service repair manual

1. SERVICE REPAIR
W20ZA W25ZA [A495]

2. 4000 SRM 1046 General
General
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
This section contains the removal, installation, and
adjustment procedures for the two-stage, zero free-
lift mast. The description and operation of the mast
is outlined in the section Mast Description 4000
SRM 1045.
The repair procedures for the W20ZA and W25ZA
masts are outlined in this section.
The main components of the mast include:
• Mast Weldments
• Lift Cylinders
• Carriage
• Lift Chains
• Hydraulic Tubing
The mast assembly has wear strips and shims that
prevent wear to the mast weldments and allow for
limited adjustment. The wear strips are replaceable
components where friction points cannot be avoided,
such as the outside edge of the channel flange. Load
rollers sustain the forward and backward forces on
the mast and carriage while reducing friction on the
mast weldments. Wear strips must be shimmed peri-
odically, however, no adjustment is necessary for load
rollers. Both may be replaced when necessary. Refer
to Mast Repair, Remove.
WARNING
The mast and carriage assemblies and their
components are heavy. To help prevent dam-
age or injury, a lifting device must be used
during all service procedures.
The mast assemblies must have the mast weldments
parallel with equal clearance on each side between
all weldments. Correct operation depends on peri-
odic cleaning, lubrication, shimming the wear strips,
and adjustment of the lift chains.
NOTE: For the proper maintenance and inspection
procedures for the mast, hydraulic cylinders, forks,
chains, and carriages for your truck, see Periodic
Maintenance 8000 SRM 1048.
NOTE: The carriage can be removed from the mast
assembly with the load backrest and forks installed.
Likewise, the mast can be removed from the truck
without removing the carriage. Perform only the pro-
cedures necessary for repair.
1

3. Safety Procedures When Working Near Mast 4000 SRM 1046
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure the power is off and the key
is removed. Put a DO NOT OPERATE tag in
the operator’s compartment.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• DO NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely.
Push the LOWER button and make sure
there is no movement in the mast. Make
sure all parts of the mast that move are fully
lowered.
OR
• If parts of the mast must be in a raised po-
sition, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
these procedures:
1. Put the mast in a vertical position.
2. Raise the mast to align the bottom crossmember
of the inner weldment with the top of the outer
weldment. See Figure 1.
3. Use a 9.5 mm (3/8 in.) minimum safety chain
with a hook to fasten the weldments together so
the inner weldment cannot lower. Put the hook
on the back side of the mast. Make sure the hook
is completely engaged with a link in the chain.
Make sure the safety chain does not touch lift
chains or chain sheaves, tubes, hoses, fittings, or
other parts on the mast.
4. Lower the mast until there is tension in the
safety chain and the lift cylinder is completely
retracted. If running, stop the engine. Apply the
parking brake. Install a DO NOT REMOVE
tag on the safety chain(s).
NOTE: After lowering or restraining the mast, shut
off the power and remove the key. Put a DO NOT
OPERATE tag in the operator’s compartment.
1. OUTER
WELDMENT
2. INNER WELDMENT
3. SAFETY CHAIN
4. CARRIAGE
Figure 1. Safety Chain the Mast
2

4. 4000 SRM 1046 Mast Repair
Mast Repair
REMOVE
The following instructions are for mast removal.
Mast removal may not be necessary to perform some
repairs, such as removing the lift cylinders. See Lift
Cylinders 4000 SRM 1047, Remove. Remove the
mast only if necessary.
WARNING
Mast parts are heavy and may shift. Distances
between parts are small. Serious injury can re-
sult if part of the body is hit by parts of the mast
or carriage. A lifting device must be used to
support or lift the mast components.
WARNING
Do not make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained
service technicians.
WARNING
Never allow anyone under a raised carriage.
Do not put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the battery is dis-
connected.
Always read and follow ALL warnings and wear pro-
tective clothing and eye protection.
1. Move lift truck to a safe location where work can
be performed. Position truck where mast can be
accessed by a crane or overhead lifting device be-
fore beginning work.
2. Remove carriage from mast. See Carriage Re-
pair.
3. Turn key switch to OFF position, disconnect bat-
tery, and tag control handle DO NOT OPER-
ATE. Block wheels to prevent movement.
4. Disconnect hydraulic hose from tube assembly.
See Figure 2. Cap fitting on hydraulic hose and
plug tube assembly to contain oil leakage.
Figure 2. Tube Assembly
5. Remove two mast mounting capscrews. See Fig-
ure 4.
6. Loosen mast setscrews. See Figure 3.
WARNING
Use only lifting devices with a capacity greater
than the weight of the object being lifted.
7. Attach an overhead lifting device to outer weld-
ment at hook point. See Figure 4.
CAUTION
If lift truck begins to rise off the ground
when lifting mast, lower the lift truck IM-
MEDIATELY and continue prying and lifting
alternately.
8. Slowly raise mast in small increments using an
overhead lifting device. DO NOT allow truck to
be raised off the ground while lifting mast. Lift
approximately 5 mm (.25 in.) at a time prying
crossmember out of mounting brackets with a
pry bar between lifts. See Figure 3. Continue
until mast is free from mounting brackets.
9. Place mast front side face down across two hard-
wood blocks on floor where it can be disassembled
or transported.
3

5. Mast Repair 4000 SRM 1046
1. MAST SETSCREW AND JAM NUT
2. TUBE ASSEMBLY
Figure 3. Mast Setscrews and Tube Assembly
DISASSEMBLE
WARNING
Do not make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained
service technicians.
WARNING
Be careful when installing/removing snap
rings. Use snap ring pliers. Always wear pro-
tective clothing and eye protection.
WARNING
Mast parts are heavy and may shift. Distances
between parts are small. Serious injury can re-
sult if part of the body is hit by parts of the mast
or carriage. A lifting device must be used to
support or lift the mast components.
Mast disassembly is performed with the mast front
side face down across two hardwood blocks on floor
with the carriage removed. Refer to Remove. The
following instructions describe the steps for disas-
sembling the mast. See Figure 7.
1. Remove operator guard.
2. Remove capscrews (29) and washers (28) attach-
ing left and right brackets and dampers to mast.
Disassemble brackets from damper by removing
nut (17), screw (12), and washers (14).
1. HOOK POINT
2. MAST MOUNTING
3. CROSSMEMBER
Figure 4. Mast Removal
4

6. 4000 SRM 1046 Mast Repair
3. Remove tubing assembly. Cap fittings on bottom
of lift cylinders to prevent oil leakage.
4. Remove snap rings, shims, and washers from top
of lift cylinder rods. See Figure 7.
5. Pull inner weldment out until clear of lift cylin-
der rods.
6. Remove O-ring and spacer from lift cylinder rod.
7. Remove snap ring and washer from fitting on bot-
tom of lift cylinders. See Figure 5.
8. Attach an overhead lifting device and sling to lift
cylinder. Tighten the lifting device just enough to
support the lift cylinder when cylinder retainer
is removed. Remove cylinder retainer and lift
cylinder. Repeat for other lift cylinder.
9. Pull inner weldment approximately three-
fourths out of outer weldment.
10. Place two hardwood blocks on the floor positioned
to hold the inner weldment when removed.
11. Attach an overhead lifting device and chain or
sling to each side of inner weldment. Tighten
overhead lifting device until weight is off load
rollers. See Figure 6.
12. Slide inner mast completely out of outer weld-
ment and lower onto hardwood blocks. Remove
chain or sling from inner weldment.
13. Remove snap rings and load rollers from inner
weldment.
14. Remove sheave assemblies:
a. Remove cotter pin.
b. Remove pin using hammer and soft punch.
c. Remove sheaves and washers. See Figure 7.
15. Remove four wear strips, shims, and securing
Allen-head screws (two each) from weldments.
1. LIFT CYLINDER
2. SNAP RING AND WASHER
3. HYDRAULIC FITTING
4. TUBING ASSEMBLY
Figure 5. Tubing Assembly and Hydraulic
Fitting
Figure 6. Moving the Inner Weldment
5

7. Mast Repair 4000 SRM 1046
ASSEMBLE
WARNING
Do not make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained
service technicians.
WARNING
Be careful when installing/removing snap
rings. Use snap ring pliers. Always wear pro-
tective clothing and eye protection.
WARNING
Mast parts are heavy and may shift. Distances
between parts are small. Serious injury can re-
sult if part of the body is hit by parts of the mast
or carriage. A lifting device must be used to
support or lift the mast components.
Mast assembly procedures are performed with the
mast weldments front side face down across wooden
blocks. The bottom of the inner weldment should be
positioned just above the top of the outer weldment.
Always read and follow ALL warnings and directions
and wear protective clothing and eye protection.
1. Install four wear strips and shims (as necessary)
to weldments using capscrews (22). Torque to
10 N•m (89 lbf in).
2. Install sheaves and washers to inner weldment
using pin. Secure pin using cotter pin.
3. Install load rollers to inner weldment using snap
rings.
4. Install inner weldment into outer weldment:
a. Install a chain or sling and overhead lifting
device to inner weldment.
b. Lift inner weldment and position to outer
weldment.
c. Slide inner weldment into outer weldment
until it rolls freely on load rollers.
d. Remove chain or sling and overhead lifting
device.
5. Install lift cylinders using a lifting device:
a. Position fitting and pin on bottom of lift cylin-
der into holes in mounting plate on outer
weldment.
b. Position top end of lift cylinders in place and
secure with cylinder retainer.
c. Install spacer and O-ring to top of lift cylin-
der.
d. Install washer and snap ring to fitting on bot-
tom of lift cylinder. See Figure 5.
e. Repeat for other lift cylinder.
f. Pull inner weldment down onto lift cylinder
rods until completely lowered.
g. Install washers, shims, and snap rings to top
of lift cylinder rods. See Figure 7.
6. Assemble brackets and dampers using screws,
washers, and nuts. Install the left and right
damper and bracket assemblies to the mast us-
ing capscrews and lockwashers.
7. Remove plugs from bottom of cylinders and in-
stall hydraulic fittings.
8. Install tubing assembly to bottom of lift cylin-
ders. See Figure 5.
9. Install operator guard.
INSTALL
The following instructions describe the proper proce-
dure for installing the mast to the frame of the lift
truck. Always read and follow ALL warnings and
directions.
6

8. Thank you very much
for your reading. Please
Click Here Then Get
More Information.
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

9. 4000 SRM 1046 Mast Repair
WARNING
Do not make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained
service technicians.
WARNING
Mast parts are heavy and may shift. Distances
between parts are small. Serious injury can re-
sult if part of the body is hit by parts of the mast
or carriage. A lifting device must be used to
support or lift the mast components.
WARNING
Never allow anyone under a raised carriage.
Do not put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the battery is dis-
connected.
WARNING
Use only lifting devices with a capacity greater
than the weight of the object being lifted.
Always wear protective clothing and eye protection.
1. Attach overhead crane or hoist to mast at hook
point. Refer to Figure 4.
CAUTION
Check that crossmember is completely seated
before removing overhead lifting device.
2. Raise mast to a vertical position directly in front
of truck using overhead crane or hoist. Place
back of mast against front of truck and lower
crossmember of mast into receiver on frame.
3. Center mast using mast set screws and install
mast mounting capscrews.
4. Torque mast mounting capscrews to 225 N•m
(166 lbf ft). See Figure 4.
5. Install hydraulic supply hose to tubing assembly.
See Figure 2.
6. Tighten mast setscrews. Tighten jam nut until it
touches frame and then tighten one half turn to
secure setscrews.
7. Check hydraulic oil level and fill to the FULL
mark if necessary.
8. Install carriage. See Carriage Repair.
CAUTION
The air must be bled from the hydraulic system
before the truck is put into operation.
9. Bleed air from hydraulic system:
a. Connect battery and turn key switch to ON
position.
b. Fully extend and then lower mast several
times to purge air from the hydraulic system.
c. Loosen bleed screws near top of cylinders.
d. Briefly press and release LIFT button. Re-
peat until hydraulic oil flows from bleed
screws without bubbling.
e. Retighten bleed screws.
f. Clean up spilled hydraulic oil.
g. Raise and lower mast to check for proper op-
eration.
h. Repeat procedures for bleeding hydraulic
system if necessary.
10. Adjust chains to proper tension. See Lift Chain
Adjustment in this section.
11. Remove blocks from drive tire and remove DO
NOT OPERATE tag from control handle. Check
mast for proper operation before returning to ser-
vice.
7

10. Mast Repair 4000 SRM 1046
Figure 7. Mast Assembly
8

11. 4000 SRM 1046 Carriage Repair
Legend for Figure 7
1. LIFT CYLINDER
2. SNAP RING
3. SHIM
4. WASHER
5. O-RING
6. SPACER
7. CHAIN PIN
8. COTTER PIN
9. CHAIN ANCHOR
10. LOCK NUT
11. OUTER WELDMENT
12. SCREW
13. DAMPER
14. WASHER
15. CYLINDER RETAINER
16. BRACKET (LH)
17. NUT
18. SCREW
19. WEAR STRIP
20. SHIM
21. SNAP RING
22. WASHER
23. LOAD ROLLER (INNER)
24. SNAP RING
25. WASHER
26. OPERATOR GUARD
27. BRACKET (RH)
28. LOCKWASHER
29. SCREW
30. PIN
31. COTTER PIN
32. WASHER
33. SHEAVE
34. WASHER
35. CHAIN
36. INNER WELDMENT
Carriage Repair
REMOVE
For the following removal steps, refer to Figure 8.
1. Put a one-quarter capacity load on forks.
NOTE: The load provides stability to prevent the car-
riage from falling when it is removed from mast. If
mast is disabled, lift and then lower carriage on to
pallet using an overhead lifting device. Then load
forks using another lift truck.
2. Lower carriage and forks on to a pallet so that lift
chains become loose.
3. Turn key switch to OFF position and disconnect
battery.
WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Prevent the lift chains from
falling from the sheaves and causing an injury
or damage.
4. Disconnect lift chains:
a. Remove chain anchors from outer weldment
of mast by removing cotter pins and nuts.
b. Connect a tag to each lift chain specifying
from which side it was removed.
c. Remove cotter pin and pin from chain anchor
at carriage.
d. Store chains in a clean box or bucket.
5. Connect battery and turn key switch to ON posi-
tion.
WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast weld-
ment is above the load rollers of the carriage.
6. Raise inner mast weldment by pressing LIFT
button. If mast is disabled, disconnect lift cylin-
ders from inner weldment. See Lift Cylinders
4000 SRM 1047. Connect an overhead lifting de-
vice to top of inner weldment. Carefully raise
inner weldment until it is above carriage load
rollers.
7. Move lift truck away from carriage. If using an
overhead lifting device, move pallet using an-
other lift truck. Completely lower inner weld-
ment.
9

12. Carriage Repair 4000 SRM 1046
1. CARRIAGE
2. LOAD BACKREST
3. LOAD BACKREST
CAPSCREWS
4. FORK RETAINING
CAPSCREW
5. FORKS REMOVAL
NOTCH
6. FORK
7. LATCH PIN
ASSEMBLY
8. LATCH
9. PIN
10. WASHER
11. SPRING
12. LATCH PIN
Figure 8. Carriage Assembly
DISASSEMBLE
Total disassembly may not be necessary to repair car-
riage. Only perform steps necessary to make repairs.
See Figure 8.
WARNING
Forks are heavy. Use a lifting device and a sling
to move the forks if necessary.
WARNING
Be careful when removing snap rings. Use snap
ring pliers. Always wear protective clothing
and eye protection.
1. Connect a lifting device to top of load backrest.
Remove load from forks with another lift truck.
2. Remove forks from carriage. See Fork Repair,
Remove. Tag each fork with truck serial number.
Store forks on their side.
3. Lower carriage to floor so that load rollers are
facing up.
4. Remove load backrest.
5. Remove snap rings and load rollers.
ASSEMBLE
WARNING
Forks are heavy. Use a lifting device and a sling
to move the forks if necessary.
WARNING
Be careful when installing snap rings. Use
snap ring pliers. Always wear protective cloth-
ing and eye protection.
Refer to Figure 8 for the following procedures.
1. Install load rollers and snap rings.
2. Position load backrest on carriage and install
four capscrews. Torque to 75 N•m (55 lbf ft).
3. Connect a lifting device to top of load backrest.
4. Raise carriage to an upright position.
5. Locate forks and verify number tagged on forks
matches the truck serial number.
6. Install forks to center of carriage so top of fork
hangs on carriage and lower portion of fork
passes through fork removal notch. Place latch
pin assembly in UP position and slide forks
to either side. Place latch pin assembly in the
DOWN position and check that fork is locked
into place.
7. Install fork retaining capscrew.
10

13. 4000 SRM 1046 Fork Repair
INSTALL
1. Connect a lifting device to carriage and position
carriage on a pallet for installation.
2. Place a one-quarter capacity load on forks and
disconnect overhead lifting device.
NOTE: The load provides stability to prevent the car-
riage from falling when it is installed to the mast.
3. Move lift truck or move carriage using another
lift truck to position carriage load rollers directly
in front of mast inner weldment.
4. Raise inner mast weldment by pressing LIFT
button. If mast is disabled, connect an overhead
lifting device to top of inner weldment. Raise
inner weldment until it is above carriage load
rollers.
5. Position carriage so load rollers are directly un-
der inner weldment and directly between chan-
nels of outer weldment.
6. Slowly lower inner weldment onto carriage load
rollers by pressing LOWER button. Stop to
check that load rollers are entering inner weld-
ment channels correctly. If binding occurs, raise
inner weldment and reposition carriage as nec-
essary.
WARNING
When installing the lift chains, keep control of
the ends. Prevent the lift chains from falling
from the sheaves and causing an injury or dam-
age.
7. Install lift chains as removed:
a. Position chain anchors through mounting
holes in outer weldment.
b. Install nuts and cotter pin to chain anchors.
c. Route lift chains through the chain sheaves
mounted to the top of the inner weldment.
d. Install chains to chain anchors on carriage.
e. Install pins to chain anchors.
8. Connect battery and turn key switch to ON posi-
tion.
9. Raise inner weldment 50-75 mm (2-3 in.) by
pressing LIFT button. Remove pallet from un-
der carriage and lower mast completely by press-
ing LOWER button. If mast is disabled, raise
and lower mast using an overhead lifting device
and connect lift cylinders to inner weldment. See
Lift Cylinders 4000 SRM 1047.
10. Check mast for proper operation and lift chain
adjustment. Adjust lift chains if necessary. See
Lift Chain Adjustment in this section.
Fork Repair
CHECK
The forks are held on the carriage by hooks. The
forks are kept in position by latch pins that fit
through the top fork hooks and into slots in the top
bar of carriage. Always check that the latch pins
keep the forks in position on the carriage. Replace
damaged latch pin parts. The forks can be removed
from the carriage for replacement or storage.
Inspect the forks for cracks and wear. See Figure 9.
Check that the fork tips are aligned within 3 percent
of each fork length [32 mm (1.26 in.) for a standard
1067 mm (42 in.) fork]. Some applications can re-
quire closer alignment. Check that the bottom of the
fork is not worn. Check that the thickness of the
fork blade is at least 90 percent of the thickness of
the fork shank (DIMENSION X). The fork’s thick-
ness can also be checked using fork tool 3140731.
11

14. Fork Repair 4000 SRM 1046
Fork Tip Alignment
Length of Forks 3% Dimension
0914 mm (36 in.)
1067 mm (42 in.)
1220 mm (48 in.)
1371 mm (54 in.)
1524 mm (60 in.)
27 mm (1.10 in.)
32 mm (1.26 in.)
37 mm (1.46 in.)
40 mm (1.57 in.)
46 mm (1.81 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. THICKNESS OF BOTTOM OF FORK (MUST BE
90% OF DIMENSION X)
5. FORK BLADE (BOTTOM OF FORK)
6. FORK TOOL 3020387
Figure 9. Check the Forks
REMOVE
WARNING
Forks are heavy. Use a lifting device and a sling
to move the forks if necessary.
Remove the fork retaining capscrew. Slide the fork
to the fork removal notch in the bottom bar of the
carriage. See Figure 10 and Figure 8. Lower the
tip of the fork onto blocks so the bottom hook of the
fork moves through the fork removal notch. See Fig-
ure 10. Lower the carriage further so the top hook
of the fork is disengaged from the top carriage bar.
Move the carriage away from the fork, or use a lift-
ing device to move the fork away from the carriage.
INSTALL
WARNING
Forks are heavy. Use a lifting device and a sling
to move the forks if necessary.
Position the fork to carriage so the top hook on the
fork can engage the upper carriage bar. Raise the
carriage or lower the fork to move the lower hook
through the fork removal notch. Slide the fork on
the carriage so both upper and lower hooks engage
the carriage bars. Engage the latch pins with a notch
in the upper carriage bar. Install the fork retaining
capscrew. See Figure 10 and Figure 8.
12

15. 4000 SRM 1046 Lift Chain Adjustment
Figure 10. Hook Fork Removal
Legend for Figure 10
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Lift Chain Adjustment
INSPECT
WARNING
All chains, ropes, and lifting equipment MUST
be fully examined by qualified personnel at
least once a year or more at frequent intervals
according to the local conditions of use.
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
Never allow anyone under a raised carriage.
DO NOT put any part of your body in or
through the lift mechanism unless all parts
of the mast are completely lowered and the
battery is disconnected.
The chains may be inspected while in position on the
truck. Use solvent to clean the chains periodically
and before inspecting. Lubricate the chains IMME-
DIATELY after cleaning. DO NOT use steam to
clean the chains.
Inspect the chains and associated components for the
following defects:
• Damaged or missing link plates
• Loose pins or pins with damaged heads
• Pins that rotate in the pin link plate
• Chain does not flex
• Wear on the edges of the pin link plates caused by
chains sliding over sheave
• Damage to the locking mechanism of the anchor
pin
• Wear and/or corrosion of the anchor pin
• Chain wear and/or signs of stress between the pin
and the link plate and/or associated components
If any of the above defects are found, the chain(s)
MUST be replaced.
ADJUST
WARNING
All chains, ropes, and lifting equipment MUST
be fully examined by qualified personnel at
least once a year or more at frequent intervals
according to the local conditions of use.
WARNING
Do not make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained
service technicians.
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
Never allow anyone under a raised carriage.
DO NOT put any part of your body in or
through the lift mechanism unless all parts of
the mast are completely lowered.
When the lift chains are correctly adjusted:
• The tension MUST be the same on each chain of
the chain set. Check tension by pushing on both
chains at the same time.
13