4. FORK REMOVAL NOTCH
5. CARRIAGE
Some applications may require closer alignment. If Figure 4. Fork Check

the forks do not meet specification, they both must
Sheaves
The following procedures relate to removing, repair- b. Attach an overhead lifting device of suitable
ing, and replacing sheaves on a mast installed to a capacity to the top of the reach carriage.
lift truck. If the mast has been removed, skip to the Raise the reach carriage 305 mm (12 in.) to
appropriate steps. Complete only the steps necessary loosen the free-lift chains and hoses.
to safely complete the repairs.
2. Install safety chains to the mast to prevent unex-
1. Remove the weight of the mast from the hoses pected movements. See Safety Procedures When
and chains from the sheave assemblies: Working Near Mast.
a. Attach an overhead lifting device of suitable 3. Remove the retaining ring(s) securing the sheave
capacity to the top of the inner mast. Raise assembly(s) to be removed, and slide the sheaves
the inner mast 305 mm (12 in.) to loosen the and bearings from the stub shaft. See Figure 5,
main lift chains and hoses. Figure 6, and Figure 7.
4
4000 SRM 1195 Sheaves
1. CAPSCREW 11. LOCKWASHER 21. HOSE SHEAVE

2. SHOULDER WASHER 12. CAPSCREW 22. RETAINING RING
3. RETAINING RING 13. CAPSCREW 23. RETAINING RING
4. BEARING 14. RETAINING RING 24. CHAIN SHEAVE
5. SHEAVE 15. BEARING 25. BEARING
6. STUB SHAFT 16. RETAINING RING 26. STUB SHAFT
7. GUIDE BOLT 17. SHEAVE 27. FOAM CUSHIONS
8. TUBE CLAMP 18. STUB SHAFT 28. INTERMEDIATE MAST
9. HOSE CLAMP 19. RETAINING RING
10. FLAT WASHER 20. WASHER
Figure 5. Sheaves (5.5 Mast)
5
Sheaves 4000 SRM 1195
1. BEARING 7. RETAINING RING

2. RETAINING RING 8. CHAIN SHEAVE
3. CHAIN SHEAVE 9. CAPSCREW
4. RETAINING RING 10. RETAINING RING
5. HOSE SHEAVES 11. WIRE SHEAVE
6. WASHER 12. BEARING
Figure 6. Sheaves (6.9 Mast)
6
4000 SRM 1195 Sheaves
4. Clean and inspect the sheave assembly compo-

nents. Replace the damaged components. Check
the bearings and stub shafts for damage or ex-
cessive wear. Repair or replace as necessary.
5. Reassemble the sheave assembly(s) onto the stub

shafts as removed.
6. Position the lift chains and hoses onto the

sheaves as removed and secure with retaining
rings.
7. Remove the safety chains and lower the mast

weldments and carriage to tighten the lift chains
and hoses.
8. Check the mast for proper operation. Verify

proper tracking of the hoses and chains.
1. SCREW 4. HOSE SHEAVES

2. GUARD BRACKET 5. RETAINING RING
3. STUB SHAFT 6. MAST CHANNEL
Figure 7. Lower Sheave (6.9 Mast)
7
Hydraulic System 4000 SRM 1195
Hydraulic System
leaked out. Check around fittings and hose con-
WARNING nections for seeping oil. Replace hoses immediately
Always wear the proper protective equipment when damage or significant wear is found. Loosen
including eye protection and petroleum-resis- fittings slowly and cover with a cloth to make sure
tant gloves when handling hydraulic oil. Thor- pressure has been relieved in the system. Empty the
oughly wash oil from exposed areas of skin as hoses into a drain pan and cap or plug all open ports
soon as possible. and hoses at once to prevent contaminants from
entering the system. All hydraulic hoses and tubes
Completely lower all mast components and re-
must be thoroughly cleaned before installation.
lieve pressure by opening the manual lowering
valve before disassembling any part of the lift
pump or disconnecting any hydraulic hoses. WARNING
Failure to return the manual lowering valve
The hydraulic oil is hot at normal operating knob to the full clockwise position will cause
temperatures. Be careful when draining the the forks to lower unexpectedly.
oil.
The hydraulic system may remain pressurized even
Never put your hands on pressurized hydraulic after the mast is completely lowered and all hy-
components. Highly-pressurized hydraulic oil draulic components are at rest. Pressure can be
escaping through pin-hole leaks can be in- relieved from the system by opening the manual
jected into the skin. Visually inspect to find lowering valve located on the main lift pump. Turn
hydraulic leaks. the manual lowing valve knob counterclockwise to
open the valve. Make certain the valve is closed be-
CAUTION fore returning to service. See Figure 8 and Figure 9.
Protect the hydraulic system from dirt and NOTE: The hydraulic system (including the mast)
contaminants when servicing the hydraulic must be purged of air when refilling the hydraulic
system. system with oil.
Never operate the pump without the proper When making repairs, use the least number of fit-
amount of oil in the hydraulic system. The tings and connections to minimize flow resistance
operation of the hydraulic pump with low oil and the possibility of leakage. Route new hoses prop-
levels will damage the pump. erly to avoid contact that may cause premature wear.
Close the manual lowering valve and refill the hy-
The hydraulic oil in the system performs the dual
draulic system with oil when repairs are complete.
function of power transmission and lubrication. Us-
ing the proper oil is essential to system operation. Various types of fittings are used to connect hoses
The hydraulic oil level should be checked first when and hydraulic system components. Some of these in-
troubleshooting mast hydraulic problems. Low oil clude flared fittings, O-ring fittings, and flat-faced
levels may cause it to appear that a problem exists O-ring fittings. Certain fittings have properties that
with the mast or other hydraulic components. make them better suited for particular applications.
Check the threads and mating surfaces of each fit-
NOTE: The hydraulic oil must be completely drained
ting when removed. Fittings with O-rings should be
from the system before any hydraulic hoses may be
inspected carefully and the O-ring replaced if it is
removed. Refer to Hydraulic Oil for the proper proce-
brittle, cracked, or otherwise damaged. Make sure
dures for your lift truck. Oil will remain in the hoses
mating surfaces are clean and smooth and DO NOT
even when the hydraulic system has been drained.
over tighten fittings. Inspect fittings for leaks often
Visually inspect the hoses for leaks. Small oil leaks following repairs.
may appear as wet, oily leaks or unusually dirty ar-
eas where dirt and dust sticks to oil that has slowly
8
4000 SRM 1195 Hydraulic System
1. LOWERING VALVE
2. UPPER MOUNTING HOLE 1. HYDRAULIC GEAR PUMP
3. M2 PORT 2. SUPPLY FITTING
4. MANUAL LOWERING VALVE KNOB 3. PRESSURE FITTING
5. M1 PORT 4. MOUNTING CAPSCREW
6. RETURN FITTING 5. LOCKWASHER
7. RELIEF VALVE 6. PUMP SPLINES
8. SUPPLY FITTING
9. LOWER MOUNTING HOLE Figure 9. Lift Pump Components (N30ZDRS,
10. OVERRUN CHECK VALVE N35-40ZRS)
11. PRESSURE FLANGE
Figure 8. Lift Pump Components (N35ZDR,

N45ZR, N30ZDR, N35-40ZR)
9
HYDRAULIC OIL 4. Remove the breather cap from the top of the tank.
Drain 5. Position a suitable container oil with a minimum

capacity of 19 liter (5 gal) next to the lift truck to
drain the oil.
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis- CAUTION
tant gloves when handling hydraulic oil. Thor- DO NOT cut the hose when removing the wire
oughly wash oil from exposed areas of skin as tie.
soon as possible.
6. Locate the drain hose at the bottom of the hy-
Completely lower all mast components and re- draulic tank. See Figure 10. Carefully clip the
lieve pressure by opening the manual lowering wire tie securing the hose. Loosen and remove
valve before disassembling any part of the lift the hose clamp securing the plug in the end of the
pump or disconnecting any hydraulic hoses. hose. Remove the plug from the hose and drain
the hydraulic oil into the container.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the 7. Some lift trucks use displacement-type, main lift
oil. cylinders, which retain some amounts of oil even
when at rest. Refer to Cylinder Identification.
Never put your hands on pressurized hydraulic These cylinders may be further drained to re-
components. Highly-pressurized hydraulic oil duce levels of contaminants left in the hydraulic
escaping through pin-hole leaks can be in- system. If your truck is equipped with displace-
jected into the skin. Visually inspect to find ment-type, main lift cylinders:
hydraulic leaks.
a. Loosen both main lift cylinder bleed screws
1/2 turn.
CAUTION
Disposal of lubricants and fluids must meet lo- b. Open the lowering control valve.
cal environmental regulations.
c. Allow time for the oil to gravity feed into the
The hydraulic oil should be changed every 2000 tank.
hours or yearly. When the hydraulic system com-
ponents such as the pump or cylinders have been d. Turn the lowering control valve to the OFF
damaged or the oil has otherwise been contaminated, position.
the hydraulic system should be drained, flushed,
e. Retighten the bleed screws at the top of the
and refilled with new hydraulic oil.
main lift cylinder shells.
1. Park the lift truck on a level surface and lower
8. Drain the remaining oil from the tank. Place the
the mast. Turn the key switch to the OFF po-
plug into the hose and secure with hose clamp
sition, and attach a DO NOT OPERATE tag to
as removed. Coil the drain hose and secure with
the control handle. Block the wheels to prevent
wire tie as removed.
unexpected movement.
9. Inspect the tank. Check for damage to the tank
2. Disconnect the battery power cable connector
or hoses. Clean the tank, if necessary.
from the truck connector located on the right side
of the frame. Pull the battery cable connector 10. Reinstall the breather cap as removed.
handle to separate the battery connector from
the truck connector.
3. Remove the operator compartment cover and the

drive unit compartment door to access the hy-
draulic tank.
10
Cylinder Identification
Two main lift cylinders and one free-lift cylinder are
present on all models of this series lift truck. How-
ever, cylinders may be either displacement-type or
piston-type. Certain cylinder types require different
hydraulic oil drain and fill procedures.
The main lift cylinders may be identified by the pres-

ence of a bleed screw near the top of the cylinder shell
on displacement-type cylinders. Piston-type, main
lift cylinders are not equipped with bleed screws. See
Figure 11.
1. PLUG 4. TANK
2. HOSE 5. WIRE TIE
3. ELBOW (WITH 6. CLAMP 1. TOP OF INTERMEDIATE MAST
CLAMP) 2. CYLINDER ROD
3. BLEED SCREW
Figure 10. Drain Hose (INDICATES DISPLACEMENT-TYPE
CYLINDER)
4. CYLINDER SHELL
Figure 11. Main Lift Cylinder Identification
11
Free-lift cylinders can be identified by the cylinder Table 2. Cylinder Identification

rod diameter. Measure the diameter of the free-lift
cylinder rod to determine your lift truck configura- Type Free-Lift Cylinders
tion. See Figure 12 and Table 2.
Displacement 73.00 mm (2.87 in.)
Piston 44.40 mm (1.75 in.)
Fill
NOTE: Refer to Capacities and Specifications
8000 SRM 1198 for the proper hydraulic oil selection.
1. Fill the hydraulic tank to the proper level with

new hydraulic oil. The hydraulic oil should be
filled to 25 mm (1 in.) below the bottom of the
hydraulic filter housing on the tank. DO NOT
overfill the hydraulic tank. See Figure 13.
1. HYDRAULIC FILTER HOUSING

1. CROSSHEAD ASSEMBLY 2. HYDRAULIC RETURN FITTING
2. CYLINDER ROD DIAMETER 3. HYDRAULIC OIL FILL LEVEL
3. BLEED OR FILL SCREW 4. HYDRAULIC TANK
4. RETAINER BRACKET
5. CYLINDER SHELL Figure 13. Hydraulic Oil Level
6. GLAND
Figure 12. Free-Lift Cylinder Rod
12
2. Install the breather cap. d. Slightly open the bleed screw of either main
lift cylinder by turning it counterclockwise
3. Determine the types of main lift cylinders and until air and/or oil foam is expelled. Allow
free-lift cylinders used. Refer to Cylinder Iden- air/foam to bleed from cylinder until clear hy-
tification. draulic oil is present. Close the bleed screw
and tighten to 6 to 8 N•m (53 to 71 lbf in). If
Main Lift Cylinders
the free-lift cylinder completely lowers before
1. Piston-type, main lift cylinders do not require all the air is expelled, close the bleed screw
bleeding. If your lift truck is equipped with pis- and return to Step a. Wipe up the expelled
ton-type, main lift cylinders, skip to Free-Lift oil and repeat procedure for the other main
Cylinders. lift cylinder.
Free-Lift Cylinders
WARNING
Keep clear of the mast when bleeding the cylin- 1. Piston-type, free-lift cylinders are not bled but
ders. Mast parts may shift or lower unexpect- do have an oil chamber that must be filled for
edly. cylinder cushion functions to work properly:
Never put your hands on pressurized hydraulic a. Completely lower the mast and carriage.
components. Highly-pressurized hydraulic oil Turn the key switch to the OFF position and
escaping through pin-hole leaks can be in- disconnect the battery.
jected into the skin. Visually inspect to find b. Slightly open the fill screw on the side of
hydraulic leaks. the free-lift cylinder shell near the gland by
2. Displacement-type, main lift cylinders must be turning it counterclockwise to make sure the
bled: cylinder is not pressurized. Slowly remove
the fill screw and seal.
a. Engage the battery connectors and turn the
key switch to the ON position. NOTE: Use a clean oil can to measure and inject hy-
draulic oil into the cylinder fill hole.
b. Activate the lift function using the operator
controls. Continue until the free-lift cylinder c. Measure approximately 150 cc (5 oz) of clean
rod extends approximately 150 mm (6 in.) to hydraulic oil and fill the oil chamber through
apply pressure to the hydraulic system. the fill hole. Fill until all the oil is used or
until oil flows out of the fill hole.
c. Turn the key switch to the OFF position and
remove the key. d. Install the fill screw and seal and tighten to
6 to 8 N•m (53 to 71 lbf in). Wipe up any
spilled oil.
WARNING
Use a personnel lift or a ladder to access the e. Connect the battery and turn the key switch
bleed screws. DO NOT climb on the mast or lift to the ON position. Completely raise and
truck. lower the mast several times to check for
proper operation. The free-lift cylinder
should slow smoothly near the end of its
CAUTION stroke. Check the hydraulic oil level in the
DO NOT completely remove the bleed screw. tank and fill as necessary. Replace all covers
Loosen it slowly and gradually. as removed, remove blocks from the wheels,
and return the lift truck to service.
NOTE: Use a cloth to wipe up foam and oil as it is
expelled to minimize spills.
13
Reach Carriage Assembly 4000 SRM 1195
d. Slightly open the bleed screw on the side

WARNING of the free-lift cylinder shell near the gland
Keep clear of the mast when bleeding the cylin- by turning it counterclockwise until air
ders. Mast parts may shift or lower unexpect- and/or oil foam is expelled. Allow air/foam to
edly. bleed from the cylinder until clear hydraulic
oil is present. Close the bleed screw and
Never put your hands on pressurized hydraulic tighten to 6 to 8 N•m (53 to 71 lbf in). If the
components. Highly-pressurized hydraulic oil free-lift cylinder completely lowers before all
escaping through pin-hole leaks can be in- air/foam is expelled, close the bleed screw
jected into the skin. Visually inspect to find and repeat Step a. Wipe up the expelled
hydraulic leaks. oil. Some displacement-type, free-lift cylin-
2. Displacement-type, free-lift cylinders must be ders also have an additional bleed screw
bled: located in the end of the cylinder rod. In-
spect the cylinder rod where it emerges from
a. Engage the battery connectors and turn the the crosshead. If the rod is equipped with
key switch to the ON position. the additional bleed screw, repeat the bleed
procedure using the additional bleed screw.
b. Activate the lift function using the operator
controls. Continue until the free-lift cylinder e. Connect the battery and turn the key switch
rod extends approximately 150 mm (6 in.) to to the ON position. Completely raise and
apply pressure to the hydraulic system. lower the mast several times to check for
proper operation. Repeat the bleed proce-
c. Turn the key switch to the OFF position and dure until no air is present when bleeding
disconnect the battery. the free-lift cylinder. Check the hydraulic oil
level in the tank and fill as necessary. Re-
CAUTION place all covers as removed, remove blocks
from the wheels, and return the lift truck to
DO NOT completely remove the bleed screw.
service.
NOTE: Use a cloth to wipe up foam and oil as it is
expelled to minimize cleanup.
Reach Carriage Assembly

REMOVE b. Install a chain loop or sling through each
clamp separately, and attach each loop to the
1. Remove the forks. See Forks. overhead lifting device.
2. Remove the load backrest. See Load Backrest. 5. Raise the reach carriage assembly high enough
to access the hydraulic and wiring harness con-
3. Remove the hardware securing the operator
nections on the rear frame.
guard from the rear of the mast, and remove the
operator guard. 6. Safety chain the reach carriage assembly in
place. See Safety Procedures When Working
WARNING Near Mast.
Reach carriage assemblies are heavy. Be sure 7. Disconnect the lift chains from the reach carriage
that all lifting devices are suitable and of ade- assembly:
quate capacity to lift the components.
a. Remove the cotter pin and chain anchor pin
4. Attach an overhead lifting device to the top of the securing the chain to the anchors.
reach carriage assembly:
b. Secure chains to the mast using stiff wire to
a. Install heavy-duty, industrial C-clamps to keep them from falling from the sheaves.
the top of each side of the rear frame. See
Figure 14.
14
4000 SRM 1195 Reach Carriage Assembly
c. If the mast must be disassembled or the

chains need to be cleaned/lubricated, remove WARNING
the lift chains and clean and inspect. Mast assemblies are heavy. Be sure that all lift-
ing devices are suitable and of adequate capac-
8. Tag and disconnect the attachment hoses from ity to lift the components.
the two fittings at the bottom of the rear frame
of the reach carriage assembly. Cap or plug all NOTE: Use a lifting device or a second lift truck to
open hydraulic hoses. move the reach carriage assembly.
9. Disconnect the reach wiring connector. Remove 11. Attach an overhead lifting device to the top
the reach wiring harness from the top of the rear of the inner mast. Raise the inner mast until
frame. clearly higher than the reach carriage assembly.
Move the reach carriage assembly away and
10. Remove the safety chains and completely lower completely lower the mast.
the reach carriage assembly to the floor.
12. Disconnect the lifting device from the inner mast.
Figure 14. C-Clamp Installation
15
Reach Carriage Assembly 4000 SRM 1195
INSTALL 5. Raise the reach carriage assembly high enough

to access the hydraulic connections and wiring
1. Position the reach carriage assembly in an up- harness connection on the rear frame.
right position with the back of the reach carriage
aligned with the front of the mast assembly. 6. Safety chain the reach carriage assembly. See
Safety Procedures When Working Near Mast.
WARNING
Mast assemblies are heavy. Be sure that all lift- CAUTION
ing devices are suitable and of adequate capac- If reusing chains, make sure chains have been
ity to lift the components. properly inspected, cleaned, and lubricated.
See Lift Chains.
NOTE: Use an overhead lifting device of suitable ca-
pacity to raise the inner mast when installing the 7. Reconnect the lift chains to anchors on reach car-
reach carriage assembly. Use a second lifting device riage assembly as removed. Install anchor pins
or lift truck to position the reach carriage assembly and cotter pins.
under the inner mast channels.
8. Connect the wiring connector to the top of the
2. Raise the inner mast until clearly higher than rear frame.
the reach carriage assembly. Position the reach
carriage assembly so the load rollers of the rear 9. Remove caps/plugs from the attachment hoses
frame are centered under the channels of the in- and fittings. Reconnect the hoses as removed.
ner mast.
NOTE: Check that all lift chains, hoses, and wiring
NOTE: Check that all lift chains, hoses, and wiring are seated properly on the sheaves as the reach car-
are seated properly on the sheaves as the inner mast riage assembly is lowered.
is lowered.
10. Remove the safety chains and completely lower
3. Lower the inner mast channels onto the load the reach carriage assembly.
rollers of the rear frame. If the inner mast does
11. Remove the C-clamps and lifting device from the
not lower smoothly and completely, raise the
reach carriage assembly.
inner mast, reposition the reach carriage assem-
bly, and lower the inner mast again. 12. Raise and lower the mast several times to remove
air from the system. Cycle the tilt and side shift
WARNING (if so equipped) functions several times to remove
Reach carriage assemblies are heavy. Be sure air from the system. Check for proper operation.
that all lifting devices are suitable and of ade-
13. Check the hydraulic oil level and add as required.
quate capacity to lift the components.
14. Check reach carriage assembly height and align-
4. Attach an overhead lifting device to the top of the
ment and adjust the lift chains as required. See
reach carriage assembly:
Carriage Adjustments.
a. Install heavy-duty, industrial C-clamps to
15. Install the load backrest. See Load Backrest.
each side of the rear frame. See Figure 14.
16. Install the forks. See Forks.
b. Install a chain loop or sling through each
clamp separately, and attach each loop to the 17. Install the operator guard as removed.
overhead lifting device.
16
4000 SRM 1195 Load Rollers
Load Rollers
MAST 5. Remove the wear plugs by inserting a screw-
driver through the setscrew hole and pushing
NOTE: It is necessary to remove the mast assembly the wear plug out of the stub shaft. Inspect the
from the truck to remove or replace load rollers, wear wear plug for wear and replace as necessary.
plugs, weldments, or lift cylinders.
1. Remove the reach carriage assembly from the WARNING

mast. Refer to Reach Carriage Assembly. Be careful when removing or installing snap
rings. Snap rings can eject during removal or
2. Remove the mast from the lift truck and posi- installation with enough force to cause an in-
tion it face down and level with the floor across jury. Always use the correct snap ring pliers,
wooden beams. See Mast, Remove in this section. and wear eye and face protection during re-
moval or installation.
3. Disconnect the lift chains, hoses, and wiring as
necessary to slide the mast weldments up or 6. Remove the snap rings from the stub shaft.
down to access each of the load rollers. Secure
the weldments in place using chains to prevent 7. Use a pry bar to remove the load roller from the
unexpected movement. stub shaft. Refer to Figure 16 and Figure 17.
4. Remove the jam nuts and setscrews from the load

rollers. See Figure 15.
1. LOAD ROLLER WITH SNAP RING REMOVED

2. PRY BAR
3. REAR FRAME
4. SIDE ROLLER
1. LOAD ROLLER 5. JAM NUT Figure 16. Removing Load Roller (6.9 Mast
2. WEAR PLUG 6. STUB SHAFT
3. RETAINING RING 7. MAST CHANNEL Shown)
4. SETSCREW
Figure 15. Load Roller and Wear Plug
17
Load Rollers 4000 SRM 1195
REACH ASSEMBLY
Load Rollers
1. Check the reach assembly for loose play where
shims may need to be added.
2. Remove the reach assembly from the mast as-

sembly to access the rear frame load rollers. See
Reach Carriage Assembly.
WARNING
Be careful when removing or installing snap
rings. Snap rings can eject during removal or
installation with enough force to cause an in-
jury. Always use the correct snap ring pliers,
and wear eye and face protection during re-
moval or installation.
3. Remove the snap rings from the stub shaft. Use

a pry bar to remove the load roller from the stub
shaft. See Figure 16.
4. Recover the shims from behind the load roller.

Tag the shim pack and identify the location for
proper reassembly. See Figure 18.
2. RETAINING RING 5. SETSCREW 5. Use a cloth to clean each load roller. Inspect the
3. LOAD ROLLER 6. JAM NUT
load rollers for cracks, flat spots, or bearings that
Figure 17. Load Roller and Wear Plug do not turn freely. Replace any roller that shows
wear or is damaged.
8. Use a cloth to clean each load roller. Inspect the
load rollers for cracks, flat spots, or bearings that
do not turn freely. Replace any roller that shows
wear or is damaged.
9. Install the load rollers onto the stub shafts and

install the retaining rings as removed.
10. Install the wear plugs as removed. Adjust as nec-

essary. See Mast Adjustments.
11. Reconnect the lift chains, hoses, and wiring as

removed.
12. Install the mast to the lift truck. Refer to Mast,

Install.
13. Install the reach carriage assembly as removed. 1. RETAINING RING 3. SHIM PACK
See Reach Carriage Assembly. 2. LOAD ROLLER 4. STUB SHAFT
Figure 18. Load Roller and Shims
18
4000 SRM 1195 Mast
6. Install an equal number of shims to both sides NOTE: Observe the position of the shims.
of the rear frame stub shafts. Install additional
shims as necessary. See Mast Adjustments. NOTE: Correct placement of shims is critical for the
operation of the reach mechanism. The reach mech-
7. Install the load rollers onto the stub shafts and anism will not operate if the shims are installed in-
install the retaining rings as removed. correctly.
8. Install the reach carriage assembly if repairs are 3. Inspect and replace all damaged or worn parts.
complete. Check for proper operation.
4. Install an equal number of shims to both sides
under the side rollers. Install additional shims
as necessary. See Mast Adjustments.
Side Rollers
5. Install the load rollers onto the stub shafts and
NOTE: Check the side roller adjustment before reinstall the retaining rings as removed.
moving the reach assembly from the mast.
6. Install and check the reach assembly when re-
1. Remove the reach assembly from the mast to repairs are complete.
place the side rollers.
2. Remove the capscrews that fasten the side roller

bracket. See Figure 16.
Mast
REMOVE NOTE: If the mast assembly will not be disassembled,
it may not be necessary to remove the reach assembly
WARNING before removing the mast.
DO NOT remove the mast assembly unless it is 3. If the reach assembly will not be removed from
completely assembled or has safety chains in- the mast, secure the reach assembly using safety
stalled. Mast parts can move and cause an in- chains:
jury if not secured together during removal.
a. Operate the REACH/RETRACT control but-
Mast parts are heavy and can shift. Distances ton to retract the reach assembly fully and
between parts are small. Serious injury can re- center the sideshift if equipped.
or reach assembly. NOTE: Make sure a safety chain does not touch com-
ponents other than the mast weldments.
Mast assemblies are heavy. Be sure that all lift-
ing devices are suitable and of adequate capac- b. Install the safety chains around the front
ity to lift the mast and its components. frame and rear frame so the reach carriage
assembly cannot extend.
1. Remove the mast operator guard:
NOTE: It is necessary to remove the reach assembly
a. Remove capscrews and nuts that secure the before removing the mast if the mast will be disas-
guard. sembled.
b. Lift the guard from the mast. 4. Remove the reach carriage assembly. See Reach
Carriage Assembly in this section.
2. Remove the forks from the reach assembly. See
Forks. 5. Remove the capscrews that fasten the top of the
rear leg to the overhead guard.
19
Mast 4000 SRM 1195
12. Remove the front panel covers to access the trun-

CAUTION nion caps. Mark the trunnion caps so they can
DO NOT move the control button for the reach, be reassembled in the same position and on the
retract, tilt, or sideshift functions. same trunnion from which they are removed. Re-
move the four capscrews that fasten the trunnion
6. Raise the inner and intermediate weldments caps. Remove the trunnion caps.
high enough to access to the bottom of the outer
weldment. 13. Remove the battery to expose the access hole in
the battery compartment.
7. Install safety chains to keep the mast compo-
nents from moving. See Safety Procedures When NOTE: Tag and identify the bulkhead hoses before
Working Near Mast. removal for correct connection during installation.
8. Remove the four capscrews, shims, and nutplates 14. Disconnect the mast hoses from their fittings at
attaching the bottom of the mast to the truck the front of the truck frame. Cap and plug all fit-
frame. tings and ports to prevent hydraulic system con-
tamination and leakage.
9. Remove the safety chains. Lower the inner and
intermediate weldments fully. Make sure all hy- 15. Tag and disconnect the plugs and wires of the
draulic pressure is removed from the system. wiring harness cable so the cable is completely
disconnected from the truck. The plugs are lo-
WARNING cated next to the left side trunnion.
Always wear the proper protective equipment 16. Tighten the crane to support the weight of the
including eye protection and petroleum-resis- mast assembly. Move the crane to a position so
tant gloves when handling hydraulic oil. Thor- that the mast assembly will be lifted vertically.
oughly wash oil from exposed areas of skin as Raise the mast assembly high enough to clear the
soon as possible. trunnions. Move the mast assembly away from
the truck.
NOTE: Certain lift truck models retain significant
quantities of oil in the cylinders and hoses even when NOTE: If the mast will be disassembled, position the
the hydraulic tank is empty. Drain the hydraulic sys- mast on a level floor with the overhead guard on the
tem using the appropriate procedures for your model bottom as a support. Install a support under the
before servicing to avoid large spills. Refer to Hy- other end. Make sure the mast is level. Keep the
draulic Oil. safety chains installed securing the mast weldments
together. If the mast will NOT be disassembled, put
10. Drain the oil from the hydraulic system. Refer
the mast on a level floor with the overhead guard on
to Hydraulic Oil. Store the oil in clean, approved
top, or secure it vertically to an approved mast stand.
containers if the oil is to be reused.
DISASSEMBLE
CAUTION
Make sure the chains will not damage the The following procedures refer to disassembling a
sheaves or other parts of the mast assembly. mast removed from the lift truck with the reach as-
sembly previously removed. Total disassembly of the
11. Use chains to connect a crane or other lifting de- mast weldments is not always necessary. Perform
vice to the top of the outer mast assembly. Use only the steps necessary to safely complete the re-
safety chains to fasten all the mast weldments pairs.
together so they cannot move. If the reach as-
sembly is not being removed from the mast, in-
stall a chain or sling to keep the reach assembly
from extending during removal.
20
4000 SRM 1195 Mast
4. Remove the main lift cylinders. See Lift Cylin-

WARNING ders in this section.
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury can re- 5. Remove the inner mast weldment:
or reach assembly. a. Slide the inner mast halfway out of the top of
the intermediate mast.
ing devices are suitable and of adequate capac- b. Connect the crane to the center of each side
ity to lift the mast and its components. of the inner mast using chains or slings.
See Figure 19. Tighten crane to support the
1. Position the mast horizontally on a level floor weight of the inner mast.
with the overhead guard on the bottom as a
support. Install a support under the other end. c. Carefully slide the inner mast from the in-
Make sure the mast is level. termediate mast and place it on a pallet for
transport/storage. Disconnect the crane.
2. Tag and remove the free-lift chains and wiring
and inspect for damage and wear. If the chains d. Disassemble the load rollers from the weld-
are to be reused, clean and lubricate as indicated ment as necessary.
in Lift Chains.
NOTE: The free-lift cylinder may be also removed

while the mast is installed in the lift truck. Refer
to Lift Cylinders in this section.
3. Remove the free-lift cylinder.
a. Attach a lifting device and a sling to the cylin-

der. Tighten to support the weight of the
cylinder when removed.
NOTE: Mast models consists of three categories: 5.5

Standard Masts, 5.5 Heavy Duty Masts, and 6.9
Masts. Refer to General in this section for more
information.
b. 5.5 Std Mast Only - Remove the four nuts Figure 19. Mast Disassembly
and washers securing the lower cylinder retaining
bracket to the outer mast and remove the bracket. 6. Remove the intermediate mast weldment:
Next, remove the corresponding four capscrews also
securing the hydraulic mounting bracket to the back a. Slide the intermediate mast halfway out of
of the inner mast, or thread the nuts and washers the top of the outer mast.
back on the capscrews finger tight if the hydraulic
b. Connect the crane to the center of each side of
mounting bracket is not to be removed.
the intermediate mast using chains or slings.
See Figure 19. Tighten crane to support the
c. Tag and identify the hydraulic hoses. Re- weight of the intermediate mast.
move the hoses from the cylinder and cap/
c. Carefully slide the intermediate mast from
plug the hoses and ports to prevent contami-
the outer mast and place it on a pallet for
nation to the hydraulic system.
transport/storage. Disconnect the crane.
d. Remove the two screws securing the upper
d. Disassemble the load rollers from the weld-
cylinder retaining bracket to the inner mast.
ment as necessary.
Remove the brackets and guide the cylinder
out of the mast using the lifting device.
21
Mast 4000 SRM 1195
7. Disassemble the load rollers from the outer mast check the lift chain as shown in Figure 20. If a
as necessary. Tag and identify all shims to prop- chain scale is not available, measure 20 links of
erly reinstall the weldment. the lift chain. Compare the measurement with
the lengths given in Figure 20.
8. Remove and disassemble the hose and chain
sheave assemblies from the weldments if neces-
sary. See Sheaves. WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
CAUTION using cleaning solvents, always follow the
Improper welding procedures can damage the solvent manufacturer’s recommended safety
structure of the mast or cause incorrect func- precautions.
tion of the mast. Mast weldment components
require factory approval before repairing or 3. Clean the lift chains by soaking in solvent for 30
replacing. Contact your local Hyster lift truck minutes and remove all dirt and grease. Hang
dealer for assistance. lift chains up and remove solvent using com-
pressed air. Lubricate the chains by soaking
9. Clean and inspect the weldments. Repair as nec- them in SAE 30 engine oil for 30 minutes. Hang
essary. chains over a drip pan for one hour to remove
excess oil.
CLEAN AND INSPECT
4. Inspect the chain anchors and pins. Replace any
CAUTION parts that are worn or damaged.
DO NOT use steam to clean lift chains, sheaves,
or load rollers. The bearings in the sheaves and WARNING
load rollers are sealed and lubricated. Be careful when cleaning with steam. Steam
can cause serious burns. Wear protective cloth-
1. Inspect the chain sheaves and load rollers for ing, gloves, and eye protection. Never expose
wear or damage. your skin to steam.
WARNING Cleaning solvents may be flammable and toxic

and can cause severe skin irritation. When
Never replace only the worn section of a chain.
using cleaning solvents, always follow the
Replace the complete chain. Never replace
solvent manufacturer’s recommended safety
only one chain of a chain pair. Replace both
precautions.
chains.
5. Clean the mast weldments with steam or solvent.
NOTE: The chains must be inspected in the area of
chain that passes over the chain sheave during the
first portion of a lift. Those links will show maximum CAUTION
wear. Improper welding procedures can damage
the structure of the mast or cause incorrect
NOTE: The lift chains must be installed in the mast function of the mast. Mast components require
and the mast must be installed on the lift truck to written engineering approval before repairing
be checked for correct length. Check lift chains for or replacing. Contact your local Hyster lift
proper length before removing the mast. truck dealer for factory assistance.
2. Inspect the lift chains for wear or damage. A lift 6. Inspect sliding surfaces for wear or damage. In-
chain becomes longer when it is worn. If a chain spect load roller contact surfaces for wear or dam-
is 3% longer than a new lift chain, the lift chain age. Inspect all welds for cracks.
must be replaced. If a chain scale is available,
22
4000 SRM 1195 Mast
1. Assemble and install the hose and chain sheave

assemblies if removed. See Sheaves.
2. Install the load rollers to the weldments. See

Load Rollers.
3. Assemble the intermediate weldment into the

outer weldment as removed:
a. Connect the crane to the center of each side of

the intermediate mast using chains or slings.
See Figure 19.
b. Raise the intermediate mast level with the

outer mast. Insert the bottom of the inter-
mediate mast into the top of the outer mast
as removed.
c. Carefully slide the intermediate mast

halfway into the outer mast and discon-
nect the crane.
NOTE: THE INSTRUCTIONS FOR MEASURING d. Slide the intermediate mast completely into
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR the outer mast.
SCALE
4. Assemble the inner weldment into the interme-
1. CHAIN WEAR SCALE
diate weldment as removed:
Pitch Wear Limit
Total length a. Connect the crane to the center of each side
The
of 20 links of the inner mast using chains or slings. See
maximum
(pitch) of new Figure 19.
length of 20
chain
links b. Raise the inner mast level with the interme-
12.7 mm 254.0 mm 261.6 mm diate mast. Insert the bottom of the inner
(0.50 in.) (10.0 in.) (10.3 in.) mast into the top of the intermediate mast
15.9 mm 317.5 mm 327.0 mm as removed.
(0.63 in.) (12.5 in.) (12.9 in.)
c. Carefully slide the inner mast halfway into
19.1 mm 381.0 mm 392.4 mm
the intermediate mast and disconnect the
(0.75 in.) (15.0 in.) (15.5 in.)
crane.
25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.) d. Slide the inner mast completely into the in-
termediate mast.
Figure 20. Lift Chains Check
WARNING
ASSEMBLE
including eye protection and petroleum resis-
WARNING tant gloves when handling hydraulic oil. Thor-
Mast parts are heavy and can shift. Distances oughly wash oil from exposed areas of skin as
between parts are small. Serious injury can re- soon as possible.
or reach assembly. 5. Install the main lift cylinders into the intermedi-
ate masts. See Lift Cylinders in this section.
ing devices are suitable and of adequate capac-
ity to lift the mast and its components.
23
Mast 4000 SRM 1195
NOTE: Use safety chains to keep the mast assembly

WARNING from moving as described in Safety Procedures When
Always wear the proper protective equipment Working Near Mast.
tant gloves when handling hydraulic oil. Thor- 1. Use the crane or lifting device to lift the mast as-
oughly wash oil from exposed areas of skin as sembly into an upright position and move it close
soon as possible. enough to the truck to make the necessary con-
nections. Make sure the truck and mast assem-
6. Install the free-lift cylinder: bly cannot move.
a. Attach a lifting device and a sling to the cylin- NOTE: Remove the caps and plugs from the hoses and
der. Guide the cylinder into the mast using ports and clean the threads of the hoses as necessary
the lifting device. before installation.
b. 5.5 HD and 6.9 Mast Only - Properly posi- 2. Install and tighten the mast and attachment
tion the free-lift cylinder to align the pin lo- hoses on their correct bulkhead fittings as re-
cated on the bottom of the cylinder shell with moved.
the hole in the inner mast.
3. Move the mast assembly into position where the
c. Install to the upper cylinder retaining outer weldment stub shafts are aligned directly
bracket. Install the two screws securing over the trunnion blocks on the lift truck frame.
the brackets to the inner mast. Lower the mast until the stub shafts are seated
in the trunnion blocks.
d. Install the reach hoses and wiring through
the cylinder crosshead as removed. Install NOTE: Make sure all hoses and the electrical cable
the hydraulic lines to the free-lift cylinder as are not between a mast crossmember and the truck.
removed.
4. Align the trunnion caps according to the marks
e. 5.5 Std Mast Only - Position the lower cylin- made during removal. Install the capscrews but
der retaining bracket over the bottom of the leave them loose.
free-lift cylinder and onto the four capscrews
(as removed). Install the four nuts and wash- 5. Connect all the wires of the electrical cable ac-
ers securing the bracket to the outer mast. cording to the labels made during removal.
7. Install the main lift chains. See Lift Chains.

CAUTION
8. Secure the free lift chains until they can be at- Install tape on all electrical wires for the reach
tached when the reach assembly is installed. See assembly that are not connected. Wires that
Mast, Install. are not connected can short circuit and cause
damage.
INSTALL
6. Attach a lifting device and raise the inner and in-
WARNING termediate weldments high enough to allow ac-
cess to the bottom of the outer weldment.
DO NOT install the mast assembly unless it is
completely assembled or has safety chains in- 7. Install safety chains to keep the intermediate
stalled. Mast parts can move and cause an in- and inner weldments from moving.
jury if not secured together during assembly.
8. Use a pry bar to align and install the four mount
Mast parts are heavy and can shift. Distances capscrews and the nut plates that fasten the bot-
between parts are small. Serious injury can re- tom of the mast to the truck frame. Move the
sult if part of the body is hit by parts of the mast bottom of the weldment in or out and add shims
or reach assembly. until the mast back tilt is properly adjusted. See
Mast Adjustments in this section.
Be sure that all lifting devices are suitable and
of adequate capacity to lift the mast and its 9. Tighten the four mount capscrews to 203 N•m
components. (150 lbf ft).
24
4000 SRM 1195 Mast
10. Install the hose clamps and hose bracket. Oper- NOTE: Models with displacement-type cylinders
ate the LIFT/LOWER control to raise the inner have significantly different filling procedures than
weldment high enough to carefully remove the models with piston-type cylinders. Fill the hydraulic
safety chains. Remove the safety chains. system using the appropriate procedures for your
model to ensure proper operation. Refer to Hydraulic
11. Tighten the four trunnion cap capscrews to System in this section.
210 N•m (155 lbf ft). Use the crane to remove
the safety chains and lower the inner and inter- 13. Fill the hydraulic system to the proper level and
mediate weldments. Disconnect the crane and bleed the air from the mast and hydraulic sys-
chains. tem. Refer to Hydraulic System in this section.
12. Install the mast operator guard and capscrews 14. Make all adjustments and test the operation of
that fasten the rear leg to the overhead guard. the mast assembly before returning the truck to
service. See Mast Adjustments.
WARNING
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
25
Lift Cylinders 4000 SRM 1195
Lift Cylinders
MAIN LIFT CYLINDERS hoses and ports to prevent leakage and contami-
nation to the hydraulic system.
WARNING NOTE: Use only a brass driver and a hammer to tap
Always wear the proper protective equipment the cylinder rods from the intermediate mast. Use of
including eye protection and petroleum-resis- harder material can disfigure the cylinder rod.
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as 6. Remove the retaining rings, shims, and rubber
soon as possible. bushings (5.5 HD and 6.9 mast only) from the top
of the cylinder rods. Carefully pull the interme-
Completely lower all mast components and re- diate weldment outward while lightly tapping on
lieve pressure by opening the needle valve be- the top of the cylinder rods to remove them from
fore disassembling any part of the mast or dis- their mounts in the intermediate mast. Recover
connecting any hydraulic hoses. and tag the bevelled shim packs from the shoul-
der of each cylinder rod for proper installation.
The hydraulic oil is hot at normal operating
See Figure 21.
temperatures. Be careful when draining the
oil. 7. Remove the two screws securing each lower
cylinder retaining bracket to the outer mast. Re-
The main lift cylinders can be removed only when the
move the brackets. See Figure 22 or Figure 23.
mast has been removed from the lift truck. It is rec-
ommended to service both cylinders at the same time 8. Carefully guide the cylinders from the mast.
if cylinder repair is necessary. Refer to Mast, Disas- Reposition the lifting devices as necessary to
semble for instructions on disassembling the mast. support the cylinder until completely removed
from the mast.
Remove
9. Remove the cylinder alignment pin from the bot-
1. Remove the reach assembly from the truck. tom of the lift cylinder.
NOTE: Certain lift truck models retain significant
quantities of oil in the cylinders and hoses even when
Install
the hydraulic tank is empty. Drain the hydraulic sys- 1. Attach lifting device to the cylinder using a sling
tem using the appropriate procedures for your model and guide the cylinder into the mast.
before servicing to avoid large spills. Refer to Hy-
draulic System. 2. Install the cylinder alignment pin into the bot-
tom of the cylinder shell and guide it into the hole
2. Drain the oil from the hydraulic system. Refer to in the base mount.
Hydraulic Oil in this section. Make sure any oil
remaining in the tank is well below the height 3. Position the lower retaining brackets onto the
of the components being removed. Store the oil cylinders. Secure each to the outer mast using
in clean, approved containers if the oil is to be two capscrews as removed.
reused.
4. Install bevelled shims to the top of the lift cylin-
3. Remove the mast from the lift truck. See Mast, ders as removed. Carefully slide the intermedi-
Remove. ate mast into the outer mast while guiding the
cylinder rods into their seats in the top of the in-
4. Attach a lifting device to the cylinder using a termediate mast. Tap the top of the intermediate
sling. Tighten to support the weight of the cylin- mast using a rubber mallet until the rod are com-
der when removed. pletely seated.
NOTE: Tag and identify hoses before removal. 5. Install rubber bushing (5.5 HD and 6.9 mast
only), shims and retaining ring onto the top of
5. Remove the hose clamp(s) securing the cylinder
the cylinder rods as removed.
connecting hose. Disconnect the cylinder con-
necting hose from the lift cylinders. Cap/plug the
26
4000 SRM 1195 Lift Cylinders
6. Install cylinder connecting hose as removed.
7. Remove the lifting devices and slings from the

cylinders.
8. Install the mast to the lift truck. See Mast In-

stall.
9. Install the reach assembly to the lift truck.
NOTE: Models with displacement-type cylinders

have significantly different filling procedures than
models with piston-type cylinders. Fill the hydraulic
system using the appropriate procedures for your
System in this section.
10. Fill the hydraulic system to the proper level and

bleed the air from the cylinders and the hydraulic
system. See Hydraulic System in this section.
1. OUTER MAST
2. RETAINING RING
3. SHIM(S)
4. INTERMEDIATE MAST
5. BEVELLED SHIM(S)
6. LIFT CYLINDER ASSEMBLY
Figure 21. Lift Cylinder Removal (5.5 Std)
27
1. LIFT CYLINDER 9. CAPSCREWS

2. FREE-LIFT HOSE 10. HYDRAULIC MOUNTING BRACKET
3. CYLINDER RETAINING BRACKET 11. CAPSCREWS
4. TEE FITTING 12. VELOCITY FUSE
5. CAPSCREWS 13. CAPSCREWS
6. TUBE CLAMP 14. HOSE CLAMP
7. CAPSCREWS 15. CYLINDER CONNECTING HOSE
8. DUAL TUBING CLAMP
Figure 22. Lift Cylinder Removal (5.5 Mast)
28
A. LIFT SYSTEM HOSES B. AUX SYSTEM HOSES

1. LIFT CONNECTING HOSE 7. VELOCITY FUSE
2. FREE-LIFT SHEAVE 8. LIFT CYLINDER
3. SCREW 9. FREE-LIFT SUPPLY HOSE
4. RETAINER 10. WIRING TAKE-UP SLING
5. FITTING 11. TAKE-UP SPRING
6. AUX CONNECTIONS 12. CYLINDER ALIGNMENT PIN
Figure 23. Lift Cylinder Removal (6.9 Mast)
29
FREE-LIFT CYLINDER 3. Attach an overhead lifting device to the top of

the reach assembly. Install heavy-duty, indus-
Remove trial C-clamps and a sling or chain loop to each
side of the inner frame. Raise the reach assem-
WARNING bly to the top of the inner frame. Install a safety
Always wear the proper protective equipment chain to secure the reach assembly in place.
including eye protection and petroleum-resis- 4. Attach a lifting device and a sling to the cylin-
tant gloves when handling hydraulic oil. Thor- der. Tighten to support the weight of the cylinder
oughly wash oil from exposed areas of skin as when removed.
soon as possible.
5. 5.5 Std - Remove the four nuts and washers se-
Completely lower all mast components and re- curing the lower cylinder retaining bracket to the
lieve pressure by opening the needle valve be- outer mast and remove the bracket if necessary.
fore disassembling any part of the mast or dis- Next, thread the nuts and washers back on the
connecting any hydraulic hoses. capscrews finger tight. See Figure 24 or Fig-
The hydraulic oil is hot at normal operating ure 25.
temperatures. Be careful when draining the 6. Remove the hose clamps securing the hydraulic
oil. lines to the free-lift cylinder. Tag and identify
The following procedures refer to removing the free- the hydraulic hoses. Remove the hoses from the
lift cylinder with the mast installed to the lift truck. cylinder and cap/plug the hoses and ports to pre-
The free-lift cylinder may be removed while the mast vent contamination to the hydraulic system.
is installed to the lift truck or when the mast is be- 7. Remove the two screws securing the upper cylin-
ing disassembled. For instructions for removing the der retaining bracket to the inner mast. Remove
free-lift cylinder during disassembly, see Mast, Dis- the brackets and guide the cylinder out of the
assemble - Remove. mast using the lifting device.
NOTE: Certain lift truck models retain significant 8. 5.5 HD and 6.9 Mast - Remove the cylinder
quantities of oil in the cylinders and hoses even when alignment pin from the bottom of the cylinder
the hydraulic tank is empty. Drain the hydraulic sys- shell.
tem using the appropriate procedures for your model
before servicing to avoid large spills. Refer to Hy- Install
draulic System.
For the following procedures, refer to Figure 24 or
1. Drain the oil from the hydraulic system. Refer Figure 25.
to Hydraulic Oil. Make sure any oil remaining
in the tank is well below the height of the com- 1. Attach an overhead lifting device to the lift cylin-
ponents being removed. Store the oil in clean, der using a sling.
approved containers if the oil is to be reused.
2. 5.5 HD and 6.9 Mast - Install alignment pin
NOTE: The free-lift cylinder can be removed with- to bottom of cylinder shell and align with lower
out disconnecting the free lift chains or wiring har- mounting holes in inner mast.
ness. This is done by removing the snap ring retain-
ing the crosshead assembly to the cylinder rod after 3. Position the free-lift cylinder into the mast using
the reach assembly has been raised. However, it is the lifting device.
advised to inspect, clean, and lubricate the free-lift
4. Position the upper cylinder retaining bracket
chains anytime the free-lift cylinder is removed.
onto the free-lift cylinder. Install the two screws
2. Tag and remove the free-lift chains and wiring securing the bracket to the inner mast. Remove
and inspect for damage and wear. If the chains the lifting device and sling from the free-lift
are to be reused clean and lubricate as indicated cylinder.
in Lift Chains. Remove the wiring harness from
the crosshead.
30
NOTE: Remove all caps/plugs from the hydraulic

lines and ports as necessary.
5. Install the hydraulic hoses to the cylinder as re-

moved. Install the hose clamps securing the hy-
draulic lines to the free-lift cylinder as removed.
6. 5.5 Std - Remove the nuts and washers from the

four capscrews at the bottom of the free-lift cylin-
der (finger tight). Position the lower cylinder re-
taining bracket into place. Install the four nuts
and washers securing the bracket to the outer
mast. See Figure 24.
7. Remove the safety chains from the reach assem-

bly and lower the reach assembly low enough to
install the free-lift chains.
8. Install the free-lift chains to the chain anchors

or install the crosshead to the cylinder rod if re-
moved.
NOTE: Models with displacement-type cylinders

have significantly different filling procedures than
models with piston-type cylinders. Fill the hydraulic
system using the appropriate procedures for your
System.
9. Fill the hydraulic system to the proper level and

bleed the air from the cylinders and the hydraulic
system. See Hydraulic System in this section.
10. Check that the mast is properly adjusted before

returning to service. See Mast Adjustments in
this section.
1. CROSSHEAD ASSEMBLY
2. FREE-LIFT CYLINDER
3. UPPER RETAINING BRACKET
4. CAPSCREWS AND LOCKWASHERS
5. LOCKWASHER
6. NUT
7. LOWER RETAINING BRACKET
Figure 24. Free-Lift Cylinder (5.5 Std)
31
Lift Chains 4000 SRM 1195
Legend for Figure 25

1. UPPER RETAINING BRACKET
2. FREE-LIFT CYLINDER
3. INNER MAST
4. ALIGNMENT PIN
Figure 25. Free-Lift Cylinder (5.5 HD and 6.9

Mast)
Lift Chains
CLEAN AND INSPECT chain scale is not available, measure 20 links of
the lift chain. Compare the measurement with
WARNING the lengths given in Figure 26.
Never replace only the worn section of a chain.
Replace the complete chain. Never replace WARNING
only one chain of a chain pair. Replace both Cleaning solvents may be flammable and toxic
chains. and can cause severe skin irritation. When
using cleaning solvents, always follow the
CAUTION solvent manufacturer’s recommended safety
DO NOT use steam to clean lift chains, sheaves, precautions.
or load rollers. The bearings in the sheaves and 2. Clean and lubricate the lift chains:
load rollers are sealed and lubricated.
a. Soaking the lift chains in solvent for 30 min-
NOTE: Lift chains must be checked for correct length utes and remove all dirt and grease.
while installed in the mast when the mast is installed
on the lift truck. b. Hang lift chains up and remove solvent using
compressed air.
NOTE: The chains must be inspected in the area of
chain that passes over the chain sheave during the c. Lubricate the chains by soaking them in SAE
first portion of a lift. Those links will show maximum 30 engine oil for 30 minutes.
wear.
d. Hang chains over a drip pan for one hour to
1. Inspect the lift chains for wear or damage. A lift remove excess oil.
chain becomes longer when it is worn. If a chain
is 3% longer than a new lift chain, the lift chain 3. Inspect the chain anchors and pins. Replace any
must be replaced. If a chain scale is available, parts that are worn or damaged.
check the lift chain as shown in Figure 26. If a
32
4000 SRM 1195 Mast Adjustments
NOTE: THE INSTRUCTIONS FOR MEASURING

CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE.
1. CHAIN WEAR SCALE
Pitch Wear Limit

Total length
The
of 20 links
maximum
(pitch) of new
length of 20
chain
links
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.75 in.) (15.0 in.) (15.5 in.)
Figure 26. Lift Chains Check 25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
Mast Adjustments
GENERAL MAST BACK ANGLE ADJUSTMENT
Read and follow the Safety Procedures When Work- The following procedures refer to adjusting a mast
ing Near Mast as well as all WARNINGS and CAU- already installed to the lift truck.
TIONS.
1. Move the lift truck to a safe, level area and com-
The mast weldments must be aligned so that they are pletely lower the mast. Turn the key switch to
parallel to each other during operation. Keeping the the OFF position and attach a DO NOT OPER-
weldments parallel will have the result of smoother ATE tag to the control handle. Block the drive
operation and wear. wheel to prevent unexpected movement.
The only adjustment for the load rollers is the ad- 2. Measure the angle between the outer mast and
justment of the wear plugs. These adjustments are the top of the lift truck frame. See Figure 27.
made for minimum side clearance and to keep the
weldments parallel with equal clearance on each side a. If the angle is less than 90.0°:
between all weldments.
(1) Safety chain the mast so the lower mast
Chains are adjusted for the following reasons: mounting capscrews can be accessed.
• So each lift chain of a pair has an equal load to
(2) Loosen all of the lower mast mounting
prevent too much load and wear on one chain of
hardware and add shims evenly.
a pair.
• So mast weldments move in the correct sequence. (3) Tighten all of the lower mast mounting
• So chains move over chain sheaves correctly. hardware evenly.
Adjustments must be made to both the free-lift (4) Torque to 203 N•m (150 lbf ft). Verify
(three-stage only) and main-lift chain sets. Each lift torques after tightening.
chain is adjusted at the chain anchor.
33
Mast Adjustments 4000 SRM 1195
LOAD ROLLERS ADJUSTMENT

Reach Carriage Assembly
1. Measure the width between the outside edges of
the inner mast in several places. Make a note
of the location and the value of the maximum
measurement. See Figure 28.
1. MAST MOUNTING CAPSCREW AND WASHER

2. LIFT TRUCK FRAME
3. MAST BACK ANGLE (90.0° TO 90.5°)
Figure 27. Mast Back Angle
b. If the angle is greater than 90.5°:
(1) Safety chain the mast so the lower mast

mounting capscrews can be accessed.
(2) Loosen all of the lower mast mounting

hardware and remove shims evenly.
(3) Tighten all of the lower mast mounting

hardware evenly.
(4) Torque to 203 N•m (150 lbf ft). Verify

torques after tightening.
3. Check the angle between the outer mast and the

top of the lift truck frame again. When the angle
is between 90.0° and 90.5°, the mast back angle
adjustment is correct.
4. Engage the battery connectors and remove the

DO NOT OPERATE tag from the control han-
dle. Remove the safety chains and the drive
wheel blocks.
Figure 28. Measuring Channel Width
34
2. Measure and record the distance between the

outside of the side rollers and load rollers of the
rear frame of the reach assembly. See Figure 29.
Figure 29. Side and Load Roller Widths
3. If the difference between dimension A and the

largest measurement between the inner mast
channels is more than 4 mm (0.16 in.), install
shims to the side rollers and/or load rollers
evenly. If the difference is less than 4 mm
(0.16 in.), remove shims from the side rollers
and/or load rollers evenly.
ADJUST WEAR PLUGS - MAST

Wear plugs are located in the stub shaft of the load
rollers of the mast. See Figure 30.
Adjust the wear plugs as follows:

1. TOP OF INTERMEDIATE MAST
1. Loosen the jam nut on the wear plug. See Fig- 2. BOTTOM OF INNER MAST
ure 31. Raise and lower the mast weldments sev- 3. TOP OF OUTER MAST
eral times to find the point of minimum clearance 4. BOTTOM OF INTERMEDIATE MAST
of the weldment.
Figure 30. Wear Plugs Location
35
Procedures When Working Near Mast. Loosen

the wear plugs to allow movement.
6. If necessary, operate the system so that the lift

chains are the supports and carefully remove the
safety chains. Raise and lower the weldments
with a load. Check that there is minimum clear-
ance, as described in Step 3, with free movement.
If the weldments do not move smoothly during
lowering, follow the WARNING and adjust the
wear plugs equally for more clearance.
7. Repeat Step 1 through Step 6 for each weldment.
ADJUST MAIN-LIFT CHAINS

The main lift chains must be adjusted BEFORE ad-
justing the free-lift chains.
Adjust chain anchors at main lift cylinders so top of

inner mast weldment is even with top of outer mast
1. LOAD ROLLER 5. JAM NUT weldment.
3. RETAINING RING 7. MAST CHANNEL NOTE: Remove the mast operator guard if adjust-
4. SETSCREW ment is necessary.
Figure 31. Load Roller and Wear Plug Assembly 1. Completely lower the mast. Check to verify that
the top of the outer weldment is even (±1.5 mm
2. Adjust the wear plugs to attain zero clearance be-
(0.06 in.)) with the top of the inner mast.
tween the wear plug and the weldment channel
at the tightest point. Adjust wear plugs on oppo- a. If the top of the weldments are not even,
site sides to keep the weldment in the center. adjust the nuts on the chain anchors until
the weldments are even, and tighten the lock
3. Adjust the clearance to approximately 0.02 in. by
nuts.
turning the adjustment handle 1/8 turn counter-
clockwise. Keep the clearance between the weld- b. If the top of the weldments are even (within
ments equal on both sides. Keep the weldments specification), proceed to the next step.
parallel to each other.
2. Check chain tension by pushing on both main-lift
4. Tighten each jam nut without moving the chains at the same time.
setscrew.
a. If the tension is not the same, adjust the nuts
5. Raise and lower the weldments without a load. on the chain anchors until the tension is the
Check that there is minimum clearance, as de- same, and tighten the lock nuts. Recheck
scribed in Step 3, with free movement. If the that the top of the weldments are still within
weldments do not move smoothly during lower- specification. See Step 1.
ing, follow the WARNING and adjust the wear
plugs equally for more clearance. b. If the tension on both chains are equal, pro-
ceed to the next step.
WARNING 3. Adjust the free-lift chains. See Adjust Free-Lift
NEVER loosen the wear plugs if a mast weld- Chain.
ment does not move freely during checks after
an adjustment. The weldments or carriage can 4. Check the mast operation as described in Mast
suddenly move and cause an injury. Raise the Operation Check.
weldment, move the key to the OFF position,
and install safety chains as described in Safety 5. Install the mast operator guard (if removed).
36
ADJUST FREE-LIFT CHAIN

CAUTION
NOTE: Make sure the forks of the reach carriage are When the chain adjustments are complete,
parallel to the floor (no forward or backward tilt). make sure the cotter pin at the bottom of the
The main lift chains must be adjusted BEFORE ad- chain anchor can be installed under the ad-
justing the free-lift chains. justment nut. If there is no room to install
the cotter pin, the chains are too short. Make
1. Fully lower the carriage. With the forks level
sure the lock nuts on the chain anchors are
(parallel to the floor), measure the distance from
tight against the mount plate. If there are
the floor to the top of forks. The correct distance
not enough threads on the chain anchor for
is 63.5 mm (2.5 in.).
correct adjustment, new chains are too long or
2. If the distance is correct, the free-lift chains are old chains are too worn. See Lift Chains.
adjusted for the correct height. Perform Step 5
6. Check the mast operation as described in Mast
next. If the distance is NOT correct, perform all
Operation Check.
of the steps.
7. Recheck the distance from the floor to the top of
3. Raise the mast until the free-lift cylinder chain
the forks.
anchors at the rear of the free-lift cylinder can be
accessed from the operator compartment. Install 8. Raise the reach carriage to the top of the inner
safety chains as described in Safety Procedures mast. Check to ensure the reach carriage stops
When Working Near Mast. Remove the mast op- before hitting the stops at the top of the inner
erator guard for easier access to the chain an- weldment. If the reach mechanism reaches the
chors. Loosen both lock nuts at the chain anchors stops prior to full elevation, recheck fork height
to make any adjustments. with the mast fully lowered.
4. Adjust the nuts of the chain anchors equal 9. Extend the mast fully to check the maximum
amounts for the correct distance (Step 1). fork height (MFH). The MFH specifications are
stamped into the side of the outer mast. With the
5. Check chain tension by pushing on both chains
forks level (parallel to the floor), verify MFH by
at the same time. If the tension is not the same,
measuring from the floor to the top of the forks
adjust the nuts on the chain anchors until the
with the mast fully extended. See Figure 32.
tension is the same and the distance (Step 1) is
also correct. When the tension is equal on both 10. Install the mast operator guard if removed.
chains, the chain sheave assembly will be level.
Tighten the lock nuts.
37
ADJUST WEAR STRIPS

NOTE: The wear plugs and lift chains must be ad-
justed before the wear strips are checked for wear,
replaced, and adjusted.
The wear strips and shims are fastened to the lower

guide blocks of weldments that move. See Figure 33
and Figure 34.
The wear strips and shims are adjusted:

• For minimum clearance to prevent too much side
movement of the weldments.
• To keep the weldments parallel.
Check and adjust the wear strips as follows:
1. Raise the carriage for access to the wear strips.

Install safety chains as described in Safety Pro-
cedures When Working Near Mast.
2. Remove the capscrews, washers, wear strips, and

shims. Replace all worn or damaged parts. One
wear strip and one shim on each side is usually
the correct adjustment. There must be the same
number of shims under the wear strip on both
sides of the weldment. Equal shims will keep the
weldment parallel with equal clearance.
3. Use a pry bar to move the weldment to install

shims for minimum clearance. Install the shims
and new wear strips as shown in Figure 34. Re-
move the safety chains.
4. Make sure the mast operates correctly as de-

scribed in Mast Operation Check.
1. REACH CARRIAGE STOP

2. MAXIMUM FORK HEIGHT (MFH)
3. FLOOR LEVEL
Figure 32. Maximum Fork Height (MFH)
38
1. CAPSCREW 4. SHIM
2. WASHER 5. WELDMENT
3. WEAR STRIP CHANNEL
Figure 34. Typical Wear Strip Assembly
1. INNER AND INTERMEDIATE WELDMENTS

2. CAPSCREW AND WASHER
3. SHIM PACK
Figure 33. Wear Strip Locations
39
MAST RACKING 3. Retract the cylinder rods from the intermediate

mast:
1. Extend the mast fully. If the mast racks (leans)
to either side, the main lift cylinders must be ad- NOTE: Use only a brass driver and a hammer to tap
justed. Make note of direction of racking and the cylinder rods from the intermediate mast. Use of
lower the mast. See Figure 35. harder material can disfigure the cylinder rod.
a. Remove the retaining rings, shims and rub-

ber bushings (5.5 HD and 6.9 only) from the
top of the cylinder rods. Carefully pull the in-
termediate weldment outward while lightly
tapping on the top of the cylinder rods to re-
move them from their mounts in the inter-
mediate mast. Recover the bevelled shims
from the shoulder of the cylinder rod. See
Figure 36.
1. OUTER MAST
3. RETAINING RING, SHIMS, AND BUSHINGS
4. BEVELLED SHIMS
5. MAIN LIFT CYLINDER
Figure 36. Main Lift Cylinder Shims
4. Add bevelled shim(s) (5) to the main cylinder rod

on the same side as the direction of rack until
1. MAIN LIFT CYLINDER (LH) the rack is eliminated. Remove the same amount
2. FREE-LIFT CYLINDER of shims (3) from the top to install the retaining
3. MAIN LIFT CYLINDER (RH) ring. See Figure 37.
Figure 35. Mast Racking
2. Raise the mast approximately 150 mm (6 in.).

Safety chain the mast in place. See Safety Pro-
cedures When Working Near Mast.
40
the bottom of the left hand main lift cylinder which

holds the switch in position. The switch detects
the lower crossmember of the intermediate mast
when the mast weldments are lowered. When the
mast weldments raise, the proximity switch loses
its target signaling the main controller to increase
the lift pump and motor speed to compensate for the
increased load of the mast weldments. The switch
reacquires its target as the mast weldments lower
and signals the controller to slow the hydraulic flow
for the free-lift stage.
On certain models there is a second proximity switch
mounted to the bottom of the rear frame of the reach
carriage assembly. This switch detects the reach
carriage assembly height when lowered approxi-
mately 610 mm (24 in.) above the floor. At this
point, the master controller either slows the descent
of the reach carriage assembly or stops the carriage
completely, depending on the setting selected in the
dash display. The controller slows the carriage by
signaling the lift pump and motor to slow, cushioning
the final descent. It stops the carriage by signaling
the lift pump and motor to stop, holding the load at a
preset carry height. The lower button on the control
handle must be released an repressed to completely
lower the reach carriage assembly.
The proximity switches must be adjusted within

10 mm (0.39 in.) to detect their targets. Always
check wiring connections and air gap adjustments
before replacing components.
Replace
Free-Lift Proximity Switch
1. Position the mast and reach carriage assembly

for access to the proximity switch. Safety chain
1. OUTER MAST the mast in place. See Safety Procedures When
2. RETAINING RING
3. SHIM(S) Working Near Mast.
5. BEVELLED SHIM(S) 2. Disconnect the battery and attach a DO NOT
6. LIFT CYLINDER ASSEMBLY OPERATE tag to the control handle.
Figure 37. Lift Cylinder Shims (5.5 Std) 3. Disconnect the proximity switch connector.
PROXIMITY SWITCHES 4. Make note of the position of the switch within

the bracket by measuring the distance from the
The lift truck uses a proximity switch to monitor face of the switch to the bracket. Remove the nut
when the mast has passed from the free-lift stage and lockwasher from the face side of the switch
(free-lift cylinder stroke) to the main lift stage (mast and remove the switch from the bracket. See Fig-
telescoping). It is located on a mounting bracket at ure 38.
41
6. Remove one nut and lockwasher from the face

side of the new switch. Adjust the nut on the
wiring side of the switch until distance from face
of switch is same as old switch.
7. Position the new switch into the bracket. Install

the nut and lockwasher to the face side of the
switch. Secure in place.
8. Connect the switch wiring to the mast wiring.
9. Reconnect the battery.
10. Remove the safety chains from the mast.
11. Test for proper operation. Remove the tag from

the control handle and return to service.
Load Lowering Proximity Switch (Optional)
1. Position the reach carriage assembly for access

to the proximity switch.
2. Disconnect the battery and attach a DO NOT

OPERATE tag to the control handle.
3. Disconnect the proximity switch connector. Clip

wire ties securing wiring in place.
4. Make note of the position of the switch within the

bracket by measuring the distance from the face
of the switch to the bracket. Remove the nut and
lockwasher from the face side of the switch and
remove the switch from the bracket.
5. Remove one nut and lockwasher from the face

side of the new switch. Adjust the nut on the
wiring side of the switch until distance from face
of switch is same as old switch.
6. Position the new switch into the bracket. Install

1. AIR GAP 4. LOCKWASHERS the nut and lockwasher to the face side of the
2. SWITCH FACE 5. NUT switch. Secure in place.
3. NUT 6. WIRING
7. Connect the switch wiring to the mast wiring.
Figure 38. Proximity Switch
Secure with wire ties as removed.
5. If necessary to replace the bracket, remove the
8. Reconnect the battery. Test for proper operation.
capscrews and hardware securing the mounting
Remove the tag from the control handle and re-
bracket to the mast. Install new bracket using
turn to service.
capscrews and hardware as removed.
42
4000 SRM 1195 Lift System Leak Check
Adjust 3. Adjust the nuts to move the switch to a position

within 10 mm (0.39 in.) from its target.
The proximity switch must be adjusted within 10 mm
(0.39 in.) to detect its target. 4. Tighten the jam nuts.
1. Position the mast and reach carriage for access 5. Remove the safety chains and test for proper op-
to the proximity switch. If raised, safety chain eration. If moving the switch in the direction of
the mast in place. See Safety Procedures When the target does not restore correct function, the
Working Near Mast. switch may be faulty. See Proximity Switches,
Replace.
2. Slightly loosen jam nuts.
Mast Operation Check

Read and follow the Safety Procedures When Work- NOTE: Some parts of the mast move at different
ing Near Mast as well as all WARNINGS and CAU- speeds during raising and lowering.
TIONS.
3. The weldments and the carriage must lower com-
pletely.
WARNING
DO NOT try to locate hydraulic leaks by 4. Check that the controls for the carriage operate
putting hands on pressurized hydraulic com- the functions of the carriage. See the symbols by
ponents. Hydraulic oil can be injected into the each of the controls and refer to the Operating
body by pressure. Manual for your lift truck. Make sure all of the
hydraulic lines are connected correctly and do not
1. Check for leaks in the hydraulic system. Check leak.
the condition of the hydraulic hoses and tubes.
2. Slowly raise and lower the mast several times

without a load. The mast components must raise
and lower smoothly in the correct sequence.
Lift System Leak Check

LIFT CYLINDER LEAK CHECK 2. Raise carriage and load 1 m (3 ft). If carriage
slowly lowers when control valve is in NEU-
WARNING TRAL position, there are leaks in hydraulic
system. The maximum speed the carriage is
During the test procedures for the hydraulic
allowed to lower is 50 mm (2 in.) per 10 minutes
system, use chains to fasten the load to the car-
when hydraulic oil is 30°C (90°F). If oil tem-
riage to prevent it from falling. Keep all people
perature is 70°C (160°F), the maximum speed
away from the lift truck during the tests.
the carriage can lower is 150 mm (6 in.) per 10
Never put your hands on pressurized hydraulic minutes.
components. Highly-pressurized hydraulic oil
3. Check lift cylinders for internal leaks. Remove
escaping through pin-hole leaks can be in-
load from forks. Install gate valve in supply line
jected into the skin. Visually inspect to find
between main control valve and mast. Put capac-
hydraulic leaks.
ity load on forks again. Raise carriage 1 m (3 ft).
1. Operate hydraulic system. Put capacity load on Close gate valve. If carriage or mast weldments
forks. Use safety chain to hold load to carriage. lower slowly, seals in lift cylinders have leaks.
Raise and lower load several times. Lower load
and tilt mast forward and backward several
times. Check for leaks.
43
Lift System Leak Check 4000 SRM 1195
4. If carriage does not move, open gate valve and Fork Length Allowable
check movement again. If carriage lowers when Measurement
gate valve is open, check for leaks in hydraulic Difference
lines and fittings. If no leaks are found, main
control valve can be worn or damaged. Remove 914 mm (36 in.) 7.86 mm (0.31 in.)
load from forks. 1067 mm (42 in.) 9.18 mm (0.36 in.)
TILT CYLINDER LEAK CHECK 1219 mm (48 in.) 10.48 mm (0.41 in.)
1372 mm (54 in.) 11.80 mm (0.46 in.)
1. Put capacity load on forks. Use safety chain to
secure load to the reach carriage assembly. With 1524 mm (60 in.) 13.11 mm (0.52 in.)
the forks level (parallel to the floor) raise load
1829 mm (72 in.) 15.73 mm (0.62 in.)
approximately 2.5 m (8 ft).
2. Measure distance from fork tip to floor. After 1

minute re-measure distance; difference must not
exceed:
44
TECHNICAL PUBLICATIONS
4000 SRM 1195 7/13 (11/06)(10/06) Printed in U.S.A.

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MAST

PART NO. 1590956 4000 SRM 1195

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2013 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

N35ZDR, N45ZR [C264];

Safety Procedures When Working Near Mast

3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum

4. Lower mast until safety chain stops mast. Lower

5. Turn key switch to the OFF position, disconnect

6. Wrap a second safety chain, 9.5 mm (3/8 in.) min-

NOTE: The mast operator guard MUST be removed

Figure 1. Safety Chain the Mast

3. Lift the load backrest from the tilting frame us-

WARNING 1. CARRIAGE BARS 3. BLOCKS

A fork can be removed from the carriage for replace-

CHECKS be replaced. Check that the bottom of each fork is

Inspect the forks for cracks and wear. Check the

Table 1. Fork Tip Alignment

Fork Tip Alignment Specifications

Some applications may require closer alignment. If Figure 4. Fork Check

1. CAPSCREW 11. LOCKWASHER 21. HOSE SHEAVE

Figure 5. Sheaves (5.5 Mast)

1. BEARING 7. RETAINING RING

Figure 6. Sheaves (6.9 Mast)

4. Clean and inspect the sheave assembly compo-

5. Reassemble the sheave assembly(s) onto the stub

6. Position the lift chains and hoses onto the

7. Remove the safety chains and lower the mast

8. Check the mast for proper operation. Verify

1. SCREW 4. HOSE SHEAVES

Figure 7. Lower Sheave (6.9 Mast)

Figure 8. Lift Pump Components (N35ZDR,

Drain 5. Position a suitable container oil with a minimum

3. Remove the operator compartment cover and the

The main lift cylinders may be identified by the pres-

Figure 11. Main Lift Cylinder Identification

Free-lift cylinders can be identified by the cylinder Table 2. Cylinder Identification

1. Fill the hydraulic tank to the proper level with

1. HYDRAULIC FILTER HOUSING

Figure 12. Free-Lift Cylinder Rod

d. Slightly open the bleed screw on the side

Reach Carriage Assembly

c. If the mast must be disassembled or the

Figure 14. C-Clamp Installation

INSTALL 5. Raise the reach carriage assembly high enough

1. Remove the reach carriage assembly from the WARNING

4. Remove the jam nuts and setscrews from the load

1. LOAD ROLLER WITH SNAP RING REMOVED

Figure 15. Load Roller and Wear Plug

2. Remove the reach assembly from the mast as-

3. Remove the snap rings from the stub shaft. Use

4. Recover the shims from behind the load roller.

9. Install the load rollers onto the stub shafts and