ASSEMBLY GUIDE

H800-1050E (H36.00-48.00E) [D117]

PART NO. 1526432

8000 SRM 1041

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE:

The following symbols and words indicate safety information in this

manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Assembly Guide

Table of Contents

TABLE OF CONTENTS

List of All Special Tools and Equipment Needed for the Assembly ................................................................

General Considerations Before Starting the Job .............................................................................................

Preparation of the Components Before Assembly............................................................................................

Installation and Checking of the Wheels..........................................................................................................

Installation of the Cab .......................................................................................................................................

Installation of the Mast .....................................................................................................................................

Installation of Carriage Equipped With Forks.................................................................................................

Installation of the Dedicated Carriage .............................................................................................................

Installation of the Gantry..................................................................................................................................

Connection of the Hoses and Cables to the Carriages .....................................................................................

Harness Installation Instructions ................................................................................................................

Installation of the Forks ....................................................................................................................................

Low-Mounted Forks.......................................................................................................................................

Installation of the Low-Mount Quick-Disconnect Type Forks ................................................................

Installation of the Low-Mount Pin-Mounted Forks ................................................................................

High-Mounted Forks .....................................................................................................................................

Installation of the High-Mount Quick-Disconnect Forks........................................................................

Installation of the High-Mount Pin-Mounted Forks ...............................................................................

Installation of the Container Attachment on Forks ........................................................................................

Installation of the Container Attachment on the Dedicated Carriage ...........................................................

Installation of the Container Attachment on the Gantry................................................................................

Lights Installation .............................................................................................................................................

General Procedures After Assembly .................................................................................................................

This section is for the following models:

H800-1050E (H36.00-48.00E) [D117]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

8000 SRM 1041

General Considerations Before Starting the Job

List of All Special Tools and Equipment Needed for the Assembly

WARNING

Read all the instructions contained in this
manual before starting any work on the unit.
Also read all procedures contained in the
Operating Manual before operating the truck.

LIFT tools:

• A crane with a minimum capacity of 20,000 kg

(44,000 lb) when the boom is raised at the top
of the mast. This means the boom must have
a length of the mast’s retracted height + 1 m
(3 ft) + slings height + hook and cables height,
and at that height, it must have the capacity to
hoist 20,000 kg (44,000 lb).

CAUTION

When you have a full-free lift, a three-stage, a
four-stage mast, or even another special mast,
the hoist capacity must be even higher than
20,000 kg (44,000 lb) (see specifications on com-
ponents weight chart).

• Cables or slings of sufficient capacity (see compo-

nents weight chart).

• Blocks of hard wood of various lengths, widths, and

thickness.

• A small mechanical hoisting winch of 1500 kg

(3300 lb) capacity.

• Strips and two solid ropes of approximately 150 kg

(330 lb) capacity each.

• A lift truck with sufficient lift height to reach the

top of the mast.

• A safety platform fastened on the truck carriage.

Tooling:

• A complete set of imperial and metric ring and

open-end spanners/wrenches.

• A torque wrench with a capacity up to 500 N•m

(approx. 370 lbf ft).

• Gloves and protective clothing.
• Safety glasses and helmets.
• A hydraulic jack with a minimum capacity of

12,000 kg (26,500 lb).

• A safety cage for inflating tires.

Trained mechanics:

• It is recommended that personnel involved in

the assembly of the machine have followed a
specific training session on those units or have
proven understanding of the product to be able
to perform the job professionally.

• The minimum personnel required to do the job

is at least two mechanics.

General Considerations Before Starting the Job

NOTE: This assembly guide is very extensive be-
cause it is written to cover all situations. Assembly
of new trucks depends primarily upon how the truck
was transported and which carriage is supplied. If
the truck was transported overseas, it will be more
disassembled than if only shipped by land. Use the
portions of the assembly guide that meet your needs.

CAUTION

The following assembly procedures are for as-
sembling the lift truck after shipment from the
factory. Be sure to check all fluid levels and tire
pressures before removing the lift truck from
the trailer. If in doubt, check the torque of all
relevant hardware.

Safety is always the most important item!

When lifting parts or assemblies, make sure that
all slings, chains, or cables are correctly fastened
and balanced before lifting. Make sure that all
lifting devices have enough capacity to lift the
weight. If in doubt, do not hesitate to use a device
with a higher capacity than required. Always use
your common sense and avoid dangerous situa-
tions.

Plan enough personnel to do the job. Never
lift heavy parts by hand. Always use a lifting
mechanism.

The rental price of the crane, which you will
need to lift the major components, is very expen-
sive. Plan the job as well as possible in order to
limit the costs to the minimum required.

Preparation of the Components Before Assembly

8000 SRM 1041

Check that all the items ordered are available
upon receipt of the machine and its components.
Unpack the case accompanying the machine
and identify all the components contained in it.
Check that all capscrews, nuts, pins, washers,
and brackets are all presented.

Prepare the job. Do all possible preparation and
preassembly of parts, cleaning, or lubrication in
advance. Allowing yourself half a day before the
arrival of the crane will enable you to mount the
drive wheels and prepare the mast for direct as-
sembly, and will reduce the rental charges of the
crane.

Take enough time to read the instructions con-
tained in this guide and to familiarize yourself
with the procedures. It is advised to read those
procedures when the machine and components
have arrived, in order to have a better practical
understanding of the instructions.

It is recommended to perform all assembly pro-
cedures outside.

Do not forget that the mast

(front-end) assembly will be done with the mast
hanging vertically under the top of the crane.
And do not forget that, during the carriage as-
sembly, the inner mast will be almost fully ex-
tended.

Preparation of the Components Before Assembly

As previously mentioned, first check that all the
components, which will be needed later during
installation, are available. (Check this according
to the specific packaging list.)

If needed, clean all parts before installation.

Grease all fittings that will be less accessible
later (chain sheaves, for example).

Fasten the hose sheaves on the right-hand top of
the inner mast weldment.

Check that the following hanging points are
clean and free of paint and grease:

• Mast hanger holes in the frame
• Mast hanger holes in the upright
• Tilt cylinder bushings in the mast
• Tilt cylinder rod ends

8000 SRM 1041

Installation and Checking of the Wheels

Driving Wheels

WARNING

Make sure the jack which you will need for the installation of the wheels has a capacity equal to
at least half the weight of the lift truck. Refer to the nameplate for weight. The standing surface
must be solid and even. Tires and wheels must be changed and repaired by trained personnel only.
Always wear safety glasses, safety shoes, and gloves.

STEP 1.

Put wooden blocks in front and behind each of the steering tires so the truck cannot move during lifting. Put
a jack under the mounting pad of the drive axle and lift one side of the truck. Raise the truck so that the drive
tire is just above the surface. Put additional blocks of hard wood under the frame to support the lift truck so
the truck is standing stable.

WARNING

Deflate tires before removing the wheel from
the lift truck.

Air pressure in the tires can

cause the tire and rim parts to explode, caus-
ing serious injury or death. Always wear safety
glasses. Never loosen the nuts that hold the
inner and outer wheel halves together when
there is air pressure in the tire.

WARNING

Always move wheels during assembly with a
lifting device. Make sure the lifting device has
the correct capacity for the parts being moved.
Consult the specification chart for the weight
of the parts.

STEP 2.

Completely remove the air pressure from the tires of
the driving wheels. Remove the 28 wheel nuts from
the hub, including the washers and the rim clamps.
Remove the wedgeband, the temporary spacer, the
wheel spacer, and the inner wheel from the hub. The
inner wheel has to be removed by using a lifting de-
vice.

WEDGEBAND

TEMPORARY
SPACER

WHEEL SPACER

EDGE WITH THE
BEVEL

Installation and Checking of the Wheels

8000 SRM 1041

WARNING

Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of
the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the
correct air pressure is reached, check that all wheel parts are correctly installed. The clearance
at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the
correct air pressure.

STEP 3.

Add air pressure to both tires. Be sure the correct air
pressure is in the tires. Check that all wheel parts
are correctly installed.

NOTE:

Safety cage in use.

STEP 4.

Reassemble the inner wheel on the hub with a lifting device, being sure the edge with the bevel is toward the
outside of the truck.

STEP 5.

Install the valve extension for the inner wheel and fasten it. Check for proper working order, by seeing if the
pressure indicator reacts on the pressure in the rim. If working properly, reassemble the wheel spacer on the
hub.

STEP 6.

To install the outer drive wheel, be sure the edge with
the bevel is toward the inner drive wheel. Also make
sure that the outer notch in the wheel spacer aligns
with the edge with the bevel on the wheel rim. Install
the outer drive wheel on the hub with a lifting device.
Make sure the valve stem aligns with the notch in the
rim (see picture).

EDGE WITH THE
BEVEL

NOTCH

CAUTION

Make sure all the contact areas between the rim, the axle, and the spacers are clean and have a
minimum paint thickness.

STEP 7.

Install the wedgeband on the hub (see picture). Clamp the wedgeband on the hub with the rim clamps including
spacers and wheel nuts. Fasten the wheel nuts. Be sure the rim clamps are well positioned on the wedgeband,
because the wedgeband locks up the rim on the hub.

WEDGEBAND

RIM CLAMP

HUB SIDE

WEDGEBAND SIDE

8000 SRM 1041

Installation and Checking of the Wheels

CAUTION

Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and
damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer
band, or forcing rims out of round.

STEP 8.

Make sure the tires are still not touching the ground.
Tighten the wheel nuts in steps according to the
correct sequence until the torque indicated has been
reached. This torque is for driving wheels between
405 and 440 N•m (300 and 325 lbf ft).

NOTE:

Correct sequence of torquing the driving

wheels.

STEP 9.

Lower the truck, and then remove the hydraulic jack. At last, remove the wooden blocks in front and behind
the steering tires.

STEP 10.

Follow the same procedure, STEP 1 through STEP 9,
for the drive wheel on the other side.

NOTE:

Driving wheel reassembled.

Installation of the Mast

8000 SRM 1041

Steering Wheels

STEP 11.

After having completed all installation procedures for the drive wheels, check the torque of the wheel nuts for
the steering wheels in the correct sequence. This torque must be between 270 and 339 N•m (200 and 250 lbf ft).

A. CORRECT SEQUENCE OF TORQUING THE 16.00 × 25 STEERING WHEELS
B. CORRECT SEQUENCE OF TORQUING THE 18.00 × 25 STEERING WHEELS

WARNING

Add air pressure to the tires only in a safety cage. Check the nameplate of the truck before inflating
the tires. The correct pressure is mentioned on it. Inspect the safety cage for damage before use.
When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner
tube. Make sure there is enough air hose to permit the operator to stand away from the safety cage
when air is added to the tire. Do not sit or stand by the safety cage. Do not use a hammer to try
and correct the position of the side flange or lock ring when the tire has air pressure greater than
20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly
installed. The clearance at the ends of the lock ring will be 13 to 25 mm (0.5 to 1.0 in.).

WARNING

When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten
the nuts to the correct torque again. When the nuts stay tight after an 8-hour check, the interval
for checking can be extended to 250 hours.

STEP 12.

Check air pressure of the steering wheels. See nameplate for correct air pressure in the tires. If the air pressure
is less than 80% of the pressure indicated on the nameplate, remove the wheel after removing all air out of the
tire and inflate it in a safety cage.

Installation of the Cab

WARNING

Make sure the lifting device has the correct ca-
pacity for the parts being moved. Consult the
specification chart for the weight of the parts.

Loosen the straps which hold the cab during
transport.

Remove the capscrews, including

fixing plates, from the studs on the platform.

Connect a lifting device to the steps railing and
lift it into position on the steps. Bolt the railing
to the steps. Follow up the same procedure for
the platform railings.

Connect the lifting device to the handles on the
cab. Watch that nothing damages the cab during
lifting. Position the cab on the four studs on the
platform. Ensure the cab is seated well. Bolt the
cab to the studs on the platform with the fixing
plates. Do not forget to mount the second nut to
lock the first. Ensure that the cables and hoses
to the compartment are in good shape.

Position the front cover plate to the platform.
Bolt it to the platform. Remove all wood in front
of the truck between the tilt cylinders.

Installation of the Mast

8000 SRM 1041

Installation of the Mast

STEP 1.

Remove the mast pivot pins including caps, washers,
and temporary transporting sleeves from the mast
points of suspension (mast hanger points).

There are two different applications for the mast
hanger points. Always use the outer mast hanger
points. The outer brackets on the frame are for the
wider mast.

Remove all paint, rust, or grease from the pivot pins
surfaces, the inside of the caps, and the mast hanger
holes.

NOTE:

Wide mast version shown.

NOTE:

Mast points of suspension.

Installation of the Mast

8000 SRM 1041

CAUTION

During installation, the mast pivot pins and mast hanger holes must be and remain absolutely free
of grease, to assure proper seating of the end plates and prevent pin rotation during operation.

STEP 2.

In preparation to the assembly of the mast, install the hose sheave on the right-hand top of the inner mast
weldment, if not already done. Lubricate the fittings on the chain sheaves and the upright rollers.

NOTE:

Hoses and cables routed over the mast.

A. WITHOUT CONTAINER ATTACHMENT

B. WITH CONTAINER ATTACHMENT

INNER MAST

OUTER MAST

CHAIN SHEAVE

CYLINDER

STEP 3.

Clean and grease the four holes for the tilt cylinder
pins on the outer mast. Also clean the two holes for
the mast pivot pins. Leave these two holes clean and
dry. Do not grease the holes!

If required, install the chains partially into the
sheaves until they reach the back of the mast.
Connect the chains to the anchors with the chain
anchor pins. Use new snap rings to lock the chain
anchor pins. Check the threads on the chain anchors
and repair damaged thread if necessary.

Mount

the chain anchors to the brackets at the back of the
mast. Protect the threads during the installation.
Use straps to hold the ends of the chains to each
of the lift cylinders.

Adjust the chain anchors as

shown.

NOTE:

Adjust to 10.0 mm (0.4 in.)

only for the

7010 mm (23 ft) lift height assembly.

WARNING

Make sure the lifting device has the correct capacity for the parts being moved. Consult the spec-
ification chart for the weight of the parts.

STEP 4.

Connect a lifting device with a correct capacity
around the top crossmembers of the inner and outer
mast (preferably no chains, because they damage the
paint of the weldment). Make sure the lifting device
is well centered and connected to the crossmembers.
Raise the mast and make sure it is stable. Make
sure the mast is vertical and that the hanger holes
are at the same height and parallel to the ground.

8000 SRM 1041

Installation of the Mast

WARNING

Never check the alignment of the mast and frame holes with your hand or finger.

STEP 5.

Drive the truck toward the mast until approximately 30 cm (1 ft) from it. Apply the park brake and stop the
engine. Move the mast to the mounts in the frame. Align the holes in the frame with the holes in the mast.

CAUTION

Make sure the frame holes for the mast, the mast hanger holes, and the mast pivot pins are clean
and dry before continuing with STEP 5! In particular, all the conical surfaces must absolutely be
dry and free of grease.

STEP 6.

On one side, install the pivot pin, the two caps, the
capscrew, the two washers, and the nut for the sup-
port pin. Position the outer cap at the wheel side. The
lubrication fitting must be oriented to the surface.
Tighten the nut. Install the other pivot pin including
caps, capscrew, washers, nut, and support pin. Make
sure that everything is seated together, then torque
the bolts of the pivot pins (on both sides of the truck)
with 285 N•m (210 lbf ft). Lubricate the pins, using
the two grease fittings, while the weight of the mast
is off the pin, e.g., while mast is still being supported
by the crane.

NOTE:

Mast pivot pin construction.

A. TORQUE THE BOLT WITH 285 N•m (210 lbf ft).

MAST HANGER (REF.)

ORIENT LUBRICATION FITTING TO THE
SURFACE

FRAME (REF.)

STEP 7.

Operate the lifting device to move the mast so the tilt cylinders can be connected. Use a small mechanical
hoisting winch to lift both tilt cylinders on one side with the wooden transport block between them. Place
wooden blocks under the cylinders for support. Ensure they are the correct height and at the correct angle to
be fastened to the mast. Do the same on the other side of the truck.

STEP 8.

Grease the four tilt cylinder anchor pins and also prepare the four lock plates, capscrews, and washers. Check
if the rod ends are secured with the two bolts through each of the rod ends.

WARNING

Do not put your fingers in the rod end holes or tilt-cylinder anchor holes. Use a piece of wood to
push the anchor pins. The tilt cylinder can drop and cause injury.

STEP 9.

Ask a trained assistant to start the engine and
operate the tilt controls smoothly. Operate the tilt
cylinders to align the rod end holes with the mast
mounting holes. Install the two lower tilt cylinder
pins using a hammer.

Install lock plates.

The

cylinders must bottom at the same time in backward
tilt position.

A. ROD END

LOCK PLATE

PISTON

BOLTS THROUGH
THE ROD END

In case adjustment of tilt cylinder is required: Put the mast in a vertical position. Loosen the two bolts
through the cylinder rod end. Turn the piston counterclockwise to increase the length of the tilt cylinder or

Installation of the Mast

8000 SRM 1041

clockwise to reduce the length. After adjustment of the tilt cylinder, tighten the cylinder rod end hardware to
156 N•m (115 lbf ft).

Support the upper tilt cylinders, first one side and then the other, with a sling. Align the two upper tilt cylinder
rod ends with the mast mounting holes by operating the tilt cylinders smoothly. Install the pins and lock plates
as shown on picture. Operate the tilt cylinders and check proper alignment of the four tilt cylinders. All four
cylinders must bottom out at the same time in backward tilt position. Readjust one or both top cylinders
when torsion is caused in the mast. Refer to tilt cylinder adjustment procedure above.

When all cylinders are correctly adjusted, be sure lock plate is installed on each cylinder and all tilt cylinder
rod end hardware is tightened to 156 N•m (115 lbf ft). Lubricate the four rod end fittings.

STEP 10.

Disconnect the lifting device and the mechanical winch from the mast and the tilt cylinders.

8000 SRM 1041

Installation of the Mast

STEP 11.

Locate the hydraulic hoses at the front of the truck.
Disconnect the hydraulic hoses from each other so
there are four separated hoses on the junction block.
Connect the two hoists and two lower hydraulic
hoses, from the junction block to the bottom of the
two lift cylinders.

NOTE:

Hoses hanging during transport.

NOTE: The two hoses on the bottom of the junction block (hoist) in front of the truck will be connected to the
fitting on the right side of each lift cylinder. The two hoses on the top of the junction block (lower) will be
connected to the fitting on the left side of each lift cylinder. Connect the left-sided ports of the junction block
with the left cylinder, and also the right-sided ports from the junction block to the right cylinder. All are as seen
from the drivers seat. When installed, hoses will not be slack. See routing of the hoses in the picture below.

STEP 12.

Mount in accordance to this schedule.

Installation of the Mast

8000 SRM 1041

CAUTION

Check hose movement during full-forward and back-tilt operation. Route the hoses away from
sharp edges to prevent damage during use.

STEP 13.

Route hoses as shown below.

A. HOSES ROUTED ON THE LEFT

B. HOSES ROUTED ON THE RIGHT

8000 SRM 1041

Installation of Carriage Equipped With Forks

CAUTION

After assembly, check if all the hydraulic fittings, hoses, or tubes have been correctly fastened and
well positioned. Verify visually there are no leaks in the system. Make sure the hydraulic hoses or
tubes are not in contact with sharp edges, which might damage them. If this is the case, reroute
the hoses in order to avoid damage. Avoid all sharp bends in hoses, especially near fittings.

STEP 14.

Connect the two hydraulic hoses, which are mounted in the brackets on the mast (see STEP 2), to the fittings at
the front of the truck against the inside of the right fender. Watch that the code on the hoses matches with the
code on the fittings. Connect the hydraulic hose as configured and shown for narrow or wide axle. Connect the
electrical supply for the application(s) on the mast to the truck’s electrical system with one or two connectors,
as configured.

A. HYDRAULIC HOSE CONNECTION - NARROW

AXLE

B. HYDRAULIC HOSE CONNECTIONS - WIDE

AXLE

C. CONNECTIONS FOR ELECTRICAL SUPPLY
D. HOSES MOUNTED THROUGH MAST

MOUNTING BRACKET

CONNECTORS FOR ELECTRICAL SUPPLY

HYDRAULIC HOSES

Installation of Carriage Equipped With Forks

WARNING

Make sure the lifting device has the correct ca-
pacity for the parts being moved. Consult the
specification chart for the weight of the parts.

Connect a lifting device at each side of the top
crossmember of the carriage and put the carriage
in vertical position.

WARNING

When raising or lowering the mast, use two
strong ropes -- 150 kg (331 lb) capacity -- to
control the end of the two lift-chains.

It is

of vital importance that the chains are main-
tained under tension during the lifting or the
lowering of the inner mast. If the chains are
not fastened, they might fall and cause injury
or damage the piston of the hoist cylinder, the
cab, or the mast.

Operate the hoist cylinders to raise the inner
mast just past the top load rollers of the carriage.

Operate the lifting device or the truck and move
the carriage vertically into place under the inner
mast. Then lower the inner mast smoothly until
all rollers of the carriage are completely engaged.

Lift the carriage in the mast. Before mounting
the chain anchors onto the carriage, be sure the
threads are clean and in order. Watch that the
threads of the chain anchors are not damaged
during installation. If necessary, repair damaged
threads. Connect the chain anchors to the car-
riage. Install two nuts on each anchor chain, hold
4.5 cm (1.75 in.) thread free under the last nut,
and tighten them completely. Fully lower the
carriage. There must be approximately 5.1 cm
(2 in.) play between the bottom carriage bar and
the bottom bar of the outer weldment. If distance
is not achieved, adjust to attain, and then tighten
the nuts completely.

Extend the mast fully. Make sure the chain an-
chors do not touch the chain sheaves. There must
be a minimum clearance of 6.4 mm (0.25 in.) be-
tween the chain anchor and the chain sheave.
Adjust the chain anchor on the outer weldment
to achieve necessary clearance.

Installation of the Gantry

8000 SRM 1041

CAUTION

Check that both chains have equal tension.
Make sure that the rollers on the top of the
carriage do not touch the top of the inner weld-
ment on the inside. Check the side clearance
of the carriage and adjust it when needed.

There must be zero clearance at the point of
tightest fit in the inner weldment. Use shims to
adjust the side clearance on the rollers. Make
sure the carriage is in the center of the inner
weldment (side to side clearance is equal).

Installation of the Dedicated Carriage

WARNING

Make sure the lifting device has the correct ca-
pacity for the parts being moved. Consult the
specification chart for the weight of the parts.

Connect a lifting device at each side around the
tubular carriage crossmember. Also connect a
mechanical winch between the lifting device and
the crossmember at the front of the dedicated
carriage. This will allow horizontal stability of
the carriage when lifted and will allow easy in-
stallation in the inner mast.

WARNING

When raising or lowering the upright, use two
strong ropes -- 150 kg (331 lb) capacity -- to con-
trol the end of the two lift-chains. It is of vital
importance that the chains are maintained un-
der tension during the lifting or the lowering of
the inner mast. If the chains are not fastened,
they might fall and cause injury or damage the
hoist cylinder rods, the cabin, or the upright.

Operate the lift cylinders to raise the inner weld-
ment just past the top load rollers of the carriage.

Operate the lifting device or the truck and move
the carriage vertically into place under the inner
upright. Lower the inner mast completely to en-
gage all rollers of the carriage.

Lift the carriage with the lifting device. Before
mounting the chain anchors onto the carriage, be
sure the threads are clean and in order. Watch
that the threads of the chain anchors are not
damaged during installation. If necessary, re-
pair damaged threads. Connect the chain an-
chors to the carriage. Install two nuts on each
anchor chains, hold approximately two threads
clearance under the lowest nut, and tighten them
completely. Fully lower the carriage. There must
be approximately 10.2 cm (4 in.) between the bot-
tom carriage bar and the bottom bar of the outer
weldment. If not, adjust it to the right clearance.
Extend the mast fully. Make sure the chain an-
chors do not touch the chain sheaves. There must
be a minimum clearance of 6.4 mm (0.25 in.) be-
tween the chain anchor and the chain sheave.
Adjust the chain anchor on the outer weldment
to achieve necessary clearance.

CAUTION

Check that both chains have equal tension.
Make sure that the top siderollers of the
carriage do not touch the top of the inner
weldment on the inside. Check the side clear-
ance of the carriage and adjust it when needed.

Installation of the Gantry

WARNING

Make sure the lifting device has the correct ca-
pacity for the parts being moved. Consult the
specification chart for the weight of the parts.

Connect a lifting device at each side around the
tubular carriage crossmember. Also connect a

mechanical winch between the lifting device and
the crossmember at the front of the gantry. This
will allow horizontal stability of the carriage
when lifted and will allow easy installation in
the inner mast.

8000 SRM 1041

Connection of the Hoses and Cables to the Carriages

WARNING

Operate the lift cylinders to raise the inner weld-
ment just past the top load rollers of the carriage.

Operate the lifting device or the truck and move
the carriage vertically into place under the inner
mast. Lower the inner mast completely to engage
all rollers of the carriage.

Lift the carriage with the lifting device. Before
installing the chain anchors onto the carriage,
be sure the threads are clean and in order.
Watch that the threads of the chain anchors are
not damaged during installation. If necessary,
repair damaged threads.

Connect the chain

anchors to the carriage.

Install two nuts on

each anchor chain, hold approximately 4.5 cm
(1.75 in.) thread clearance under the lowest nut,
and tighten them completely. Fully lower the
carriage. There must be approximately 5.1 cm
(2 in.)

between the bottom carriage bar and

the bottom bar of the outer weldment. If not,
adjust it to the right clearance. Extend the mast
fully. Make sure the chain anchors do not touch
the chain sheaves. There must be a minimum
clearance of 6.4 mm (0.25 in.) between the chain
anchor and the chain sheave.

CAUTION

Connection of the Hoses and Cables to the Carriages

STEP 1.

Carefully lift the carriage with the lifting device. Fasten the two hydraulic hoses (supply and return), from the
sheave at the top of the right outer weldment to the fittings on the bracket at the right side of the carriage.
Fasten the electrical connector to the carriage with screws. Route the cable(s) on the carriage in the same
brackets used for the hoses. See illustration for reference.

A. ROUTE OF HOSES AND CABLES OVER THE DEDICATED CARRIAGE.

ELECTRICAL SUPPLY TO THE ATTACHMENT

HYDRAULIC HOSES TO THE ATTACHMENT

STRAP WITH SLEW-CYLINDER HOSES

HOSES FROM TOP OF THE MAST

CONNECTOR BOLTED ON THE CARRIAGE

BRACKET ON THE ATTACHMENT

DEDICATED CARRIAGE

HOSE AND CABLE BRACKET

MAST

Connection of the Hoses and Cables to the Carriages

8000 SRM 1041

CAUTION

STEP 2.

Below are the wire codes for reference. Item 21 is the
outside-routed mast hose harness and Item 22 is the
inside-routed mast hose harness.

8000 SRM 1041

Connection of the Hoses and Cables to the Carriages

HARNESS INSTALLATION INSTRUCTIONS

Cut hose item (1) into two equal lengths of 15240
mm. Put harness items (2) and (3) each through
a length of hose item (1).

Attach harness in frame.

a. Attach harness (2) to switch harness from

operator compartment and harness (3) to
container attachment harness from operator
compartment.

b. Clamp the harnesses to bracket inside RH

frame using clamp item (4).

Pull wires at far end of hoses until harnesses
are taut between frame and hose end.

d. Pull back 300 mm of each harness toward the

frame to provide harness slack.

Route the hoses/harness assemblies up the back
of the upright using existing clamps.

Clamp

hoses at the header hose bracket and route them
over sheaves. See the header hose arrangement
for clamps and routing.

Tension hoses at carriage end with 155 N (35 lb)
force and clamp with item (4).

Connect harnesses to connector housing per view
A-A.

a. Route hose/harnesses assembly (1)/(2) to the

right side of the socket assembly (5)/(6), hose/
harness assembly (1)/(3) to the left side of the
socket assembly.

b. Cut off excess hose and wire from assemblies

(1)/(2) and (1)/(3), leaving 120 mm of wire
extending beyond the hose end.

Connect the wires from harnesses (2)/(3) to
the terminals of plug (6) as shown in view
A-A.

d. Use corrosion protective compound (7) to lu-

bricate and protect all metal surfaces of the
plug and sockets before connecting wiring
from the container attachment.

Connection of the Hoses and Cables to the Carriages

8000 SRM 1041

HOSE

HARNESS

CLAMP

SOCKET ASSEMBLY

PLUG

CORROSIVE PROTECTIVE COMPOUND

8000 SRM 1041

Installation of the Forks

NOTE: The following procedures are only valid for trucks equipped with a standard or sideshift carriage. Ded-
icated carriages are not equipped with forks.

LOW-MOUNTED FORKS

Installation of the Low-Mount Quick-Disconnect Type Forks

WARNING

See the specifications chart for the weight of the forks. Make sure any lifting devices have the
correct capacity for the parts being moved.

STEP 1.

Put the forks on a 150 mm (6 in.) block. Align the lift truck so the forks are approximately 1 m (39 in.) in front
of the carriage.

STEP 2.

Remove the two fork retainers. If fork positioners are installed, make sure the fork guides are on the fork pins.
Tilt the mast forward and lower the carriage completely.

A. RH FORKGUIDE (BACKSIDE)

FORK RETAINER

FORK PIN

PIN LOCK PLATE

Installation of the Forks

8000 SRM 1041

STEP 3.

Move the truck toward the forks.

Make sure the

fork will fit between the studs for the fork retainer.
Carefully raise the carriage until the fork pins fit
into the hooks of the forks. Make sure the forks are
completely engaged with the fork pins. Make sure
the hooks at the bottom of the forks are engaged
with the carriage bar.

FORK RETAINER

FORK RETAINER STUDS

FORK PIN

STEP 4.

Install and fasten the fork retainers. If installed, connect the fork positioner cylinders to the fork guides.

8000 SRM 1041

Installation of the Forks

Installation of the Low-Mount Pin-Mounted Forks

STEP 1.

Align the lift truck so the forks are approximately 1 m (39 in.) in front of the carriage.

STEP 2.

Remove the two bolts from each fork pin lock plate. Tilt the mast forward and lower the carriage completely.
Remove the fork pins partially out of the carriage. If installed, remove the fork guides from the fork pins.

A. RH FORKGUIDE (BACKSIDE)

STEP 3.

Move the truck toward the forks. If installed, install the fork guides on the forks. Align the mounting hole
in the forks with the fork pins. Slew the fork pins through the fork guides and fork mounting holes. Position
the fork pins into the carriage. Lock the fork pins with the fork pin lock plates. Bolt them to the sides of the
carriage.

STEP 4.

If installed, connect the fork positioner cylinders to the fork guides.

Installation of the Forks

8000 SRM 1041

HIGH-MOUNTED FORKS

Installation of the High-Mount Quick-Disconnect Forks

WARNING

Make sure any lifting devices have the correct capacity for the parts being moved. See the specifi-
cations chart for the weight of the forks.

STEP 1.

Remove the two fork retainers for each fork. If fork positioners are installed, make sure the fork guides are on
the fork pins.

A. RH FORKGUIDE (BACKSIDE)

FORK RETAINER

FORK PIN

PIN LOCK PLATE

STEP 2.

Use a lifting device to install the forks on the fork
pins. Install the forks between the studs for the fork
retainers. Move the fork into position on the fork pin.
Make sure the hook at the bottom of the forks is en-
gaged with the carriage.

FORK RETAINER

FORK RETAINER STUDS

FORK PIN

STEP 3.

Install and fasten the fork retainer for each fork. If fork positioners are installed, connect the fork positioner
cylinders to the fork guides.

Installation of the High-Mount Pin-Mounted Forks

STEP 1.

Remove the two bolts from each fork pin lock plate. Lower the carriage completely. Remove the fork pins
partially out of the carriage. If installed, remove the fork guides from the fork pins.

A. RH FORKGUIDE (BACKSIDE)

STEP 2.

Use a lifting device to install the forks on the fork pins. If installed, install the fork guides on the forks. Align
the mounting hole in the forks with the fork pins. Slew the fork pins through the fork guides and fork mounting
holes. Position the fork pins into the carriage. Lock the fork pins with the fork pin lock plates. Bolt them to
the sides of the carriage. Make sure the hook at the bottom of the forks is engaged with the carriage.

STEP 3.

If fork positioners are installed, connect the fork positioner cylinders to the fork guides.

8000 SRM 1041

Installation of the Container Attachment on Forks

WARNING

Make sure any lifting devices have the correct
capacity for the parts being moved. Consult
the specification chart for the weight of the
container attachment. See Figure 1.

Ensure that the mast is vertical.

For trucks

equipped with high mount forks, use a lifting
device to raise the attachment so it can be in-
stalled. Slide the attachment carefully on the
forks of the truck.

For trucks equipped with low mount forks, put
the attachment on blocks on the ground. Position
the forks and drive carefully forward until the
forks are positioned in the attachment.

In either case leave enough space, approximately
50 cm (2 ft), between the face of the forks and the
attachment in order to fit the slew cylinders.

Connect the supply and return hydraulic hoses
to the correct fittings on the attachment. Also
connect the four hydraulic hoses for the slewing
cylinders to the correct fittings on the carriage.
These slewing cylinder hoses are equipped with
quick-disconnect couplings. Ensure that the code
on the hoses and fittings match with each other.
The fittings that will be used to control the slew-
ing cylinders are the same as used to control the
fork positioner cylinders when there is not a con-
tainer attachment on the forks. Ensure that the
hoses and cable are routed through the brackets
that are mounted on the carriage and the attach-
ment.

The second procedure is to connect the supply
and return hoses from the carriage to the correct
fittings on the attachment. Ensure that the code
on the hoses and fittings matches. Disconnect
the electrical supply for the solenoids that control
the fork positioner cylinders. Plug this connector
in the parking or dummy connector. Lubricate
the contacts of the electrical connector from the
attachment with electrical grease and plug the
connector in. Ensure that the hoses and cable are

routed through the brackets that are mounted on
the carriage.

Carefully operate the slewing cylinders to ex-
tend/retract the rod, enabling the rod ends to
be connected to the brackets on top or at the
bottom of the carriage. Location of the fixture
will depend on the fork configuration. Bolt the
rod ends with 77 N•m (57 lbf ft) to the carriage.
Check the torque on the attachment.

WARNING

Be sure the attachment is correctly fastened to
the carriage with the slew cylinders before re-
moving the lifting devices.

Remove the lifting device from the attachment.
Extend the slewing cylinders fully. Mount the
hoses and cable from the attachment to the car-
riage, in the brackets on the carriage, without
tension.

Bind the hoses as much as possible

to each other.

Ensure the hoses are not bent

sharply and are away from sharp edges.

If the machine is equipped with low mount forks,
lift the attachment approximately 50 cm (2 ft)
from the ground. Install and fasten the container
guides on the attachment.

Operate all the controls for the attachment.
Make sure the controls operate the correct
hydraulic function as shown on the labels of
the instrument panel.

Those checks must be

done with and without load. See the Operating
Manual for the correct operation of the hydraulic
controls. Also check for interference between the
slew cylinder and brackets or any other parts of
the attachment. If there is interference, make
appropriate adjustments. Check the operation
of the indicator lights and the twist-lock flags
and lift and lower interrupt function. Correct
any malfunction.

Lubricate all items according to the Maintenance
Schedule contained in the Operating Manual.

Figure 1. Container Attachment Fork Mounted

Installation of the Container Attachment on the Gantry

8000 SRM 1041

Installation of the Container Attachment on the Dedicated Carriage

WARNING

Make sure any lifting devices have the correct
capacity for the parts being moved. Consult
the specification chart for the weight of the
container attachment.

Remove the retainer bar at the bottom of the at-
tachment. Use a lifting device to raise the at-
tachment so that it can be installed. Install and
center the attachment on the two carrying arms.
See Figure 2.

Install the retainer bar to the attachment. Use
the eight bolts provided to secure retainer bar.

WARNING

Be sure the attachment is correctly fastened
to the carriage before removing the lifting de-
vices.

Connect the two hydraulic hoses from the car-
riage to the solenoid on the attachment. Match
the code on the hoses and on the solenoid.

Connect the male electrical connector from the
attachment to the female connector bolted on the
carriage.

Lubricate the contact of the electri-

cal connector with di-electrical grease before con-
necting.

Operate the slew cylinder controls carefully, mov-
ing the cylinders so they can be connected to the
brackets on top of the carriage. Do not forget to
place the shim under the cylinder rod end. Fas-
ten the bolts with 77 N•m (57 lbf ft) on both sides
of each cylinder.

Loosen the strap which supports the sideshift
cylinder. Raise the sideshift cylinder with a lift-
ing device. Operate the sideshift cylinder con-
trols carefully so the rod end can be connected
to the bracket on the carriage. Check that the
stroke is equal between left and right. Do not for-
get to mount the shim in the bracket under the
cylinder rod end.

Operate all the controls for the attachment.
Make sure the controls operate the correct
hydraulic function as shown on the labels of
the instrument panel.

Those checks must be

done with and without load. See the Operating
Manual for the correct operation of the hydraulic
controls. Also check for interference between the
slew cylinder and brackets or any other parts of
the attachment. If there is interference, make
appropriate adjustments. Check the operation
of the indicator lights and the twist-lock flags,
and also check lift and lower interrupt function.
Correct any malfunction.

Figure 2. Dedicated Attachment

Installation of the Container Attachment on the Gantry

WARNING

Make sure any lifting devices have the correct
capacity for the parts being moved. Consult
the specification chart for the weight of the
container attachment.

Use a lifting device to raise the hangers to the
correct height and into the brackets. Bolt the
four hangers to the brackets in the gantry using
150 N•m (110 lbf ft). See Figure 3.

Raise the attachment with a lifting device. Align
the holes in the brackets on the attachment with
the rod end holes in the hangers. Bolt the attach-
ment to the hangers using 150 N•m (110 lbf ft).
Ensure that the slewing cylinders are positioned

directly toward the truck and between the hang-
ers.

WARNING

Be sure the attachment is correctly fastened
to the carriage before removing the lifting de-
vices.

Connect the supply and return hydraulic hoses
from the carriage to the solenoid on the attach-
ment. Mount the hydraulic hoses in the brackets
on the gantry.

Lubricate the contact of the electrical connector
with electrical grease. Plug the male connector in

8000 SRM 1041

General Procedures After Assembly

the female connector bolted on the gantry. Mount
the cable in the brackets on the carriage.

Loosen the strap which holds the sideshift cylin-
der during transport. Raise the sideshift cylin-
der with the lifting device to the correct height
of the bracket on the gantry. Carefully operate
the sideshift cylinder, until the rod end is well
positioned in the bracket on the gantry. Bolt the
cylinder to the bracket. Ensure you mount the
shim under the rod end and in the bracket.

Loosen the straps which hold the slewing cylin-
ders during transport. Raise one slewing cylin-
der with the lifting device to the correct height
of the bracket on the gantry.

Carefully oper-

ate the slew cylinder until the rod end is in the
bracket on the gantry. Bolt the slewing cylin-
der to the bracket on the gantry using 77 N•m

(57 lbf ft). Ensure you mount the shim under the
rod end. Use the same procedure to connect the
other slewing cylinder to the gantry.

Operate all the controls for the attachment.
Make sure the controls operate the correct
hydraulic function as shown on the labels of
the instrument panel.

Those checks must be

done with and without load. See the Operating
Manual for the correct operation of the hydraulic
controls. Also check for interference between the
slew cylinder and brackets or any other parts of
the attachment. If there is interference, make
appropriate adjustments. Check the operation
of the indicator lights and the twist-lock flags,
and also check lift and lower interrupt function.
Correct any malfunction.

Figure 3. Gantry Attachment

Lights Installation

NOTE:

A set of four working lights is mounted in

brackets to a long steel bar at the top of the cabin.
This bar, light brackets, and working lights are al-
ways removed for transport. The bar and light brack-
ets are fastened to the right-side platform, next to
the cabin. The working lights are removed from the
brackets during transport.

Lift the bar and position it on the four studs
welded on the top of the cab. Fasten the four nuts
and washers.

Reassemble the working lights in the brackets
on the steel bar and connect the electrical plugs.
The same reassembly procedure will be followed
for the two working lights mounted at the rear
of the cab and the two traffic lights mounted on
the front fenders. If the unit is equipped with a
container attachment, the two working lights on
the attachment will also have to be reassembled.

Check for correct operation of all lights. Correct
any malfunction.

General Procedures After Assembly

Plumbing Check: Check that all the hydraulic
fittings, hoses, or tubes have been correctly fas-
tened and properly routed (no scuffing and run-
ning over sharp edges). Verify visually there are
no leaks in the system. Correct any discrepan-
cies.

Functional Check: Check that all functions are
working properly. Operate the machine and test
the brake, steering, and all the hydraulic func-
tions with and without load. Correct any discrep-
ancies.

Literature Package: Check content of stan-
dard literature package (may deviate per mar-
ket area). Be sure SPED literature package is
included. Deliver the literature package to the
maintenance people. Explain the purpose of each
item in the literature package. Explain where
this truck may deviate from the standard prod-
uct.

Cleaning: It is also the dealer’s responsibility
to deliver the truck to the customer in a perfectly
clean condition. During transport and reassem-
bly, grease, dust, and oil will cover some parts

General Procedures After Assembly

8000 SRM 1041

of the machine making it dirty or slippery. De-
grease and clean the machine completely. DO
NOT steam clean the hoist chains!

Labels: Check that all labels supplied by the fac-
tory are in place at the correct location. Put the
mast, truck, and attachment labels in the correct
position on the truck after having cleaned and
dried the location where they will be fitted.

Lubrication: Check that all fitting points on
the basic truck, mast, carriage/gantry, and at-
tachment are well greased. Lubricate if required.
See the Operating Manual for the maintenance
schedule. To lube the center pivot point of the
steer axle, first lift the weight of the truck off the
axle with a bottle jack. Lubricate fittings.

Instruction 1: Ensure that the operator has
read the Operating Manual. Show the operator
and maintenance people the location of all func-
tions and explain their purpose.

Instruction 2: Go over the daily checks with the
driver. Repeat the 8-hour procedures together
with the future driver in order to ensure that he
is aware of and has understood those procedures.

Hand over: Stay together with the operator
when the machine is driven for the first time
and give guidance during those first steps.

TECHNICAL PUBLICATIONS

8000 SRM 1041

7/02 Printed in United Kingdom

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