MAST REPAIR (S/N F507, F508, F562, F563) : Maintenance

Maintenance
MAST REPAIR (S/N F507, F508, F562,

F563)
TWO-STAGE LFL AND THREE-STAGE
FFL MAST
ERC22-35VG (ERC045-070VG) [A968];ERP22-35VL (ERP045-070VL) [
A976];GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910,
B910, C910];GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875, C875,
D875]
PART NO. 550093755 4000 YRM 1669

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 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 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 man-
ual:
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.
Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Safety Procedures When Working Near Mast .......................................................................................................... 2
Fork Replacement .................................................................................................................................................... 4
Standard Carriage and Integral Sideshift Carriage ............................................................................................... 4
Remove .............................................................................................................................................................4
Install .................................................................................................................................................................6
Checks .............................................................................................................................................................. 6
Fork Positioner Carriage ....................................................................................................................................... 8
Remove .............................................................................................................................................................9
Install .................................................................................................................................................................9
Checks ............................................................................................................................................................ 11
Carriages Repair, Two-Stage LFL Mast ..................................................................................................................13
Standard Carriage ...............................................................................................................................................13
Remove ...........................................................................................................................................................13
Clean and Inspect ........................................................................................................................................... 14
Install ...............................................................................................................................................................15
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 ................................................ 15
Remove ...........................................................................................................................................................15
Disassemble ....................................................................................................................................................16
Assemble ........................................................................................................................................................ 18
Install ...............................................................................................................................................................18
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 ..................... 19
Remove ...........................................................................................................................................................19
Disassemble ....................................................................................................................................................22
Assemble ........................................................................................................................................................ 23
Install ...............................................................................................................................................................23
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After ...............................................24
Remove ...........................................................................................................................................................24
Disassemble ....................................................................................................................................................27
Assemble ........................................................................................................................................................ 28
Install ...............................................................................................................................................................28
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 ...................................................29
Remove ...........................................................................................................................................................29
Install ...............................................................................................................................................................31
Fork Positioner Hydraulic Hose Adjustment ....................................................................................................33
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 ....................... 34
Remove ...........................................................................................................................................................34
Disassemble and Assemble ............................................................................................................................38
Install ...............................................................................................................................................................38
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After ................................................. 40
Remove ...........................................................................................................................................................40
Disassemble and Assemble ............................................................................................................................44
Install ...............................................................................................................................................................44
Two-Stage LFL Mast Repair ................................................................................................................................... 46
Mast With Serial Number F507 ...........................................................................................................................46
©2019 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Remove ...........................................................................................................................................................46
Disassemble ....................................................................................................................................................50
Assemble ........................................................................................................................................................ 59
Install ...............................................................................................................................................................60
Header Hoses ................................................................................................................................................. 62
Remove .......................................................................................................................................................62
Installation ................................................................................................................................................... 62
Adjustment .................................................................................................................................................. 66
Mast With Serial Number F562 ...........................................................................................................................67
Remove ...........................................................................................................................................................67
Disassemble ....................................................................................................................................................71
Assemble ........................................................................................................................................................ 80
Install ...............................................................................................................................................................81
Header Hose Installation and Adjustment .......................................................................................................82
Remove .......................................................................................................................................................82
Installation ................................................................................................................................................... 83
Adjustment .................................................................................................................................................. 87
Carriages Repair, Three-Stage FFL Mast ...............................................................................................................88
Standard Carriage ...............................................................................................................................................88
Remove ...........................................................................................................................................................88
Install ...............................................................................................................................................................90
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 ................................................ 90
Remove ...........................................................................................................................................................90
Disassemble ....................................................................................................................................................92
Assemble ........................................................................................................................................................ 94
Install ...............................................................................................................................................................94
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 .................... 95
Remove ...........................................................................................................................................................95
Disassemble ....................................................................................................................................................97
Assemble ........................................................................................................................................................ 99
Install ...............................................................................................................................................................99
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After .............................................100
Remove .........................................................................................................................................................100
Disassemble ..................................................................................................................................................102
Clean and Inspect ......................................................................................................................................... 103
Assemble ...................................................................................................................................................... 104
Install .............................................................................................................................................................104
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 .................................................105
Remove .........................................................................................................................................................105
Install .............................................................................................................................................................107
Fork Positioner Hydraulic Hose Adjustment ..................................................................................................109
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 ..................... 110
Remove ......................................................................................................................................................... 110
Disassemble and Assemble .......................................................................................................................... 112
Install ............................................................................................................................................................. 112
ii
Table of Contents
TABLE OF CONTENTS (Continued)

Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 ...................................................... 114
Remove ......................................................................................................................................................... 114
Disassemble and Assemble .......................................................................................................................... 117
Install ............................................................................................................................................................. 117
Three-Stage FFL Mast Repair .............................................................................................................................. 119
Mast With Serial Number F508 ......................................................................................................................... 119
Remove ......................................................................................................................................................... 119
Disassemble ..................................................................................................................................................123
Assemble ...................................................................................................................................................... 136
Install .............................................................................................................................................................137
Header Hose Installation and Adjustment .....................................................................................................139
Remove .....................................................................................................................................................139
Installation ................................................................................................................................................. 139
Adjustment ................................................................................................................................................ 147
Mast With Serial Number F563 .........................................................................................................................148
Remove .........................................................................................................................................................148
Disassemble ..................................................................................................................................................151
Assemble ...................................................................................................................................................... 164
Install .............................................................................................................................................................165
Header Hose Installation and Adjustment .....................................................................................................167
Remove .....................................................................................................................................................167
Installation ................................................................................................................................................. 167
Adjustment ................................................................................................................................................ 175
Mast Adjustments ................................................................................................................................................. 176
Load Roller, Adjust ............................................................................................................................................176
Mast Side Kicking, Adjust ................................................................................................................................. 178
Carriage Adjustments ........................................................................................................................................... 178
Lift Chains Adjustment ..........................................................................................................................................180
Lift Trucks Equipped with Forks .................................................................................................................... 181
Lift Trucks Equipped with Hook-Type Carriage and Attachment Without Forks ........................................... 181
Lift Trucks Equipped With Pin-Type Carriage and Attachment Without Forks ..............................................181
Hydraulic Quick Disconnect Hoses .......................................................................................................................182
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models
GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/
GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) ........................................................................ 182
Lift Trucks Equipped With E-Hydraulic Controls ........................................................................................... 182
Lift Trucks Equipped With Manual Hydraulic Controls .................................................................................. 183
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX
(GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/
CDP040-070VX) (B875, C875, D875) .............................................................................................................. 183
Lift Trucks Equipped With E-Hydraulic Controls ........................................................................................... 183
Lift Trucks Equipped With Manual Hydraulic Controls .................................................................................. 184
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG
(ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) .............................................................184
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG
(ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) .............................................................184
iii
Table of Contents
This section is for the following models:
ERC22-35VG (ERC045-070VG) [A968];

ERP22-35VL (ERP045-070VL) [A976];
GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910, B910, C910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875, C875, D875]
iv
4000 YRM 1669 General
General
a new hose that is the correct replacement for the
WARNING hose you are inspecting.
Before working on or near the mast, see the This section contains the repair procedures for the
section Safety Procedures When Working Near Two-Stage, Limited Free-Lift (LFL) mast with serial
Mast. numbers F507 and F562 and the Three-Stage, Full
Free-Lift (FFL) mast with serial numbers F508 and
NOTE: Hoses have a service life that is determined F563. The mast serial number is located on the right
by application and time. Install a new hose if the hose side of the outer mast. Other information about the
is leaking, worn through, or damaged. A hose has mast can also be found in this area. See Figure 1.
been damaged if the hose cover is cracked, exposing
Procedures to repair the carriage, replace the forks,
the braiding, or if the hose has been kinked or
and adjust the lift chains, carriage, and mast are also
crushed, or if the hose is no longer flexible. Install a
covered in this manual.
new hose if the hose has been tensioned beyond the
adjustment range. If necessary, make a comparison to
1
Safety Procedures When Working Near Mast 4000 YRM 1669
1. MAST SERIAL NUMBER 4. MAST LIFT HEIGHT (IN MILIMETERS)

2. MANUFACTURING PLANT 5. MAST ASSEMBLY PART NUMBER
3. PRODUCTION SEQUENCE
Figure 1. Mast Serial Number Location
Safety Procedures When Working Near Mast

The following procedures MUST be used when repairing or removing the mast. See the correct
inspecting or working near the mast. Additional Service Manual section for the specific mast being
precautions and procedures can be required when repaired.
2
4000 YRM 1669 Safety Procedures When Working Near Mast
1. Put mast in vertical position.

WARNING 2. Raise mast to align bottom crossmember of
The following procedures MUST be used when weldment that moves in the outer weldment with
inspecting or working near the mast. Additional a crossmember on the outer weldment. On the
precautions and procedures can be required when two-stage and free-lift mast, the moving part is
repairing or removing the mast. See the correct the inner weldment. On the three-stage mast, it is
Service Manual section for the specific mast being the intermediate weldment. See Figure 2.
repaired.
3. Use a 3/8 inch minimum safety chain with a hook
• Never put any part of the body into or under the to fasten the crossmembers together so the
mast or carriage unless all parts are completely movable member cannot lower. Put the hook on
lowered or a safety chain is installed. Also make the back side of the mast. Make sure the hook is
sure that the power is off and the key is completely engaged with a link in the chain. Make
removed. Put a DO NOT OPERATE tag in the sure the safety chain does not touch lift chains or
operator's compartment. Disconnect the battery
chain sheaves, tubes, hoses, fittings, or other
on electric lift trucks and put a tag or lock on the
battery connector. parts on the mast.
• Be careful of the forks. When the mast is raised, 4. Lower mast until there is tension in the safety
the forks can be at a height to cause an injury. chain and the free-lift cylinder (three-stage) is
• DO NOT climb on the mast or lift truck at any completely retracted. If running, stop the engine.
time. Use a ladder or personnel lift to work on Apply parking brake. Install a DO NOT REMOVE
the mast. tag on the safety chain(s).
• DO NOT use blocks to support the mast
weldments or to restrain their movement. 5. Install another safety chain (3/8 inch minimum)
• Mast repairs require disassembly and removal between the top or bottom crossmember of the
of parts and can require removal of the mast or carriage and a crossmember on the outer
carriage. Follow the repair procedures in the weldment. See Figure 2.
correct Service Manual for the mast.
WHEN WORKING NEAR THE MAST ALWAYS: NOTE: Apply parking brake. After lowering or
restraining the mast, shut off power and remove key.
• Lower the mast and carriage completely. Push Put a DO NOT OPERATE tag in the operator's
the lift/lower control lever forward and make compartment. Disconnect battery on electric lift trucks
sure there is no movement in the mast. Make
and put a tag or lock on battery connector.
sure that all parts of the mast that move are fully
lowered.
OR
• If parts of the mast must be in a raised position,
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:
3
Fork Replacement 4000 YRM 1669
A. TWO-STAGE LFL MAST B. THREE-STAGE FFL MAST
1. OUTER WELDMENT 5. FREE-LIFT CYLINDER

2. INNER WELDMENT 6. CROSSMEMBER
3. INTERMEDIATE WELDMENT 7. CROSSMEMBER
4. HOOK
Figure 2. Two-Stage LFL and Three-Stage FFL Masts
Fork Replacement
STANDARD CARRIAGE AND INTEGRAL Remove
SIDESHIFT CARRIAGE
On lift trucks equipped with a standard carriage or an WARNING
integral sideshift carriage, the forks are held on the DO NOT try to remove a fork without a lifting
carriage by hooks. Forks are held in position by pins device. Each hook fork for these lift trucks can
that fit through the top fork hooks and into slots in top weigh 45 to 115 kg (99 to 254 lb).
carriage bar.
NOTE: Forks are to be replace in sets by trained
If pin does not remain engaged in carriage slot,
personnel only. DO NOT replace forks individually.
replace with new pin. Always check that pins for forks
keep forks in position on carriage. Replace damaged 1. Slide fork to fork removal notch on bottom bar of
fork pin parts. carriage. See Figure 3.
2. Lower fork onto blocks (see Figure 4), so bottom

hook of fork moves through fork removal notch.
4
4000 YRM 1669 Fork Replacement
3. Lower carriage further so top hook of fork is 4. Move carriage away from fork or use a lifting
disengaged from top carriage bar. device to move fork away from carriage.
1. LOAD BACKREST 6. WEDGE

2. CARRIAGE 7. WASHER
3. FORKS 8. SPRING
4. FORK 9. PIN
5. KNOB 10. FORK REMOVAL NOTCH
Figure 3. Carriage and Forks
5
1. Inspect forks for cracks and wear. Check

alignment of fork tips. The difference in height of
fork tips must be less than three percent of length
of forks. See Table 1 and Figure 5.
Some applications may require closer alignment.
If forks do not meet specification, they both must
be replaced.
2. Check for smooth and proper operation of fork

lock pins. Repair or replace any damaged or
broken fork lock pins or components and
lubricate, as necessary.
3. Inspect fork wear. Ensure heel wear is not more

than 10% of original thickness. If fork wear is
more than 10% fork must be replaced or rerated.
Perform fork wear inspection using a BOL256N1
caliper ruler Yale P/N 550088603 as follows. See
1. CARRIAGE BARS Figure 6.
2. HOOK FORK
3. BLOCKS a. Determine normal thickness of the "N" of the
fork using scale or ruler portion of caliper ruler.
Figure 4. Hook Fork, Remove Measurement has to be done on fork shank
using caliper ruler.
Install
b. Position caliper at end of heel internal radius
WARNING (item A, Figure 5) with opening corresponding
to measured thickness of fork shank in Step a
DO NOT try to install a fork without a lifting device.
above. (e.g. for N 1.75 use N 1.75 opening).
Each hook fork for these lift trucks can weigh
This is typically the section of fork where wear
45 to 115 kg (99 to 254 lb).
is greatest. Note that opening distance has
NOTE: Forks are to be replace in sets by trained been reduced by 10% from nominal thickness.
c. If fork enters opening, it is mandatory to
1. Move fork and carriage so top hook of fork can replace it. DANGER OF BREAKING.
engage upper carriage bar. Furthermore a 10% reduction in fork blade
thickness results in 20% reduction in operating
2. Raise carriage to move bottom hook of fork capacity.
through fork removal notch.
3. Slide fork on carriage so both upper and lower

hooks engage carriage bars. See Figure 4.
4. Install latch pin in top hook and notch in upper

carriage bar. See Figure 3.
Checks
WARNING
Never repair damaged forks by heating or welding.
Forks are made of tempered steel using special
procedures. Always replace damaged forks as a
pair.
6
Table 1. Fork Tip Alignment

Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip Difference*
mm (in.) mm (in.)
914 (36) 27 (1.08)
1000 (39) 30 (1.17)
1016 (40) 30 (1.2)
1067 (42) 32 (1.26)
1100 (43) 33 (1.29)
1200 (47) 36 (1.42)
1207 (47.5) 36 (1.42)
1219 (48) 37 (1.44)
1372 (54) 41 (1.62)
1400 (55) 42 (1.65
1500 (59) 42 (1.77)
1524 (60) 46 (1.80)
1829 (72) 55 (2.16)
*Difference of alignment between fork tips must be no more than 3% of the total fork length.
7
A. HEEL OF FORK (MUST BE 90% OF DIMENSION

B)
B. ORIGINAL FORK THICKNESS (DIMENSION B)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS Figure 6. Fork Wear Check
3. MAXIMUM ANGLE 93°
4. FORK REMOVAL NOTCH
5. CARRIAGE FORK POSITIONER CARRIAGE
NOTE: The fork positioner can be removed from the
Figure 5. Fork Checks integral sideshift carriage with integral sideshift
carriage on or off the mast. In the steps below, the fork
positioner is removed with integral sideshift carriage
on the mast. If integral sideshift carriage must be
removed from mast first, go to section Carriages
Repair, Two-Stage LFL Mast or Carriages Repair,
Three-Stage FFL Mast for removal procedures.
Forks used on an integral sideshift carriage equipped
with a fork positioner attachment, are held in position
with fork carriers (inner and outer) that slide along the
fork positioner cylinder. Depending on the size and
configuration of forks installed on lift truck, there may
be a spacer bar between inner and outer fork carriers.
See Figure 7. Forks are removed from carriage by
aligning forks with fork removal notch. Fork removal
notch is in the bottom bar of carriage. See Figure 8.
8
See Figure 8 for lift trucks manufactured prior to

December, 2016
See Figure 9 for lift truck models ERC22-35VG
(ERC045-070VG) (A968), GLC20-35VX (GC/
GLC40-70VX) (C910), and GP/GLP/
GDP040-070VX (D875) manufactured after
December, 2016
3. Lower forks onto blocks (see Figure 4) so bottom

hook of fork moves through fork removal notch.
Lower carriage further so top hook of fork is
disengaged from top carriage bar.
1. OUTER FORK CARRIER 4. Move carriage away from fork or use a lifting
2. CAPSCREW device to move fork away from carriage.
3. SPACER BAR*
4. INNER FORK CARRIER
*Spacer Bar used on 977 mm (38.5 in.) and Install
1067 mm (42 in.) class II carriages.
WARNING
Figure 7. Fork Carrier Components
DO NOT try to install a fork without a lifting device.
Remove 45 to 115 kg (99 to 254 lb).
WARNING
DO NOT try to remove a fork without a lifting CAUTION
device. Each hook fork for these lift trucks can Remove fork latch pins if adding a fork positioner
weigh 45 to 115 kg (99 to 254 lb). attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment.
CAUTION
NOTE: Forks are to be replace in sets by trained
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not 1. Move fork and carriage so top hook of fork can
removed prior to using attachment. engage upper carriage bar.
NOTE: Forks are to be replace in sets by trained 2. Raise carriage to move bottom hook of fork
personnel only. DO NOT replace forks individually. through fork removal notch.
1. Lower carriage and remove four capscrews from See Figure 8 for lift trucks manufactured prior to
inner fork carriers. Slide inner fork carriers down December, 2016
cylinder shell to remove forks. See Figure 9 for lift truck models ERC22-35VG
See Figure 8 for lift trucks manufactured prior to (ERC045-070VG) (A968), GLC20-35VX (GC/
December, 2016 GLC40-70VX) (C910), and GP/GLP/
Figure 9 for lift truck models ERC22-35VG
December, 2016
(ERC045-070VG) (A968), GLC20-35VX (GC/
GLC40-70VX) (C910), and GP/GLP/
3. Slide fork on carriage so both upper and lower
hooks engage carriage bars. See Figure 4.
December, 2016
2. Slide fork to fork removal notch in bottom bar of

carriage.
9
4. Move fork into place on outer fork carrier. Secure See Figure 9 for lift truck models ERC22-35VG
inner fork carrier to outer fork carrier using four (ERC045-070VG) (A968), GLC20-35VX (GC/
capscrews. Tighten capscrew to GLC40-70VX) (C910), and GP/GLP/
35 N•m (25 lbf ft). GDP040-070VX (D875) manufactured after
December, 2016
See Figure 8 for lift trucks manufactured prior to
December, 2016
NOTE: FORK POSITIONER FOR LIFT TRUCK EQUIPPED WITH THREE-STAGE FFL MAST SHOWN. RE-
MOVAL OF FORKS FROM FORK POSITIONER ON LIFT TRUCKS EQUIPPED WITH TWO-STAGE LFL MAST
IS SIMILAR.
1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME
Figure 8. Fork Positioner Fork Removal, Lift Trucks Manufactured Prior To December, 2016
10
1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME
Figure 9. Fork Positioner Fork Removal, Lift Truck Models Manufactured After December,
2016ERC22-35VG (ERC045-070VG) (A968), GLC20-35VX (GC/GLC40-70VX) (C910), and GP/GLP/
GDP040-070VX (D875)
Checks 2. Check for smooth and proper operation of the fork

lock pins. Repair or replace any damaged or
broken fork lock pins or components and
WARNING lubricate, as necessary.
Never repair damaged forks by heating or welding.
Forks are made of tempered steel using special 3. Inspect fork wear. Ensure heel wear is not more
procedures. Always replace damaged forks as a than 10% of original thickness. If fork wear is
pair. more than 10% , fork must be replaced or rerated.
Perform fork wear inspection using a BOL256N1
1. Inspect forks for cracks and wear. Check caliper ruler Yale P/N 550088603 as follows. See
alignment of fork tips. The difference in height of Figure 11.
fork tips must be less than three percent of the
length of the forks. See Table 2 and Figure 10. a. Determine normal thickness of "N" of fork
Some applications may require closer alignment. using scale or ruler portion of caliper ruler.
If forks do not meet specification, they both must Measurement has to be done on fork shank
be replaced. using caliper ruler.
11
b. Position caliper at end of heal internal radius c. If fork enters opening, it is mandatory to
(item A, ) with opening corresponding to replace it. DANGER OF BREAKING.
measured thickness of fork shank in Step a Furthermore, a 10% reduction in fork blade
above. (e.g. for N 1.75 use N 1.75 opening). thickness results in 20% reduction in operating
This is typically the section of fork where wear capacity.
is greatest. Note that the opening distance has
been reduced by 10% from nominal thickness.
Table 2. Fork Tip Alignment

Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip Difference*
mm (in.) mm (in.)
914 (36) 27 (1.08)
1000 (39) 30 (1.17)
1016 (40) 30 (1.2)
1067 (42) 32 (1.26)
1100 (43) 33 (1.29)
1200 (47) 36 (1.42)
1207 (47.5) 36 (1.42)
1219 (48) 37 (1.44)
1372 (54) 41 (1.62)
1400 (55) 42 (1.65
1500 (59) 42 (1.77)
1524 (60) 46 (1.80)
1829 (72) 55 (2.16)
*Difference of alignment between fork tips must be no more than 3% of the total fork length.
12
4000 YRM 1669 Carriages Repair, Two-Stage LFL Mast
A. HEEL OF FORK (MUST BE 90% OF DIMENSION

B
B. ORIGINAL FORK THICKNESS (DIMENSION B)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS Figure 11. Fork Wear Check
3. MAXIMUM ANGLE 93°
4. FORK REMOVAL NOTCH
5. CARRIAGE
Figure 10. Fork Checks
Carriages Repair, Two-Stage LFL Mast

STANDARD CARRIAGE 4. Remove chain pin from each chain anchor at the
carriage. Disconnect lift chains from carriage. Use
Remove wire to connect the ends of lift chains to a part of
1. Remove forks. See Fork Replacement for the mast. Make sure chains can move freely
procedures. when inner mast is raised. See Figure 13.
2. Remove four capscrews, washers, nuts, and load

backrest from carriage. See Figure 12.
3. Connect a lifting device to the carriage. Lift

carriage so that lift chains become loose.
WARNING
When disconnecting the lift chains, keep control of
the ends. Use wire to temporarily connect the ends
of the lift chains to the mast. This procedure will
prevent the lift chains from falling and causing an
injury or damage.
13
Carriages Repair, Two-Stage LFL Mast 4000 YRM 1669
WARNING
To help prevent possible injury, make sure the
carriage is stable and will not fall over when the
inner mast is raised above the load rollers of the
carriage.
5. Use lift cylinders to raise inner mast. If hydraulic

system cannot be used, disconnect lift cylinders
from inner mast. See the section Cylinder Repair
(Mast S/N F507, F508, F562, F563)
2100YRM1668.
6. Connect a crane with a capacity of at least

681 kg (1501 lb), to top of inner mast. Carefully
raise inner mast until it is above the load rollers of
the carriage. Install safety chains to secure mast
in its extended position and disconnect the crane.
1. CAPSCREW 4. CARRIAGE See Safety Procedures When Working Near
2. WASHER 5. LOAD BACKREST Mast.
3. NUT
7. Move lift truck away from carriage. Completely
Figure 12. Load Backrest, Remove lower inner mast so it cannot move.
Clean and Inspect

NOTE: Shims are installed on the bottom and middle
load rollers only.
1. If load rollers must be replaced (see Figure 13),
make a note of the location and number of shims.
Install shims, load rollers, and snap rings. See
Carriage Adjustments section for correct
adjustment of the load rollers.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning
1. CARRIAGE 6. CHAIN PIN solvents, always follow the recommendations of
2. SNAP RING 7. COTTER PIN the manufacturer.
3. SHIM 8. ANCHOR PIN
4. LOAD ROLLER 9. SPACER
5. CHAIN ANCHOR
Figure 13. Standard Carriage Components
14
5. Install forks. See section Fork Replacement for

CAUTION procedures.
DO NOT use cleaning solvent, compressed air, or
steam to clean lift chain sheaves or load rollers. INTEGRAL SIDESHIFT CARRIAGE, LIFT
The bearings in the lift chain sheaves and load TRUCKS MANUFACTURED PRIOR TO
rollers are sealed and lubricated. Cleaning solvent, DECEMBER, 2016
compressed air, and steam can damage the load
roller bearings. Remove
1. Lower carriage completely. Remove forks. See
2. Clean any oil, grease, dirt, and other debris from Fork Replacement for removal procedures.
carriage frame. Use a cleaning solvent and
compressed air to dry. 2. Remove four capscrews, washers, nuts, and load
WARNING
Improper welding procedures can damage the WARNING
structure of the mast or cause incorrect function Before disconnecting the hydraulic hoses, relieve
of the mast. Consult a Resident Service the pressure in the hydraulic system. Serious
Engineering through the Contact Management injury can occur if pressure is not relieved from
System before welding on the mast. hydraulic system prior to disconnecting hydraulic
hoses.
3. If carriage bars have any protruding welds or
damaged notches, repair by grinding, filing, or 3. Relieve hydraulic pressure to the sideshift
welding. cylinder by moving sideshift lever in both
directions several times.
4. Clean and inspect the chain anchors and chain
anchor pins. See Figure 13. Check chain anchors
and anchor pins for wear and serviceability. WARNING
Discard worn or unserviceable chain anchors and
Always wear the proper protective equipment
chain anchor pins. Discard used cotter pins.
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
Install wash oil from exposed areas of skin as soon as
1. Move the lift truck towards the carriage until inner possible.
mast is aligned with carriage rollers. If inner mast The hydraulic oil is hot at normal operating
has been raised and secured using a crane and temperatures. Be careful when draining the oil.
safety chains, connect the crane, raise inner
mast, and remove safety chains. Carefully lower
inner mast until it engages all of the load rollers.
Disconnect the crane, if attached, and reconnect WARNING
lift cylinders. See Cylinder Repair (Mast S/N Never check for leaks by putting hands on
F507, F508, F562, F563) 2100YRM1668. hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
2. Check the clearance of the load rollers. See the skin.
Carriage Adjustments section for procedures.
NOTE: Tag hydraulic lines and fittings prior to
NOTE: Use new cotter pins each time chain pins are disconnecting to aid in connecting during installation.
removed. 4. Disconnect hydraulic lines from sideshift cylinder.
3. Connect lift chains to chain anchors at the Put caps and plugs on open lines and cylinder
carriage. Install cotter pins in chain pins. Adjust lift ports.
chains as described in Lift Chains Adjustment.
5. Remove lower mounting hooks by removing four
4. Install load backrest on carriage. Tighten capscrews and washers securing the hooks. See
capscrews to 195 N•m (144 lbf ft). Figure 14.
15
6. Remove sideshift cylinder from carriage. See 7. Use a crane with a capacity of at least
Cylinder Repair (Mast S/N F507, F508, F562, 48 kg (106 lb) to lift outer frame away from inner
F563) 2100YRM1668. frame. Lay outer frame flat on a pallet or work
bench. See Figure 15.
1. INNER FRAME 11. LUBE FITTING

2. OUTER FRAME 12. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 13. COTTER PIN
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. LOAD ROLLER
6. LOWER HOOK 16. SHIMS
7. CAPSCREW 17. SPACER
8. WASHER 18. FORK REMOVAL NOTCH
9. CLEVIS PIN 19. CHAIN ANCHOR PIN
10. PIN
Figure 14. Integral Sideshift Carriage Component Parts
Disassemble 2. If damaged, remove lube fittings from outer

frame. See Figure 14.
1. Remove upper and lower bearings from inner
frame. See Clean and Inspect section for 3. Disassemble the intergral sideshift cylinder. See
procedures. See Figure 14. Cylinder Repair (Mast S/N F507, F508, F562,
F563) 2100YRM1668 for procedures.
16
a. If either upper bearing is worn to less than

2.5 mm (0.1 in.) thickness, replace both upper
bearings by driving the upper bearings from
the inner frame. See Figure 17.
b. If either lower bearing is worn to less than

2.5 mm (0.1 in.) thickness, replace lower
bearings by prying the lower bearings from the
inner frame. See Figure 17.
4. Inspect the sideshift cylinder. See Cylinder

Repair (Mast S/N F507, F508, F562, F563)
2100YRM1668 for procedures.
5. Inspect load rollers for wear or damage (see

Figure 14). If load rollers must be replaced, make
a note of the location and number of shims. Install
1. OUTER FRAME shims, load rollers and snap rings. See section
2. LIFTING HOOK Carriage Adjustments for correct adjustment.
3. LIFTING DEVICE
Figure 15. Remove Outer Frame
Clean and Inspect

1. Inspect lower mounting hooks for wear. Replace
hooks if they are worn beyond the wear limit. The
wear limit clearance range is 0.76 mm (0.03 in.)
minimum and 1.52 mm (0.06 in.) maximum. See
A in Figure 16.
CAUTION
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast. Consult your Yale lift truck dealer for
more information before welding on the mast.
2. Clean and inspect carriage bars for damage and

smoothness. Ensure carriage bars are parallel
and ends are flush. If carriage bars have any A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
protruding welds or damaged notches, repair by 1.52 mm (0.06 in.) MAXIMUM
grinding, filing, or welding. B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM
3. Clean bearing areas. Inspect sideshift bearings
for wear as follows: Figure 16. Lower Mounting Hooks Wear Limit and
Clearance Adjustment
17
A. MINIMUM THICKNESS 2.5 mm (0.1 in.).
1. LOWER BEARINGS 3. UPPER BEARINGS

2. CARRIAGE BARS
*Bold arrows indicate which side to apply grease.
Figure 17. Upper and Lower Bearings
Assemble 2. Use a crane with a capacity of at least

48 kg (106 lb) and install outer frame onto inner
1. Assemble integral sideshift cylinder. See frame. See Figure 14.
Cylinder Repair (Mast S/N F507, F508, F562,
F563) 2100YRM1668 for procedures. 3. Install lower mounting hooks using four
capscrews. Tighten to
2. If lube fittings were removed, install new lube 150 to 180 N•m (108 to 132 lbf ft). For proper
fittings into outer frame. See Figure 14. sideshift operation, make sure there is
0.76 to 1.52 mm (0.03 to 0.06 in.) clearance
NOTE: Use a wood block or a plastic hammer to fully
between the bottom of the hooks and the outer
seat upper bearings onto inner frame. Proper lower
frame. See B in Figure 16.
hook clearance requires the upper bearings be fully
seated. 4. Connect hydraulic lines, as noted during removal,
3. Apply a 1 mm (0.040 in.) layer of multipurpose to sideshift cylinder.
grease to upper and lower bearing surfaces.
Install upper and lower bearings into the inner 5. Install load backrest to sideshift carriage. Tighten
frame. Bearings snap into place. See Figure 17. capscrews to 195 N•m (144 lbf ft). See Figure 12.
Install 6. Install forks. See section Fork Replacement, in

this manual, for procedures.
1. Install integral sideshift cylinder onto carriage.
See Cylinder Repair (Mast S/N F507, F508,
F562, F563) 2100YRM1668 for procedures.
18
INTEGRAL SIDESHIFT CARRIAGE, LIFT

TRUCKS MANUFACTURED DECEMBER, WARNING
2016 THROUGH LATE JUNE, 2018 Always wear the proper protective equipment
This section covers lift truck models ERC22-35VG gloves when handling hydraulic oil. Thoroughly
(ERC045-070VG) (A968), GLC20-35VX (GC/ wash oil from exposed areas of skin as soon as
GLC40-70VX) (C910), and GP/GLP/GDP040-070VX possible.
(D875) equipped with an integral sideshift carriage
and manufactured between December, 2016 and late The hydraulic oil is hot at normal operating
June, 2018. temperatures. Be careful when draining the oil.
Never check for leaks by putting hands on
Remove hydraulic lines or components under pressure.
1. Lower carriage completely. Remove forks. See Hydraulic oil under pressure can be injected into
Fork Replacement for removal procedures. the skin.
2. Remove four capscrews, nuts, washers, and load

backrest from carriage. See Figure 12. CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
WARNING system.
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious NOTE: Tag hydraulic lines and fittings prior to
injury can occur if pressure is not relieved from disconnecting to aid in connecting during installation.
hydraulic system prior to disconnecting hydraulic 4. Disconnect hydraulic lines from sideshift cylinder.
hoses. Put caps and plugs on open lines and cylinder
ports. See Figure 18.
3. Relieve hydraulic pressure to the sideshift
cylinder by moving sideshift lever in both
19
NOTE: CLASS II CARRIAGE SHOWN. CLASS III CARRIAGE IS SIMILAR.
1. HYDRAULIC HOSE FITTINGS

2. INTEGRAL SIDESHIFT HYDRAULIC HOSES
3. INTEGRAL SIDESHIFT CYLINDER
4. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY
Figure 18. Integral Sideshift Carriage Hydraulic Hose Connections

capscrews and washers securing the hooks. See
Figure 19.
20
NOTE: TWO-STAGE LFL, CLASS II INTEGRAL SIDESHIFT CARRIAGE SHOWN. TWO-STAGE LFL, CLASS III
INTEGRAL SIDESHIFT CARRIAGE IS SIMILAR.
1. OUTER FRAME 10. INNER FRAME

2. LUBE FITTING 11. LOAD ROLLER
3. SNAP RING 12. SPACER
4. CAPSCREW 13. SHIMS
5. WASHER 14. COTTER PIN
6. LOWER BEARING 15. CHAIN ANCHOR
7. LOWER HOOK 16. PIN
8. INTEGRAL SIDESHIFT CYLINDER 17. CHAIN ANCHOR PIN
9. UPPER BEARING
Figure 19. Integral Sideshift Carriage, Two-Stage LFL Mast
6. Remove integral sideshift cylinder from carriage.

7. Use a crane with a capacity of at least

48 kg (106 lb) to lift outer frame away from the
inner frame (see Figure 20). Lay outer frame flat
on a pallet or workbench.
21
3. Disassemble sideshift cylinder. See Cylinder

Clean and Inspect
WARNING

smoothness. Ensure the carriage bars are parallel
and the ends are flush. If carriage bars have any
protruding welds or damaged notches, repair by
grinding, filing, or welding.
2. Clean the bearing areas. Inspect the sideshift

bearings for wear as follows:
1. OUTER FRAME
2. LIFTING HOOK a. If either upper bearing is worn to less than
3. LIFTING DEVICE 2.5 mm (0.1 in.) thickness, replace both upper
Figure 20. Remove Outer Frame the inner frame. See Assemble section for
procedures to replace upper bearings and
Disassemble Figure 21.
1. Remove the upper and lower bearings from the
inner frame. See Clean and Inspect section for
2.5 mm (0.1 in.) thickness, replace both lower
procedures.
2. If damaged, remove lube fittings from outer inner frame. See Assemble section for
frame. See Figure 19. procedures to replace lower bearings and
Figure 21.
22
A. MINIMUM THICKNESS, 2.5 mm (0.1 in.)

2. CARRIAGE BARS
3. Inspect sideshift cylinder. See Cylinder Repair 3. Apply a 1 mm (0.040 in.) layer of multipurpose
(Mast S/N F507, F508, F562, F563) grease to upper and lower bearing surfaces.
2100YRM1668 for procedures. Install the upper and lower bearings onto inner
frame:
4. Inspect load rollers for wear and damage (see
Figure 19). If load rollers must be replaced, make a. To install new upper bearing, align the pins on
a note of the location and number of the shims to the bottom side of bearing to notches on top
ensure correct installation. See Carriage carriage bar and slide into place on top
Adjustments. carriage. See Figure 21.
Assemble b. To install new lower bearing, align the circular

pins on backside of lower bearing to holes on
1. Assemble sideshift cylinder. See Cylinder Repair lower carriage bar and tap bearing into place
(Mast S/N F507, F508, F562, F563) on lower carriage bar using a rubber or brass
2100YRM1668 for procedures. hammer. See Figure 21.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 19.
Install
NOTE: Use a wood block or a plastic hammer to fully See Cylinder Repair (Mast S/N F507, F508,
seat the upper bearings onto the inner frame. Proper F562, F563) 2100YRM1668 for procedures.
lower hook clearance requires the upper bearings be
fully seated.
23
2. Use a crane, with a capacity of 48 kg (106 lb),

and install outer frame onto inner frame. See
Figure 20.
3. Install lower mounting hook using four capscrews
and washers. Tighten capscrews to
150 to 180 N•m (108 to 132 lbf ft).
WARNING
4. Connect hydraulic lines, as noted during removal, including eye protection and petroleum-resistant
to sideshift cylinder. See Figure 18. gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
5. Install load backrest onto integral sideshift possible.
carriage. Tighten capscrews to The hydraulic oil is hot at normal operating
195 N•m (144 lbf ft). See Figure 12. temperatures. Be careful when draining the oil.
6. Install forks. See Fork Replacement section for Never check for leaks by putting hands on
procedures. hydraulic lines or components under pressure.
INTEGRAL SIDESHIFT CARRIAGE, LIFT the skin.
TRUCKS MANUFACTURED LATE JUNE,
2018 AND AFTER
CAUTION
This section covers lift truck models ERC22-35VG Protect the hydraulic system from dirt and
(ERC045-070VG) (A968), GLC20-35VX (GC/ contaminants when servicing the hydraulic
GLC40-70VX) (C910), and GP/GLP/GDP040-070VX system.
(D875) equipped with an integral sideshift carriage
and manufactured after late June, 2018. NOTE: Tag hydraulic lines and fittings prior to
disconnecting to aid in connecting during installation.
Remove 4. Disconnect hydraulic lines from sideshift cylinder.
1. Lower carriage completely. Remove forks. See Put caps and plugs on open lines and cylinder
Figure 12 for removal procedures. ports. See Figure 22.
2. Remove four capscrews, nuts, washers, and load

WARNING
the pressure in the hydraulic system. Serious
injury can occur if pressure is not relieved from
hydraulic system prior to disconnecting hydraulic
hoses.
24
NOTE: CLASS II CARRIAGE SHOWN. CLASS III CARRIAGE IS SIMILAR.
1. HYDRAULIC HOSE FITTINGS

2. INTEGRAL SIDESHIFT HYDRAULIC HOSES
3. INTEGRAL SIDESHIFT CYLINDER
4. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY
Figure 22. Integral Sideshift Carriage Hydraulic Hose Connections

capscrews and washers securing the hooks. See
Figure 23.
25
NOTE: TWO-STAGE LFL, CLASS II INTEGRAL SIDESHIFT CARRIAGE SHOWN. TWO-STAGE LFL, CLASS III
INTEGRAL SIDESHIFT CARRIAGE IS SIMILAR.

2. LUBE FITTING 11. LOAD ROLLER
7. LOWER HOOK 16. PIN
8. INTEGRAL SIDESHIFT CYLINDER 17. CHAIN ANCHOR PIN
9. UPPER BEARING
Figure 23. Integral Sideshift Carriage, Two-Stage LFL Mast


48 kg (106 lb) to lift outer frame away from the
inner frame (see Figure 24). Lay outer frame flat
on a pallet or workbench.
26
3. Disassemble sideshift cylinder. See Cylinder

Clean and Inspect
WARNING

smoothness. Ensure the carriage bars are parallel
and the ends are flush. If carriage bars have any
2. Clean the bearing areas. Inspect the sideshift

bearings for wear as follows:
1. OUTER FRAME
2. LIFTING HOOK a. If either upper bearing is worn to less than
3. LIFTING DEVICE 2.5 mm (0.1 in.) thickness, replace both upper
Figure 24. Remove Outer Frame the inner frame. See Assemble section for
procedures to replace upper bearings and
Disassemble Figure 25.
1. Remove the upper and lower bearings from the
inner frame. See Clean and Inspect section for
2.5 mm (0.1 in.) thickness, replace both lower
procedures.
2. If damaged, remove lube fittings from outer inner frame. See Assemble section for
frame. See Figure 23. procedures to replace lower bearings and
Figure 25.
27
A. MINIMUM THICKNESS, 2.5 mm (0.1 in.)

2. CARRIAGE BARS
3. Inspect sideshift cylinder. See Cylinder Repair 3. Apply a 1 mm (0.040 in.) layer of multipurpose
(Mast S/N F507, F508, F562, F563) grease to upper and lower bearing surfaces.
2100YRM1668 for procedures. Install the upper and lower bearings onto inner
frame:
4. Inspect load rollers for wear and damage (see
Figure 23). If load rollers must be replaced, make a. To install new upper bearing, align the pins on
a note of the location and number of the shims to the bottom side of bearing to notches on top
ensure correct installation. carriage bar and slide into place on top
carriage. See Figure 23.
Assemble
b. To install new lower bearing, align the circular
1. Assemble sideshift cylinder. See Cylinder Repair pins on backside of lower bearing to holes on
(Mast S/N F507, F508, F562, F563) lower carriage bar and tap bearing into place
2100YRM1668 for procedures. on lower carriage bar using a rubber or brass
hammer. See Figure 23.
Install
NOTE: Use a wood block or a plastic hammer to fully 1. Install integral sideshift cylinder onto carriage.
seat the upper bearings onto the inner frame. Proper See Cylinder Repair (Mast S/N F507, F508,
lower hook clearance requires the upper bearings be F562, F563) 2100YRM1668 for procedures.
fully seated.
28
2. Use a crane, with a capacity of 48 kg (106 lb),

and install outer frame onto inner frame. See
Figure 24. WARNING
The hydraulic oil is hot at normal operating
3. Install lower mounting hook using four capscrews temperatures. Be careful when draining the oil.
and washers. Tighten capscrews to
150 to 180 N•m (108 to 132 lbf ft).
hydraulic lines or components under pressure.
4. Connect hydraulic lines, as noted during removal,
the skin.
to sideshift cylinder. See Figure 22.
5. Install load backrest onto integral sideshift

carriage. Tighten capscrews to CAUTION
195 N•m (144 lbf ft). See Figure 12. Protect the hydraulic system from dirt and
6. Install forks. See Fork Replacement section for system.
procedures.
FORK POSITIONER CARRIAGE, LIFT CAUTION

TRUCKS MANUFACTURED PRIOR TO DO NOT bend tube assemblies during removal.
DECEMBER, 2016
NOTE: Tag all hydraulic hoses, lines, and fittings prior
Remove to removal to aid in installation.
NOTE: The fork positioner can be removed from the 3. Disconnect and cap tube assemblies (8,
integral sideshift carriage with integral sideshift Figure 26) from header hoses.
positioner is removed with integral sideshift carriage 4. Remove capscrews and washers and remove
on the mast. If integral sideshift carriage must be lower hooks and bracket weldments from
removed from mast first, go to Integral Sideshift carriage. See Figure 27 and Figure 29.
Carriage, Lift Trucks Manufactured Prior To December,
2016 in this section. 5. Install lifting eye in hole (see Figure 27 ) on
integral sideshift carriage and use lifting device to
1. Remove forks. See Fork Replacement section for
lift outer frame up.
procedures.
6. Disconnect relief tube assembly and hydraulic
hoses (open and close) from fork positioner. See
Figure 27.
NOTE: Make note of shims used to aid in reassembly.

WARNING
Before disconnecting the hydraulic hoses, relieve 7. Remove capscrews, lockwashers, and shims
the pressure in the hydraulic system. Serious from integral sideshift carriage. See Figure 27.
8. Remove fork positioner from outer frame.
hoses.
WARNING
possible.
29
NOTE: BACK (DRIVER'S) VIEW SHOWN.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 6. FORK CARRIER

2. FORK POSITIONER HYDRAULIC HOSE 7. RELIEF TUBE ASSEMBLY
(CLOSED) 8. TUBE ASSEMBLY
3. INTEGRAL SIDESHIFT CARRIAGE HYDRAULIC 9. HOSE GUIDE
HOSES
4. FORK POSITIONER
5. OUTER FRAME
Figure 26. Hydraulic Connections, Fork Positioner Cylinder
30
NOTE: RIGHT OUTER FRAME BAR REMOVED FOR CLARITY.

NOTE: FRONT VIEW SHOWN.
1. CAPSCREW AND LOCKWASHER 5. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY

2. SHIM 6. LOWER HOOK
3. FORK POSITIONER CYLINDER 7. TAPPED HOLE FOR LIFT EYE
4. FORK CARRIER
Figure 27. Fork Positioner Cylinder Removal
For procedures to repair the fork positioner cylinder, 2. Install second lockwasher and capscrew. Tighten
see Cylinder Repair (Mast S/N F507, F508, F562, both capscrews to 65 N•m (50 lbf ft). See
F563) 2100YRM1668. Figure 27.
Install 3. Connect fork positioner hydraulic hoses to fork

positioner manifold. Tighten hoses to
1. Place fork positioner cylinders onto outer frame. 21 N•m (186 lbf in). See Figure 26.
Install lockwasher and capscrew on one side and
hand tighten capscrew. See Figure 27. Add shims 4. Thread fork positioner hydraulic hoses through
as follows: hose guides. See Figure 26.
NOTE: The maximum number of shims per side is 5. Install outer frame, with fork positioner, on inner
five. The maximum difference in number of shims per frame.
side is two. The maximum gap allowed before
tightening capscrews is 0.50 mm (.020 in.). 6. Using a lifting device, position outer frame at the
a. Measure gap at opposite side and determine same height of inner frame and 150 mm (6 in.)
the number of shims required. away.
b. Install shims on both sides of the fork

positioner assembly.
31
7. From rear of outer frame, connect fork positioner

hydraulic tubes to header hoses and hand
tighten. See Figure 26.
8. Position fork positioner hydraulic tubes so they

are in line with inner frame retainer plates. See
Figure 28.
9. Using washer and capscrew, install bracket

weldment to lower hook and hand tighten
capscrew. Install lower hook on retainer plate with
washer and capscrew and tighten capscrews to
165 N•m (122 lbf ft). See Figure 29.
10. Position bracket weldment over fork positioner

hydraulic hoses (see Figure 26) and adjust so
that bracket weldment makes contact with fork
positioner hoses. Tighten capscrew to
8 N•m (71 lbf in). See Figure 29.
11. Tighten fork positioner hydraulic tubes to header

hoses to 42 N•m (31 lbf ft).
WARNING 1. RETAINER PLATE

DO NOT try to install a fork without a lifting device. 2. INNER FRAME
45 to 115 kg (99 to 254 lb). Figure 28. Inner Frame Retainer Plates
CAUTION
Remove fork latch pins (see Figure 3) if adding a
fork positioner attachment. Damage to forks and
other carriage components can occur if fork latch
pins are not removed prior to using a fork
positioner attachment.
NOTE: Before proceeding to Step 12 and Step 13,

adjust the fork positioner hydraulic hoses. See Fork
Positioner Hydraulic Hose Adjustment for procedures.
12. Install forks to outer fork carriers. Secure inner
fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to
13. To adjust the fork positioner cylinders, see

32
Fork Positioner Hydraulic Hose

Adjustment
1. To adjust the fork positioner hydraulic hoses, hold
the large hex nut and rotate the small hex nut
towards the load face of the carriage (towards the
forks). See Figure 30.
2. Fork positioner hoses are correctly adjusted when

fork positioner hydraulic hoses stay entirely within
the integral sideshift carriage and do not contact
mast channels under all conditions.
3. Move fork positioner and check to ensure fork

carriers clear fork positioner relief tubes through
complete fork carrier cycle. See Figure 30.
4. Install load backrest to sideshift carriage. Tighten

capscrews to 195 N•m (144 lbf ft). See Figure 12.
1. BRACKET WELDMENT
2. RETAINER PLATE
3. WASHER
4. LOWER HOOK
5. CAPSCREW (LOWER HOOK)
6. CAPSCREW (BRACKET WELDMENT)
Figure 29. Bracket Weldment and Lower Hook

Assembly
33
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. TUBE ASSEMBLY

(CLOSE) 7. INTEGRAL SIDESHIFT HYDRAULIC HOSES
3. SMALL HEX NUT
4. LARGE HEX NUT
Figure 30. Fork Positioner Hydraulic Hose Adjustment
FORK POSITIONER CARRIAGE, LIFT 2. Remove four capscrews, washers, nuts and load
TRUCKS MANUFACTURED DECEMBER, backrest from carriage. See Figure 12.
2016 THROUGH LATE JUNE, 2018
This section covers lift truck models ERC22-35VG WARNING
(ERC045-070VG) (A968), GLC20-35VX (GC/ Before disconnecting the hydraulic hoses, relieve
GLC40-70VX) (C910), and GP/GLP/GDP040-070VX the pressure in the hydraulic system. Serious
(D875) equipped with a fork positioner on an integral injury can occur if pressure is not relieved from
sideshift carriage and manufactured between hydraulic system prior to disconnecting hydraulic
December, 2016 and late June, 2018. hoses.
Remove
NOTE: The fork positioner can be removed from the WARNING
integral sideshift carriage with integral sideshift Always wear the proper protective equipment
carriage on or off the mast. In the steps below, the fork including eye protection and petroleum-resistant
positioner is removed with integral sideshift carriage gloves when handling hydraulic oil. Thoroughly
on the mast. If integral sideshift carriage must be wash oil from exposed areas of skin as soon as
removed from mast first, go to Integral Sideshift possible.
Carriage, Lift Trucks Manufactured December, 2016
through Late June, 2018 in this section for procedures.
procedures.
34
4. Remove capscrews and washers and remove

WARNING lower hooks from retainer plates on inner frame.
See Figure 32.
temperatures. Be careful when draining the oil. 5. Install lifting eye in hole (7, Figure 32) on outer
Never check for leaks by putting hands on frame of integral sideshift carriage. Use a lifting
hydraulic lines or components under pressure. device with a capacity of 62 kg (136 lb), to lift
Hydraulic oil under pressure can be injected into outer frame with fork positioner attached. See
the skin. Figure 33 .

CAUTION hoses (open and close) from fork positioner. See
Figure 31.
system.
7. Remove capscrews, lockwashers, and shims
from integral sideshift carriage. See Figure 32.
CAUTION
DO NOT bend tube assemblies during removal.
For procedures to repair the fork positioner
NOTE: Tag all hydraulic hoses, lines, and fittings prior cylinder, see Cylinder Repair (Mast S/N F507,
to removal to aid in installation. F508, F562, F563) 2100YRM1668
3. Disconnect and cap tube assemblies (8,
Figure 31) from header hoses.
35

(CLOSE) 8. TUBE ASSEMBLY
HOSES 10. MANIFOLD
4. FORK POSITIONER CYLINDER
5. OUTER FRAME
36

2. SHIMS 6. LOWER HOOK
4. FORK CARRIER
37
2. Install second lockwasher and capscrew. Tighten

both capscrews to 65 N•m (50 lbf ft). See
Figure 32.
3. Connect fork positioner hydraulic hoses to fork

4. Thread fork positioner hydraulic hoses through

hose guides. See Figure 31.
5. Install lifting eye and use a lifting device, with a

capacity of 62 kg (136 lb), to install outer frame,
with fork positioner attached, onto inner frame.
See Figure 33.
6. Using a lifting device, position outer frame at the

same height of inner frame and 150 mm (6 in.)
away.

1. OUTER FRAME hydraulic tubes to header hoses and hand
2. LIFTING HOOK tighten. See Figure 31.
3. LIFTING DEVICE
Figure 33. Remove Outer Frame are in line with retainer plates on inner frame. See
Figure 34.
Disassemble and Assemble
9. Using a washer and capscrew, install lower hook
See Cylinder Repair (Mast S/N F507, F508, F562,
to retainer plates and tighten capscrews to
F563) 2100YRM1668 for disassemble and assemble
165 N•m (122 lbf ft).
procedures for fork positioner cylinder.
Clean and Inspect hoses to 42 N•m (31 lbf ft).
F563) 2100YRM1668 for cleaning and inspection
procedures on the fork positioner cylinder. CAUTION
Remove fork latch pins (see Fork Replacement) if
Install adding a fork positioner attachment. Damage to
forks and other carriage components can occur if
1. Place fork positioner cylinders onto outer frame.
fork latch pins are not removed prior to using a
fork positioner attachment.
hand tighten capscrew. See Figure 32. Add shims
as follows: NOTE: Before proceeding to Step 11 and Step 12,
NOTE: The maximum number of shims per side is
five. The maximum difference in number of shims per
side is two. The maximum gap allowed before 11. Install forks to outer fork carriers. See Fork
tightening capscrews is 0.50 mm (.020 in.). Replacement section for procedures.
a. Measure gap at opposite side and determine 12. To adjust the fork positioner cylinders, see
the number of shims required. Cylinder Repair (Mast S/N F507, F508, F562,
38

Adjustment



1. RETAINER PLATES
2. OUTER FRAME (FORK BAR)
3. INNER FRAME
Figure 34. Retainer Plates and Inner and Outer

Frame
39
1. LARGE HEX NUT 4. FORK POSITIONER HYDRAULIC HOSE (CLOSE)

2. SMALL HEX NUT 5. RELIEF TUBE ASSEMBLY
3. FORK POSITIONER HYDRAULIC HOSE (OPEN) 6. INTEGRAL SIDESHIFT HYDRAULIC HOSES
Figure 35. Fork Positioner Hydraulic Hoses Adjustment
FORK POSITIONER CARRIAGE, LIFT 2. Remove four capscrews, washers, nuts and load
TRUCKS MANUFACTURED LATE JUNE, backrest from carriage. See Figure 12.
2018 AND AFTER
This section covers lift truck models ERC22-35VG WARNING
sideshift carriage and manufactured after late June, hydraulic system prior to disconnecting hydraulic
2018. hoses.
Remove
Carriage, Lift Trucks Manufactured Late June, 2018
and After in this section for procedures.
procedures.
40

See Figure 37.
hydraulic lines or components under pressure. device with a capacity of 62 kg (136 lb), to lift
Hydraulic oil under pressure can be injected into outer frame with fork positioner attached. See
the skin. Figure 38.

CAUTION hoses (open and close) from fork positioner. See
Figure 36.
system.
CAUTION
DO NOT bend tube assemblies during removal.
For procedures to repair the fork positioner
NOTE: Tag all hydraulic hoses, lines, and fittings prior cylinder, see Cylinder Repair (Mast S/N F507,
to removal to aid in installation. F508, F562, F563) 2100YRM1668 .
41

HOSES 10. MANIFOLD
5. OUTER FRAME
42

4. FORK CARRIER
43
2. Install second lockwasher and capscrew. Tighten

both capscrews to 65 N•m (50 lbf ft). See
Figure 37.

4. Thread fork positioner hydraulic hoses through


See Figure 38.

away.

1. OUTER FRAME hydraulic tubes to header hoses and hand
2. LIFTING HOOK tighten. See Figure 36.
3. LIFTING DEVICE
Figure 38. Remove Outer Frame are in line with retainer plates on inner frame. See
Figure 39.
Disassemble and Assemble
F563) 2100YRM1668 for disassemble and assemble
165 N•m (122 lbf ft).
procedures for fork positioner cylinder.
Clean and Inspect hoses to 42 N•m (31 lbf ft).
F563) 2100YRM1668 for cleaning and inspection
procedures on the fork positioner cylinder. CAUTION
Install adding a fork positioner attachment. Damage to
forks and other carriage components can occur if
fork positioner attachment.
as follows: NOTE: Before proceeding to Step 11 and Step 12,
side is two. The maximum gap allowed before 11. Install forks to outer fork carriers. See Fork
tightening capscrews is 0.50 mm (.020 in.). Replacement section for procedures.
a. Measure gap at opposite side and determine 12. To adjust the fork positioner cylinders, see
the number of shims required. Cylinder Repair (Mast S/N F507, F508, F562,
44

Adjustment



1. RETAINER PLATES
2. OUTER FRAME (FORK BAR)
3. INNER FRAME

Frame
45
Two-Stage LFL Mast Repair 4000 YRM 1669

Two-Stage LFL Mast Repair

MAST WITH SERIAL NUMBER F507
Remove WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
WARNING manual.
The mast is heavy. The mast can weigh
approximately 907 kg (2000 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.) CAUTION
are suitable and of adequate capacity to lift the Make sure all the mast weldments are fastened
mast. together. Make sure the safety chains will not
damage the sheaves, tubing, or other parts of the
mast.
WARNING
Mast weldments can slide when the mast is
moved. A weldment that slides can cause serious
injury.
46
4000 YRM 1669 Two-Stage LFL Mast Repair
NOTE: If mast needs to be disassembled, remove the 4. On lift trucks NOT equipped with optional boot on
forks and carriage. See sections Carriages Repair, tilt cylinders, remove capscrews, washers, anchor
Two-Stage LFL Mast and Fork Replacement in this pins, and pivot pins at the tilt cylinder mounts on
manual for procedures. If only the main lift cylinders the outer mast. See Figure 41.
need to be removed for repair, the mast does not need
to be removed from lift truck. See Cylinder Repair 5. Using a brass drift pin, remove tilt rod bushings
(Mast S/N F507, F508, F562, F563) 2100YRM1668 from outer mast. Discard tilt rod bushings. See
for procedures to remove the main lift cylinders. Figure 43.
NOTE: The length of the lift chains must be checked NOTE: Allow mast to tilt forward enough to gain
before mast is removed. See Lift Chains Adjustment. access to the mast mount capscrews.
1. Fully lower all mast weldments. Tilt mast fully 6. Disconnect lower mast mounts from lift truck by
forward. removing capscrews that hold mast pivot pins to
the mounts on the drive axle. See Figure 44 and
Figure 45.
907 kg (2000 lb) to top of mast using chains to
support mast in an upright position when tilt
cylinders are disconnected. See section Safety
WARNING
manual. The mast is heavy. The mast can weigh
lifting devices (hoists, cables, chains, slings, etc.)
WARNING are suitable and of adequate capacity to lift the
mast.
including eye protection and petroleum-resistant 7. Use the crane to lift the mast assembly from lift
gloves when handling hydraulic oil. Thoroughly truck. Position mast across wooden beams on the
wash oil from exposed areas of skin as soon as floor with the carriage side up.
possible.
Completely lower forks to relieve hydraulic NOTE: If mast mounting bushing needs to be
pressure before disassembling any part of the lift replaced in Step 8, go to Step 10 for procedures.
pump or disconnecting any hoses. 8. Check the mast and mounting flanges for wear or
The hydraulic oil is hot at normal operating damage by removing mast pivot pins from outer
temperatures. Be careful when draining the oil. mast. See Figure 45.
9. Check that pins fit snug in the outer mast. If pins

can be moved up and down a minimum of
CAUTION 4 mm (0.20 in.), replace bushings in outer mast
Protect the hydraulic system from dirt and and/or mast pivot pins as required. See
contaminants when servicing the hydraulic Figure 43.
system.
10. Remove lube fitting, lube capscrew, and washer
3. Position a drip pan under the area of hydraulic
from mast mounts. See Figure 49. Use a brass
fittings. Disconnect hydraulic line at the external
drift pin to remove mast mounting bushings from
lowering control valve on outer mast. See
outer mast. Discard mast mounting bushings. See
Figure 46.
Figure 43.
WARNING
Use a driver, NOT your fingers, to push the anchor
pins from the clevises on the tilt cylinders. The
cylinder or mast can move and cause serious
injury.
47
1. GREASE FITTING 7. BOOT

1. O-RING 7. PIVOT PIN 2. PIVOT PIN 8. SHIM
2. SPACER 8. GREASE FITTING 3. ANCHOR PIN 9. SPACER
3. SHIMS 9. ANCHOR PIN 4. ROD END 10. TILT CYLINDER
4. NUT 10. CAPSCREW 5. CAPSCREW 11. WASHER
5. WASHER 11. ROD END 6. CLAMP 12. NUT
6. CAPSCREW
Figure 42. Mast Mounting, Tilt Cylinder With Boot,
Figure 41. Mast Mounting, Tilt Cylinder Without Lift Truck Models ERP22-35VL (ERP045-070VL)
Boot (A976)
48
1. TILT ROD BUSHING 5. LUBE FITTING

2. MAST MOUNTING BUSHING (BRONZE) 6. WASHER
3. OUTER MAST 7. BUSHING HOLE
4. BUSHING SPLIT 8. LUBE CAPSCREW
Figure 43. Tilt Rod and Mast Mounting Bushings
1. HANGER MOUNTS 1. MAST PIVOT PIN

2. TRACTION MOTOR 2. MAST MOUNTING BUSHING (BRONZE)
3. DRIVE AXLE 3. OUTER MAST
Figure 44. Mast Mounts, Drive Axle Figure 45. Mast Pivot Pins
49
Disassemble
WARNING
Be careful when removing or installing snap rings.
WARNING
These snap rings can come loose during removal
Always wear the proper protective equipment or installation with enough force to cause an
including eye protection and petroleum-resistant injury. Always use the correct snap ring pliers, and
gloves when handling hydraulic oil. Thoroughly wear eye and face protection during removal or
wash oil from exposed areas of skin as soon as installation.
possible.
4. Remove the nut, capscrew, spacer, and washer at
the mount near top of each main lift cylinder.
WARNING Remove snap rings and washers from top of each
Completely lower forks to relieve hydraulic main lift cylinder. Disconnect main lift chains at
pressure before disconnecting any hydraulic the mounts. See Figure 46.
hoses.
WARNING
WARNING The mast weldments can slide when the mast is
Hydraulic oil is hot after system operation and can moved. A weldment that slides can cause injury.
cause burns. DO NOT disconnect any hydraulic
5. Slide the inner mast from the outer mast
hoses until the oil in the system has cooled.
approximately 30 cm (12 in.) to disengage the
main lift cylinders from the inner mast. Remove
the main lift cylinders from the outer mast.
CAUTION
Protect the hydraulic system from dirt and 6. Slide the inner mast from the bottom of the outer
contaminants when disconnecting hydraulic hoses mast 30 cm (12 in.). See Figure 46.
from the mast. If hydraulic system becomes
contaminated, damage to the hydraulic system can 7. Remove the strip bearings and load rollers from
occur. the top of the outer mast. See Figure 49.
NOTE: If only the main lift cylinders need to be 8. Remove the load rollers from the bottom of the
removed and repaired, see Cylinder Repair (Mast inner mast. Make a note of each shim
S/N F507, F508, F562, F563) 2100YRM1668 for arrangement and load roller location. The shim
procedures. When mast has header hoses, see arrangements will be the same during assembly.
section Header Hoses for procedures to install and See Figure 47.
adjust the header hoses.
1. Clean the area around hydraulic fittings for lift
cylinders. Disconnect fittings at the lift cylinders WARNING
and put caps on the open lines. See Figure 46. The mast is heavy. The mast can weigh
2. Remove chains and header hoses. lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
3. Disconnect hydraulic lines and fittings between mast.
lowering control valve housing and main lift
cylinders. Remove capscrews and nuts and NOTE: When replacing the outer mast, copy the part
remove lowering control valve housing and valve number and date code information from the old
from bracket on outer mast. See Figure 46. channel and stamp that information on the new
channel with a letter R at the end to indicate that it has
been replaced.
50
9. Slide inner mast halfway out of the top of the 10. Remove chain sheaves and disassemble them as
outer mast. Connect a crane with a capacity of at necessary for repair and cleaning. See Figure 47.
least 907 kg (2000 lb) to the center of the inner
mast. See Figure 48. Slide inner mast out of the
outer mast until the mast stub shafts of the inner
mast are in the notches of the outer channels.
Remove the inner mast from the outer mast.
51
Figure 46. Main Lift Cylinders
52
Legend for Figure 46.
1. LOWERING CONTROL VALVE HOUSING 9. WASHER

2. CAPSCREW 10. ISOLATOR
3. LOWERING CONTROL VALVE 11. LEFT MAIN LIFT CYLINDER
4. FITTING 12. WASHER
5. NUT 13. RIGHT MAIN LIFT CYLINDER
6. HYDRAULIC VELOCITY FUSE 14. INNER MAST
7. HOSE ASSEMBLY 15. OUTER MAST
8. SNAP RING
53
Figure 47. Inner Mast Components
54
1. INNER MAST 7. O-RING

2. LOAD ROLLER 8. CHAIN SHEAVE
3. SNAP RING 9. BEARING
4. SHIM 10. SNAP RING
5. BEARING STRIP 11. MAIN LIFT CHAIN
6. SHIM 12. SPACER
Figure 48. Connecting A Crane
55
Figure 49. Outer Mast
56
1. OUTER MAST 11. RING

2. LOAD ROLLER 12. NUT
3. SNAP RING 13. CHAIN ANCHOR RESTRAINT
4. SHIM 14. CAPSCREW
5. BUSHING 15. CHAIN ANCHOR
6. BUSHING (BRONZE) 16. NUT
7. INNER MAST 17. LUBE FITTING
8. LIFT CHAIN 18. LUBE CAPSCREW
9. PIN 19. WASHER
10. COTTER PIN
Clean and Inspect 2. Clean lift chains by soaking in solvent for 30

minutes to remove all dirt and grease. Hang lift
CAUTION chains up and remove solvent using compressed
air.
DO NOT use steam or high-pressure water to clean
the load rollers or the lift chains. Steam and high-
pressure water can remove the lubrication from
the bearings in the load rollers. Water in the
WARNING
bearings of the sheaves and the link pins of chains Never replace only the worn section of a chain.
can also shorten the service life of these parts. Replace the complete chain. Never replace only
one chain of a chain pair. Replace both chains.
1. Inspect chain sheaves and load rollers (see Damage to the lift truck and serious injury can
Figure 47 and Figure 49) for wear or damage. DO occur if lift chains are not replaced correctly.
NOT use steam to clean lift chain sheaves or load
rollers. The bearings in the sheaves and load NOTE: The chains must be inspected in the area of
rollers are sealed and lubricated. chain that passes over chain sheave during the first
portion of a lift. These links will show maximum wear.
3. Inspect lift chains for wear and damage. A lift
WARNING chain becomes longer when it is worn. If a chain
Cleaning solvents may be flammable and toxic and is 3% longer than a new lift chain, the lift chain
can cause severe skin irritation. When using must be replaced.
commercial cleaning solvents, always comply with
solvent manufacturer's recommended safety
precautions.
WARNING
57
Pitch Total Length of 20 Links (Pitch) of Wear Limit - The Maximum Length
New Chain of 20 Links
12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20. in.) 523.3 mm (20.6 in.)
NOTE: THE INSTRUCTION FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE.
1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE
Figure 50. Lift Chain Check
4. Lubricate lift chains by soaking them in SAE 30

engine oil for 30 minutes. Hang chains over a drip WARNING
pan for one hour to remove excess oil. Cleaning solvents may be flammable and toxic and
can cause severe skin irritation. When using
NOTE: Chain anchor pins Must be replaced anytime commercial cleaning solvents, always comply with
chains are replaced. solvent manufacturer's recommended safety
5. Inspect chain anchors, chain anchor pins, and precautions.
chain anchor restraints. Replace any parts that
are worn or damaged. See Figure 49.
WARNING
Steam can cause serious burns. Wear protective
clothing, gloves, and eye protection. Never expose
your skin to steam.
58
6. Clean mast weldments with steam or solvent. 3. Install load rollers and shims on both weldments.
Check the clearance of the load rollers as
described in sections Mast Adjustments and
WARNING Carriage Adjustments in this service manual.
structure of the mast or cause incorrect function 4. Push the inner mast to engage the rods of the
of the mast which can result in serious injury to main lift cylinders. Install washer and snap ring.
personnel. Consult your lift truck dealer for more See Figure 46.
information before welding on the mast
5. Install capscrews, isolators, and O-rings at the
7. Inspect sliding surfaces for wear or damage. mounts for main lift cylinders. Tighten capscrews
Inspect the load roller contact surfaces for wear to 38 N•m (28 lbf ft). See Figure 46.
or damage. Inspect all welds for cracks.
Assemble
WARNING
mast.
NOTE: Shims for the load rollers keep the mast

weldments parallel and provide correct clearance.
During assembly, shims should be reinstalled in the
same location they were in before disassembly. Check
clearance and adjust shims for wear or for changes Figure 51. Strip Bearings
caused by repairs. The strip bearings are also
adjusted by using shims and should also be reinstalled 6. Install housing for lowering control valve on
in the same location they were in before disassembly. bracket on outer mast. Tighten the nuts for the
See the section Mast Adjustments in this service lowering control valve housing to
manual for the adjustment procedures. 18 N•m (13 lbf ft). Install the lowering control
NOTE: When the mast has header hoses, see section valve in the housing. Connect the hydraulic lines
Header Hoses for procedures to install and adjust the and fittings between the housing and the main lift
header hoses. cylinders. See Figure 46.
7. Install the chain sheaves at the inner mast. Be

1. Connect a crane with a capacity of at least sure to install both pins that hold the shaft for the
907 kg (2000 lb) to the center of the inner mast. chain sheave in position. See Figure 49.
See Figure 48. Fit the stub shafts through the
notches in the outer mast. Slide the inner mast 8. Connect the lift chains to the chain anchors at the
into the outer mast so the stub shafts are seen at main lift cylinder mounts. See Figure 46.
the top and bottom of the weldments. See
Figure 47. 9. Attach wires between the ends of the lift chains
and the crossmember to control the lift chains
2. Install the strip bearings and shims on the outer during mast installation.
mast. See Figure 51. Apply chassis lube to the
bearing surface. Check the clearance of the strip
bearings as described in Mast Adjustments
section in this manual.
59
Install 7. Apply an even coat of grease to pivot pins and

connect tilt cylinders to mast using pivot pins.
1. Install new bushings into mast mounts at bottom Install anchor pins and capscrews to rod ends.
of outer mast. Be sure to align the hole in the Apply anti-seize compound to capscrew threads
bushing with the lube fitting hole in the bottom of and tighten 38 N•m (28 lbf ft).
the outer mast. See Figure 43. Bushing must be
flush with outer mast surface. See Figure 52 for lift trucks equipped with tilt
cylinders without optional boots.
2. Apply an even coat of grease to pivot pins and See Figure 53 for lift trucks equipped with tilt
install them into mast mounts at bottom of outer cylinders with optional boots.
mast. See Figure 45.
3. Install washer and lube capscrew in hole in

bottom of outer mast. Tighten lube capscrew to
25 N•m (18 lbf ft). Install lube fitting onto lube
capscrew. Tighten lube fitting to 6 N•m (53 lbf in).
See Figure 43 or Figure 49.
WARNING
mast.
4. Connect crane to top of mast using chains. Make

sure all mast uprights are fastened together.
Make sure chains will not damage sheaves,
tubing, or other parts of mast. Make sure crane
has a capacity of at least 907 kg (2000 lb).
5. Use crane to position mast assembly onto its

lower mounts. Position mast so pivot pins seat
into hanger mounts on drive axle. Install
capscrews that hold mast pivot pins to drive axle 1. O-RING 7. PIVOT PIN
hangers. Tighten capscrews to 2. SPACER 8. GREASE FITTING
3. SHIMS 9. ANCHOR PIN
270 N•m (199 lbf ft). See Figure 44. 4. NUT 10. CAPSCREW
5. WASHER 11. ROD END
6. Install new bushings into the tilt anchors on the 6. CAPSCREW
outer mast. Be sure tilt bushing split is installed at
the correct angle as shown in Figure 43. Figure 52. Mast Mounting, Tilt Cylinder Without
Boot
WARNING
Use a pry bar, NOT your fingers, to align the tilt
cylinder clevises with the outer mast. The cylinder
or mast can shift and cause serious injury.
NOTE: Use multipurpose grease #2 with 2 to 4%

molybdenum disulfide for normal operations.
60
WARNING
the skin.
11. Check tilt cylinder adjustments as described in

F563) 2100YRM1668. Operate mast and check
for leaks and correct operation. Check lift chains
as described in Lift Chains Adjustment section in
this manual.
NOTE: Before checking for mast side kicking, the

mast must be fully assembled to include the carriage,
forks, load backrest and any attachments.
12. Raise mast, without a load to its full height and
check for side kicking. Mast side kicking is when
the mast moves either to the right or left as it is
being raised to its full height. If mast is side
kicking, see Mast Adjustments section in this
1. GREASE FITTING 7. BOOT manual for procedures to correct mast side
2. PIVOT PIN 8. SHIM kicking.
3. ANCHOR PIN 9. SPACER
4. ROD END 10. TILT CYLINDER
5. CAPSCREW 11. WASHER NOTE: Load rollers and sheaves have sealed
6. CLAMP 12. NUT bearings and do not need additional lubrication.
13. Lubricate sliding surfaces and load roller surfaces
along full length of channels as shown in
Lift Truck Models ERP22-35VL (ERP045-070VL)
Figure 54. Apply lubricant only to surfaces
(A976)
indicated.
8. Connect hydraulic lines to lowering control valve.
9. Install carriage as described in section Carriages

Repair, Two-Stage LFL Mast.
WARNING
the skin.
10. Check tilt cylinder adjustments as described in

F563) 2100YRM1668. Operate mast and check A. UPPER LOAD ROLLERS
for leaks and correct operation. Check lift chains B. LOWER LOAD ROLLERS
as described in Lift Chains Adjustment section in
1. LUBRICATE STRIP BEARING SURFACES
this manual. 2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 54. Lubricate Mast
61
Header Hoses
Remove WARNING
Read and follow the Safety Procedures When Working Before working on or near the mast, see Safety
Near Mast as well as all WARNINGS and CAUTIONS Procedures When Working Near Mast in this
before removing any header hoses. manual.
NOTE: Access to some of the fittings can be difficult. 1. Some lift trucks are equipped with auxiliary
If necessary, operate hydraulic system to move mast hydraulic functions that are fastened to the
weldments or carriage. Make sure the hydraulic carriage. Examples of attachments that use these
system does not have pressure as described in auxiliary functions are sideshift carriages, roll
Step 1. clamps, and fork positioners. These auxiliary
functions require header hoses for their operation.
1. To replace any header hoses, fully lower carriage.
Make sure hydraulic system does not have NOTE: The procedures in this section are for the four
hydraulic pressure. Hold the control for each function option. Lift trucks equipped with three-function
function in the forward position for approximately option will only have hoses A and B. See Figure 55.
five seconds to release pressure. Make sure NOTE: The carriage height must be correct before the
hydraulic pump does not operate. Move key or header hose tension can be measured. See Lift
keyless switch, if equipped, to the OFF position. Chains Adjustment for carriage adjustment
procedures.
2. Disconnect battery and put a tag or lock on
battery connector. Mark each hose with a single letter: A, B, C, and
D.
3. Disconnect header hoses and install caps on All four hoses are the same length. Before
ends to prevent dirt and debris from entering the installing new header hoses, add tension marks
hydraulic system. to each hose. See Figure 56.
Installation 2. Clamp one end of the hose in a vise. DO NOT

clamp on the threads. Pull on the other end until
hose is straight. DO NOT apply enough force to
WARNING stretch the hose.
possible.
WARNING
the skin.
62
A. HEADER HOSE D. HEADER HOSE

B. HEADER HOSE E. REAR VIEW
C. HEADER HOSE F. TOP VIEW
Figure 55. Header Hose Alignment for Two-Stage LFL Mast
NOTE: Header hose tension specification is 2.0% 4. From dimension M1, place another mark at
±1%. Install hose caps to marked end (truck end) of 500 ±2.0 mm (20.0 ±0.08 in.). This is dimension
hoses. M2. See Figure 56.
3. Put reference marks on the header hoses.
5. Attach three-function hoses (A and B) and four-
Starting at either end of each of the hoses, place
function hoses (C and D) to turnaround brackets
a mark at 100 ±10 mm (4.0 ±0.40 in.). This is
on carriage. See Figure 56.
dimension M1. See Figure 56.
63
6. Route hoses over the turnaround brackets and a. Measure the distance between marks M1 and
secure the end of the hose to the turnaround M2. See Figure 56.
bracket with hose clamps and worm screw
clamps. Worm screw clamps go through the hose b. The header hose specification between marks
clamps and around the turnaround bracket to M1 and M2 is 510 ±5 mm (2.0% ±1.0%).
protect the header hoses. See Figure 56.
c. If tension mark measurement is
7. Route hoses up over hose sheaves and secure 505 mm (20.0 in.) or lower, adjust plate
hoses to hose sheaves with spacers. attached to bracket on mid-outer
crossmember, downward by one hole and re-
8. Clamp marked end of hoses to brackets on mid- measure tension mark. If tension mark is still
outer crossmember. See Figure 56. 505 mm (20.0 in.) or lower, replace hose and
re-set plate to the upper position.
9. With header hoses installed on mast and the
carriage correctly adjusted (see Carriage d. If tension mark is 515 mm (20.3 in.) or higher,
Adjustments) and the forks off the ground, adjust carriage to maximum height allowed.
measure header hose tension on mast as follows: See Carriage Adjustments section for
procedures.
64
Figure 56. Header Hose Dimensions and Installation, Two-Stage LFL Mast (Sheet 1 of 2)
65
A. DIMENSION = 100 ±10 mm (4.0 ±0.40 in.) B. DIMENSION = 500 ±2.0 mm (20.0 ±0.08 in.)
1. SPACER 5. TURNAROUND BRACKET (THREE-FUNCTION)

2. HOSE SHEAVE 6. TURNAROUND BRACKET (FOUR-FUNCTION)
3. MID-OUTER CROSSMEMBER 7. HOSE CLAMP
4. BRACKET 8. WORM SCREW CLAMP
Distance Installed Hose Tension
505 mm (19.8 in.) 1%
510 mm (20.1 in.) 2%
515 mm (20.3 in.) 3%
Adjustment 3. Loosen hardware on bracket on mid-outer

crossmember for the three and/or four function
NOTE: Tire size variations and adjusting of the lift hoses needing adjustment. Lower bracket and
chains may require adjustment of header hose tighten nut to 18 N•m (159 lbf in). See Figure 57.
tension. Lift chain adjustment for tire wear will reduce
header hose tension. 4. Release chain, remove block, and lower the
1. To increase header hose tension, raise carriage carriage.
at least 100 mm (4.0 in.).
5. With no load on the forks, check the header hose
2. Place a block under lower carriage bar and lower adjustment by operating the mast through the full
carriage onto block to relieve hose tension. Chain lift cycle two times.
carriage to inner mast. See Safety Procedures
When Working Near Mast in this manual.
66
CAUTION
Make sure all the mast weldments are fastened
together. Make sure the safety chains will not
mast.
NOTE: If mast needs to be disassembled, remove the

forks and carriage. See sections Carriages Repair,
Two-Stage LFL Mast and Fork Replacement in this
manual for procedures. If only the main lift cylinders
need to be removed for repair, the mast does not need
to be removed from lift truck. See section Cylinder
2100YRM1668 for procedures to remove the main lift
cylinders.
NOTE: The length of the lift chains must be checked
before the mast is removed. See Lift Chains
Adjustment.
1. MID-OUTER CROSSMEMBER
2. BRACKET 1. Fully lower all mast weldments. Tilt mast fully
3. MOUNTING HARDWARE forward.
4. HEADER HOSE B
5. HEADER HOSE A 2. Connect a crane with a capacity of at least
6. HEADER HOSE D
7. HEADER HOSE C 907 kg (2000 lb) to the top of the mast using
8. PLATE chains to support the mast in an upright position
when the tilt cylinders are disconnected. See
Figure 57. Header Hose Adjustment, Two-Stage section Safety Procedures When Working Near
LFL Mast Mast in this manual.

WARNING
Remove
WARNING gloves when handling hydraulic oil. Thoroughly
The mast is heavy. The mast can weigh wash oil from exposed areas of skin as soon as
approximately 907 kg (2000 lb). Make sure all possible.
lifting devices (hoists, cables, chains, slings, etc.) Completely lower forks to relieve hydraulic
are suitable and of adequate capacity to lift the pressure before disassembling any part of the lift
mast. pump or disconnecting any hoses.
temperatures. Be careful when draining the oil.
WARNING
Mast weldments can slide when the mast is
moved. A weldment that slides can cause serious
injury.
CAUTION
system.
WARNING
manual.
67
3. Position a drip pan under the area of the hydraulic 9. Remove lube fitting, lube capscrew, and washer
fittings. Disconnect the hydraulic line at the from mast mounts. See Figure 66. Use a brass
external lowering control valve on the outer mast. drift pin to remove mast mounting bushings from
See Figure 63. outer mast. Discard mast mounting bushings. See
Figure 60.
WARNING
injury.
4. On lift trucks NOT equipped with optional boot on

tilt cylinders, remove capscrews, washers, anchor
pins, and pivot pins at the tilt cylinder mounts on
the outer mast. See Figure 58.
5. Using a brass drift pin, remove tilt rod bushings

from outer mast. Discard tilt rod bushings. See
Figure 60.
NOTE: Allow mast to tilt forward enough to gain

access to the mast mount capscrews.
6. Disconnect lower mast mounts from lift truck by
removing capscrews that hold the mast pivot pins
to the mounts on the drive axle. See Figure 61
and Figure 62.
WARNING 1. O-RING 7. PIVOT PIN

The mast is heavy. The mast can weigh 2. SPACER 8. GREASE FITTING
approximately 907 kg (2000 lb). Make sure all 3. SHIMS 9. ANCHOR PIN
4. NUT 10. CAPSCREW
lifting devices (hoists, cables, chains, slings, etc.) 5. WASHER 11. ROD END
are suitable and of adequate capacity to lift the 6. CAPSCREW
mast.
Figure 58. Mast Mounting, Tilt Cylinder Without
7. Use the crane to lift mast assembly from lift truck. Boot
Position the mast across wooden beams on floor
with carriage side up.
NOTE: If mast mounting bushing needs to be replace

in Step 8, go to Step 9 for procedures.
8. Check the mast and mounting flanges for wear or
damage by removing mast pivot pins from outer
mast. Check that pins fit snug in the outer mast.
See Figure 62. If pins can be moved up and down
a minimum of 4 mm (0.20 in.), replace bushings
in outer mast and/or mast pivot pins as required.
See Figure 60.
68

2. PIVOT PIN 8. SHIM
5. CAPSCREW 11. WASHER
6. CLAMP 12. NUT

(A976)
69

1. HANGER MOUNTS 1. MAST PIVOT PIN

70
Disassemble
WARNING
WARNING
Always wear the proper protective equipment or installation with enough force to cause an
including eye protection and petroleum-resistant injury. Always use the correct snap ring pliers, and
gloves when handling hydraulic oil. Thoroughly wear eye and face protection during removal or
wash oil from exposed areas of skin as soon as installation.
possible.
4. Remove nut, capscrew, spacer, and washer at the
mount near the top of each main lift cylinder.
WARNING Remove snap rings and washers from top of each
Completely lower forks to relieve hydraulic main lift cylinder. Disconnect main lift chains at
pressure before disconnecting any hydraulic the mounts. See Figure 63.
hoses.
WARNING
WARNING The mast weldments can slide when the mast is
Hydraulic oil is hot after system operation and can moved. A weldment that slides can cause injury.
5. Slide inner mast from outer mast 30 cm (12 in.) to
disengage the main lift cylinders from the inner
mast. Remove the main lift cylinders from the
outer mast.
CAUTION
Protect the hydraulic system from dirt and 6. Slide the inner mast from the bottom of the outer
contaminants when disconnecting hydraulic hoses mast 30 cm (12 in.). See Figure 63.
contaminated, damage to the hydraulic system can 7. Remove the strip bearings and load rollers from
occur. the top of the outer mast. See Figure 66.
NOTE: If only the main lift cylinders need to be 8. Remove the load rollers from the bottom of the
removed and repaired, see Cylinder Repair (Mast inner mast. Make a note of each shim
S/N F507, F508, F562, F563) 2100YRM1668 for arrangement and load roller location. The shim
procedures. When the mast has header hoses, see arrangements will be the same during assembly.
section Header Hose Installation and Adjustment for See Figure 64.
procedures to install and adjust the header hoses.
1. Clean area around hydraulic fittings for lift
cylinders. Disconnect fittings at lift cylinders and WARNING
put caps on the open lines. See Figure 63. The mast is heavy. The mast can weigh
2. Remove chains and header hoses. lifting devices (hoists, cables, chains, slings, etc.)
3. Disconnect hydraulic lines and fittings between mast.
lowering control valve housing and main lift
cylinders. Remove capscrews and nuts and NOTE: When replacing the outer mast, copy the part
remove lowering control valve housing and valve number and date code information from the old
from bracket on outer mast. See Figure 63. channel and stamp that information on the new
channel with a letter R at the end to indicate that it has
been replaced.
71
9. Slide the inner mast halfway out of the top of the 10. Remove chain sheaves and disassemble them as
outer mast. Connect a crane with a capacity of at necessary for repair and cleaning. See Figure 64.
least 907 kg (2000 lb) to the center of the inner
mast. See Figure 65. Slide the inner mast out of
the outer mast until the mast stub shafts of the
inner mast are in the notches of the outer
channels. Remove the inner mast from the outer
mast.
72
Figure 63. Main Lift Cylinders
73
1. LOWERING CONTROL VALVE HOUSING 9. WASHER

2. CAPSCREW 10. ISOLATOR
3. LOWERING CONTROL VALVE 11. LEFT MAIN LIFT CYLINDER
4. FITTING 12. WASHER
5. NUT 13. RIGHT MAIN LIFT CYLINDER
6. HYDRAULIC VELOCITY FUSE 14. INNER MAST
7. HOSE ASSEMBLY 15. OUTER MAST
8. SNAP RING
74
Figure 64. Inner Mast Components
75
1. INNER MAST 7. O-RING

2. LOAD ROLLER 8. CHAIN SHEAVE
3. SNAP RING 9. BEARING
4. SHIM 10. SNAP RING
5. BEARING STRIP 11. MAIN LIFT CHAIN
6. SHIM 12. SPACER
Figure 65. Connecting A Crane
76
Figure 66. Outer Mast
77
1. OUTER MAST 11. RING

3. SNAP RING 13. CHAIN ANCHOR RESTRAINT
4. SHIM 14. CAPSCREW
5. BUSHING 15. CHAIN ANCHOR
6. BUSHING (BRONZE) 16. NUT
7. INNER MAST 17. LUBE FITTING
8. LIFT CHAIN 18. LUBE CAPSCREW
9. PIN 19. WASHER
10. COTTER PIN
Clean and Inspect 2. Clean the lift chains by soaking in solvent for 30
CAUTION chains up and remove solvent using compressed
air.
DO NOT use steam or high-pressure water to clean
the load rollers or the lift chains. Steam and high-
pressure water can remove the lubrication from
the bearings in the load rollers. Water in the
WARNING
bearings of the sheaves and the link pins of chains Never replace only the worn section of a chain.
can also shorten the service life of these parts. Replace the complete chain. Never replace only
one chain of a chain pair. Replace both chains.
1. Inspect chain sheaves and load rollers (see Damage to the lift truck and serious injury can
Figure 64 and Figure 66) for wear or damage. DO occur if lift chains are not replaced correctly.
NOT use steam to clean lift chain sheaves or load
rollers. The bearings in the sheaves and load NOTE: The chains must be inspected in the area of
rollers are sealed and lubricated. chain that passes over the chain sheave during the
first portion of a lift. These links will show maximum
wear.
WARNING 3. Inspect lift chains for wear and damage. A lift
Cleaning solvents may be flammable and toxic and chain becomes longer when it is worn. If a chain
can cause severe skin irritation. When using is 3% longer than a new lift chain, the lift chain
commercial cleaning solvents, always comply with must be replaced.
solvent manufacturer's recommended safety
precautions.
WARNING
78
12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20. in.) 523.3 mm (20.6 in.)


are worn or damaged. See Figure 66.
WARNING
your skin to steam.
79
6. Clean mast weldments with steam or solvent. 3. Install the load rollers and shims on both
weldments. Check the clearance of the load
rollers as described in sections Mast Adjustments
WARNING and Carriage Adjustments in this service manual.
structure of the mast or cause incorrect function 4. Push the inner mast to engage the rods of the
of the mast which can result in serious injury to main lift cylinders. Install washer and snap ring.
personnel. Consult your lift truck dealer for more See Figure 63.
5. Install capscrews, isolators, and O-rings at the
7. Inspect the sliding surfaces for wear or damage. mounts for main lift cylinders. Tighten capscrews
Inspect the load roller contact surfaces for wear to 38 N•m (28 lbf ft). See Figure 63.
Assemble
WARNING
mast.
NOTE: The shims for the load rollers keep the mast
During assembly, shims should be reinstalled in the
same location they were in before disassembly. Check
the clearance and adjust the shims for wear or for Figure 68. Strip Bearings
changes caused by repairs. The strip bearings are
also adjusted by using shims and should also be 6. Install housing for the lowering control valve on
reinstalled in the same location they were in before bracket on outer mast. Tighten the nuts for the
disassembly. See the section Mast Adjustments in this lowering control valve housing to
service manual for the adjustment procedures. 18 N•m (13 lbf ft). Install the lowering control
NOTE: When the mast has header hoses, see section valve in the housing. Connect the hydraulic lines
Header Hose Installation and Adjustment for and fittings between the housing and the main lift
procedures to install and adjust the header hoses. cylinders. See Figure 63.
7. Install the chain sheaves at the inner mast. Be

1. Connect a crane with a capacity of at least sure to install both pins that hold the shaft for the
907 kg (2000 lb) to the center of the inner mast. chain sheave in position. See Figure 66.
See Figure 65. Fit the stub shafts through the
notches in the outer mast. Slide the inner mast 8. Connect the lift chains to the chain anchors at the
into the outer mast so the stub shafts are seen at main lift cylinder mounts. See Figure 63.
the top and bottom of the weldments. See
Figure 64. 9. Attach wires between the ends of the lift chains
and the crossmember to control the lift chains
2. Install the strip bearings and shims on the outer during mast installation.
mast. See Figure 68. Apply chassis lube to the
bearing surface. Check the clearance of the strip
bearings as described in Mast Adjustments
section in this manual.
80
Install 7. Apply grease to pivot pins and connect tilt

cylinders to mast using pivot pins. Install anchor
1. Install new bushings into mast mounts at bottom pins and capscrews to rod ends. Apply anti-seize
of outer mast. Be sure to align the hole in the compound to capscrew threads and tighten
bushing with the lube fitting hole in the bottom of 38 N•m (28 lbf ft).
the outer mast. Bushing must be flush with outer
mast surface. See Figure 60. See Figure 69 for lift trucks equipped with tilt
cylinders without optional boots
2. Apply an even coat of grease to the pivot pins See Figure 70 for lift trucks equipped with tilt
and install them into mast mounts at bottom of cylinders with optional boots
outer mast. See Figure 62.
3. Install washer and lube capscrew in hole in

bottom of outer mast. Tighten lube capscrew to
25 N•m (18 lbf ft). Install lube fitting onto lube
capscrew. Tighten lube fitting to 6 N•m (53 lbf in).
WARNING
mast.
4. Connect crane to top of mast using chains. Make

sure all mast uprights are fastened together.
Make sure chains will not damage sheaves,
tubing, or other parts of mast. Make sure crane
5. Use crane to position mast assembly onto its

lower mounts. Position mast so pivot pins seat
into hanger mounts on drive axle. Install
capscrews that hold mast pivot pins to drive axle
hangers. Tighten capscrews to 1. O-RING 7. PIVOT PIN
270 N•m (199 lbf ft). See Figure 61. 2. SPACER 8. GREASE FITTING
4. NUT 10. CAPSCREW
6. Install new bushings into the tilt anchors on the 5. WASHER 11. ROD END
outer mast. Be sure tilt bushing split is installed at 6. CAPSCREW
the correct angle as shown in Figure 60.
Figure 69. Mast Mounting, Tilt Cylinder Without
Boot
WARNING
Use a pry bar, NOT your fingers, to align the tilt
cylinder clevises with the outer mast. The cylinder
or mast can shift and cause serious injury.

81
NOTE: Before checking for mast side kicking, the

mast must be fully assembled to include the carriage,
forks, load backrest and any attachments.
11. Raise the mast, without a load to its full height
and check for side kicking. Mast side kicking is
when the mast moves either to the right or left as
it is being raised to its full height. If the mast is
side kicking, see the Mast Adjustments section in
this manual for procedures to correct mast side
kicking.
NOTE: Load rollers and sheaves have sealed

bearings and do not need additional lubrication.
along full length of channels as shown in
indicated.

6. CLAMP 12. NUT

(A976)
8. Connect hydraulic lines to lowering control valve. A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
9. Install the carriage as described in the section
1. LUBRICATE STRIP BEARING SURFACES
Carriages Repair, Two-Stage LFL Mast. 2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
WARNING Figure 71. Lubricate Mast

hydraulic lines or components under pressure. Header Hose Installation and Adjustment
Remove
the skin.
Read and follow the Safety Procedures When Working
10. Check tilt cylinder adjustments as described in Near Mast as well as all WARNINGS and CAUTIONS
Cylinder Repair (Mast S/N F507, F508, F562, before removing any header hoses.
for leaks and correct operation. Check lift chains NOTE: Access to some of the fittings can be difficult.
as described in Lift Chains Adjustment section in If necessary, operate the hydraulic system to move
this manual. mast weldments or the carriage. Make sure the
hydraulic system does not have pressure as described
in Step 1.
82
1. To replace any header hoses, fully lower the

carriage. Make sure the hydraulic system does
not have hydraulic pressure. Hold the control for WARNING
each function in the forward position for Before working on or near the mast, see Safety
approximately five seconds to release the Procedures When Working Near Mast in this
pressure. Make sure the hydraulic pump does not manual.
operate. Move the key or keyless switch, if
equipped, to the OFF position. 1. Some lift trucks are equipped with auxiliary
hydraulic functions that are fastened to the
2. Disconnect the battery and put a tag or lock on carriage. Examples of attachments that use these
the battery connector. auxiliary functions are sideshift carriages, roll
clamps, and fork positioners. These auxiliary
3. Disconnect the header hoses and install caps on functions require header hoses for their operation.
ends to prevent dirt and debris from entering the NOTE: The procedures in this section are for the four
hydraulic system. function option. Lift trucks equipped with three-function
option will only have hoses A and B. See Figure 72.
Installation
NOTE: The carriage height must be correct before the
header hose tension can be measured. See Lift
WARNING Chains Adjustment for carriage adjustment
Always wear the proper protective equipment procedures.
Mark each hose with a single letter: A, B, C, and
D.
possible. All four hoses are the same length. Before
installing new header hoses, add tension marks
to each hose. See Figure 73.
WARNING
the skin.
83

B. HEADER HOSE E. REAR VIEW
C. HEADER HOSE F. TOP VIEW
Figure 72. Header Hose Alignment for Two-Stage LFL Mast
2. Clamp one end of the hose in a vise. DO NOT 3. Put reference marks on the header hoses.
clamp on the threads. Pull on the other end until Starting at either end of each of the hoses, place
hose is straight. DO NOT apply enough force to a mark at 100 ±10 mm (4.0 ±0.40 in.). This is
stretch the hose. dimension M1. See Figure 73.
NOTE: The header hose tension specification is 2.0% 4. From dimension M1, place another mark at
±1%. Install hose caps to marked end (truck end) of 500 ±2.0 mm (20.0 ±0.08 in.). This is dimension
hoses. M2. See Figure 73.
84
5. Attach three-function hoses (A and B) and four- a. Measure the distance between marks M1 and
function hoses (C and D) to turnaround brackets M2. See Figure 73.
on carriage. See Figure 56.
b. The header hose specification between marks
6. Route hoses over the turnaround brackets and M1 and M2 is 510 ±5 mm (2.0% ±1.0%).
secure the end of the hose to the turnaround
bracket with hose clamps and worm screw c. If tension mark measurement is
clamps. Worm screw clamps go through the hose 505 mm (20.0 in.) or lower, adjust plate
clamps and around the turnaround bracket to attached to bracket on mid-outer
protect the header hoses. See Figure 73. crossmember, downward by one hole and re-
measure tension mark. If tension mark is still
7. Route hoses up over hose sheaves and secure 505 mm (20.0 in.) or lower, replace hose and
hoses to hose sheaves with spacers. re-set plate to the upper position.
8. Clamp marked end of hoses to brackets on mid- d. If tension mark is 515 mm (20.3 in.) or higher,
outer crossmember. See Figure 73. adjust carriage to maximum height allowed.
See Carriage Adjustments section for
9. With header hoses installed on mast and the procedures.
carriage correctly adjusted (see Carriage
Adjustments) and the forks off the ground,
measure header hose tension on mast as follows:
85
86
A. DIMENSION = 100 ±10 mm (4.0 ±0.40 in.) B. DIMENSION = 500 ±2.0 mm (20.0 ±0.08 in.)
1. SPACER 5. TURNAROUND BRACKET (THREE-FUNCTION)

2. HOSE SHEAVE 6. TURNAROUND BRACKET (FOUR-FUNCTION)
3. MID-OUTER CROSSMEMBER 7. HOSE CLAMP
4. BRACKET 8. WORM SCREW CLAMP
Distance Installed Hose Tension
505 mm (19.8 in.) 1%
510 mm (20.1 in.) 2%
515 mm (20.3 in.) 3%
Adjustment 3. Loosen hardware on bracket on mid-outer

crossmember for the three and/or four function
NOTE: Tire size variations and adjusting of the lift hoses needing adjustment. Lower bracket and
chains may require adjustment of header hose tighten nut to 18 N•m (159 lbf in). See Figure 74.
tension. Lift chain adjustment for tire wear will reduce
header hose tension. 4. Release chain, remove block, and lower the
1. To increase header hose tension, raise carriage carriage.
at least 100 mm (4.0 in.).
2. Place a block under lower carriage bar and lower

carriage onto block to relieve hose tension. Chain
carriage to inner mast. See Safety Procedures
When Working Near Mast in this manual.
87
Carriages Repair, Three-Stage FFL Mast 4000 YRM 1669
5. With no load on the forks, check the header hose

adjustment by operating the mast through the full
lift cycle two times. When properly adjusted, the
hoses will not be so tight that they compress
when they pass over the hose sheaves nor will
they be so loose that they touch the load backrest
or any crossmember that is next to a sheave. If
necessary, repeat adjustment procedure until the
hoses are properly adjusted.
2. BRACKET
3. MOUNTING HARDWARE
4. HEADER HOSE B
5. HEADER HOSE A
6. HEADER HOSE D
7. HEADER HOSE C
8. PLATE
Figure 74. Header Hose Adjustment, Two-Stage

LFL Mast
Carriages Repair, Three-Stage FFL Mast

STANDARD CARRIAGE 4. Remove chain pin from each chain anchor at the
carriage. Disconnect lift chains from the carriage.
Remove Use wire to connect the ends of lift chains to a
1. Remove forks. See Fork Replacement for part of the mast. Make sure chains can move
procedures. freely when inner mast is raised. See Figure 76.

3. Connect a lifting device to the carriage. Lift

carriage so that lift chains become loose.
WARNING
When disconnecting the lift chains, keep control of
the ends. Use wire to temporarily connect the ends
of the lift chains to the mast. This procedure will
prevent the lift chains from falling and causing an
injury or damage.
88
4000 YRM 1669 Carriages Repair, Three-Stage FFL Mast
1. CARRIAGE 6. CHAIN PIN

2. SNAP RING 7. COTTER PIN
1. CAPSCREW 5. CHAIN ANCHOR
2. WASHER
3. NUT
4. CARRIAGE Figure 76. Standard Carriage Components
5. LOAD BACKREST
Figure 75. Load Backrest, Remove

WARNING
To help prevent possible injury, make sure the
carriage is stable and will not fall over when the
inner mast is raised above the load rollers of the
carriage.
5. Use lift cylinders to raise intermediate mast. If

hydraulic system cannot be used, disconnect lift
cylinders from intermediate mast. See the section
F563) 2100YRM1668.

681 kg (1501 lb), to top of the inner mast.
Carefully raise inner mast until it is above the load
rollers of the carriage. Install safety chains to
secure mast in its extended position and
disconnect the crane. See Safety Procedures
When Working Near Mast.
7. Move lift truck away from the carriage.

Completely lower inner mast so it cannot move.
89
Clean and Inspect 4. Clean and inspect the chain anchors and chain
anchor pins. See Figure 76. Check chain anchors
NOTE: Shims are installed on the bottom and middle and anchor pins for wear and serviceability.
load rollers only. Discard worn or unserviceable chain anchors and
1. If load rollers must be replaced (see Figure 76), chain anchor pins. Discard used cotter pins.
make a note of the location and number of shims.
Install shims, load rollers, and snap rings. See Install
Carriage Adjustments section for correct
1. Move lift truck towards the carriage until inner
adjustment of load rollers.
mast is aligned with carriage rollers. If inner mast
has been raised and secured using a crane and
safety chains, connect the crane, raise inner
WARNING mast, and remove safety chains. Carefully lower
Compressed air can move particles so that they inner mast until it engages all of the load rollers.
cause injury to the user or to other personnel. Disconnect the crane, if attached, and reconnect
Make sure that the path of the compressed air is lift cylinders. See Cylinder Repair (Mast S/N
away from all personnel. Wear protective goggles F507, F508, F562, F563) 2100YRM1668.
2. Check the clearance of the load rollers. See
Carriage Adjustments section for procedures.
WARNING
Cleaning solvents can be flammable and toxic, and NOTE: Use new cotter pins each time the chain pins
can cause skin irritation. When using cleaning are removed.
solvents, always follow the recommendations of 3. Connect lift chains to chain anchors at the
the manufacturer. carriage. Install cotter pins in chain pins. Adjust lift
chains as described in Lift Chains Adjustment.
CAUTION 4. Install load backrest on carriage. Tighten

DO NOT use cleaning solvent, compressed air, or capscrews to 195 N•m (144 lbf ft).
steam to clean lift chain sheaves or load rollers.
The bearings in the lift chain sheaves and load 5. Install forks. See section Fork Replacement for
rollers are sealed and lubricated. Cleaning solvent, procedures.
compressed air, and steam can damage the load
roller bearings. INTEGRAL SIDESHIFT CARRIAGE, LIFT
TRUCKS MANUFACTURED PRIOR TO
2. Clean any oil, grease, dirt, and other debris from DECEMBER, 2016
carriage frame. Use a cleaning solvent and
compressed air to dry. Remove
1. Lower carriage completely. Remove forks. See
Fork Replacement for removal procedures.
WARNING
Improper welding procedures can damage the 2. Remove four capscrews, washers, nuts, and load
structure of the mast or cause incorrect function backrest from carriage. See Figure 75.
of the mast. Consult a Resident Service
Engineering through the Contact Management
System before welding on the mast. WARNING
3. If carriage bars have any protruding welds or the pressure in the hydraulic system. Serious
damaged notches, repair by grinding, filing, or injury can occur if pressure is not relieved from
welding. hydraulic system prior to disconnecting hydraulic
hoses.
90

4. Disconnect hydraulic lines from sideshift cylinder.
Put caps and plugs on open lines and cylinder
WARNING ports.
capscrews securing the hooks. See Figure 77.
6. Remove sideshift cylinder from carriage. See
possible.
The hydraulic oil is hot at normal operating F563) 2100YRM1668.
48 kg (106 lb) to lift outer frame away from inner
WARNING frame. Lay outer frame flat on a pallet or work
the skin.
91
1. INNER FRAME 11. LUBE FITTING

2. OUTER FRAME 12. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 13. COTTER PIN
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. LOAD ROLLER
6. LOWER HOOK 16. SHIMS
7. CAPSCREW 17. SPACER
8. WASHER 18. FORK REMOVAL NOTCH
9. CLEVIS PIN 19. CHAIN ANCHOR PIN
10. PIN
Figure 77. Integral Sideshift Carriage Component Parts
Disassemble
frame. See Clean and Inspect for procedures.
See Figure 77.
2. If damaged, remove lube fittings from outer

3. Disassemble the intergral sideshift cylinder. See

92

the inner frame. See Figure 80.

inner frame. See Figure 80.
4. Inspect the sideshift cylinder. See Cylinder

5. Inspect load rollers for wear or damage (see

Figure 77). If load rollers must be replaced, make
1. OUTER FRAME shims, load rollers and snap rings. See section
2. LIFTING HOOK Carriage Adjustments for correct adjustment.
3. LIFTING DEVICE
Figure 78. Remove Outer Frame
Clean and Inspect

1. Inspect lower mounting hooks for wear. Replace
the hooks if they are worn beyond the wear limit.
The wear limit clearance range is
0.76 mm (0.03 in.) minimum and
1.52 mm (0.06 in.) maximum. See A in Figure 79.
CAUTION

and ends are flush. If carriage bars have any A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
protruding welds or damaged notches, repair by 1.52 mm (0.06 in.) MAXIMUM
grinding, filing, or welding. B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM
for wear as follows: Figure 79. Lower Mounting Hooks Wear Limit and
Clearance Adjustment
93
A. MINIMUM THICKNESS 2.5 mm (0.1 in.).

2. CARRIAGE BARS
Assemble 2. Use a crane with a capacity of at least

1. Assemble integral sideshift cylinder. See frame. See Figure 77.
F563) 2100YRM1668 for procedures. 3. Install the lower mounting hooks using four
2. If lube fittings were removed, install new lube 150 to 180 N•m (108 to 132 lbf ft). For proper
fittings into outer frame. See Figure 77. sideshift operation, make sure there is
0.76 to 1.52 mm (0.03 to 0.06 in.) clearance
NOTE: Use a wood block or a plastic hammer to fully
between the bottom of the hooks and the outer
frame. See B in Figure 79.
seated. 4. Connect hydraulic lines, as noted during removal,
3. Apply a 1 mm (0.040 in.) layer of multipurpose to sideshift cylinder.
Install upper and lower bearings into the inner 5. Install load backrest to sideshift carriage. Tighten
frame. Bearings snap into place. See Figure 80. capscrews to 195 N•m (144 lbf ft). See Figure 75.
Install 6. Install forks. See section Fork Replacement, in

this manual, for procedures.
94
INTEGRAL SIDESHIFT CARRIAGE, LIFT

TRUCKS MANUFACTURED DECEMBER, WARNING
2016 THROUGH LATE JUNE, 2018 Always wear the proper protective equipment
This section applies to lift truck modelsERC22-35VG gloves when handling hydraulic oil. Thoroughly
(ERC045-070VG) (A968), GLC20-35VX (GC/ wash oil from exposed areas of skin as soon as
GLC40-70VX) (C910), and GP/GLP/GDP040-070VX possible. The hydraulic oil is hot at normal
(D875) equipped with an integral sideshift carriage operating temperatures. Be careful when draining
and manufactured after December, 2016. the oil.
Remove
1. Lower carriage completely. Remove forks. See WARNING
Fork Replacement for removal procedures. Never check for leaks by putting hands on
2. Remove four capscrews, washers, nuts, and load Hydraulic oil under pressure can be injected into
backrest from carriage. See Figure 75. the skin.

WARNING disconnecting to aid in connecting during installation.
Before disconnecting the hydraulic hoses, relieve 4. Disconnect hydraulic hoses from sideshift
the pressure in the hydraulic system. Serious cylinder. Put caps and plugs on open lines and
injury can occur if pressure is not relieved from cylinder ports. See Figure 81.
hoses.

95
NOTE: PARTS OF CARRIAGE OMITTED FOR CLARITY.

NOTE: CLASS III INTEGRAL SIDESHIFT CARRIAGE SHOWN. CLASS II INTEGRAL SIDESHIFT CARRIAGE
IS SIMILAR.
1. HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

2. HYDRAULIC HOSES 4. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY
Figure 81. Integral Sideshift Carriage Hydraulic Hoses
5. Remove lower mounting hooks by removing four 7. Use a crane with a capacity of at least
capscrews and washers securing the hooks. See 48 kg (106 lb) to lift outer frame away from inner
Figure 82. frame. Lay outer frame flat on a pallet or work
96

2. LUBE FITTING 11. LOAD ROLLERS
7. LOWER MOUNTING HOOK 16. CHAIN ANCHOR PIN
8. INTEGRAL SIDESHIFT CYLINDER 17. WASHER
9. UPPER BEARINGS 18. NUT
Figure 82. Integral Sideshift Component Parts
Disassemble
frame. See Clean and Inspect section for
procedures.

3. Dissemble the integral sideshift cylinder. See

97

and ends are flush. If carriage bars have any

for wear as follows:

the inner frame. See Figure 84. See Assemble
section to install new upper bearings.

inner frame. See Figure 84. See Assemble
section to install new lower bearings.
NOTE: OUTER FRAME SHOWN MAY BE DIFFER-
ENT FROM WHAT IS ON YOUR LIFT TRUCK. HOW- 3. Inspect sideshift cylinder. See Cylinder Repair
EVER, REMOVING THE OUTER FRAME FROM THE (Mast S/N F507, F508, F562, F563)
INNER FRAME IS THE SAME. 2100YRM1668 for procedures.
1. OUTER FRAME 4. Inspect load rollers for wear or damage (see

2. LIFTING HOOK Figure 82). If load rollers must be replaced, make
3. LIFTING DEVICE
Figure 83. Remove Outer Frame shims, load rollers and snap rings. See section
Carriage Adjustments for correct adjustment.
Clean and Inspect 5. Clean and inspect chain anchors and chain
anchor pins. Check chain anchors and anchor
CAUTION pins for wear and serviceability. Discard worn or
Improper welding procedures can damage the unserviceable chain anchors and chain anchor
structure of the mast or cause incorrect function pins. Discard used cotter pins. See Figure 82.
98
A. MINIMUM THICKNESS 2.5 mm (0.1 in.)

2. CARRIAGE BARS
*Bold Arrows Indicate Which Side To Apply Grease.

1. Assemble the integral sideshift cylinder. See lower carriage bar and tap bearing into place
Cylinder Repair (Mast S/N F507, F508, F562, on lower carriage bar using a rubber or brass
F563) 2100YRM1668 for procedures. hammer. See Figure 84
Install
NOTE: Use a wood block or a plastic hammer to fully See Cylinder Repair (Mast S/N F507, F508,
seat upper bearings onto inner frame. Proper lower F562, F563) 2100YRM1668 for procedures.
seated. 2. Use a crane with a capacity of at least
3. Apply a 1 mm (0.040 in.) layer of multipurpose
Install upper and lower bearings onto the inner
3. Install lower mounting hooks using four
frame.
150 to 180 N•m (108 to 132 lbf ft).
a. To install new upper bearing, align the pins on
the bottom side of bearing to notches on top
4. Connect hydraulic hoses, as noted during
carriage bar and slide into place on top
removal, to sideshift cylinder. See Figure 81.
carriage. See Figure 84.
99

6. Install forks. See Fork Replacement section for
procedures.
INTEGRAL SIDESHIFT CARRIAGE, LIFT WARNING

TRUCKS MANUFACTURED LATE JUNE, including eye protection and petroleum-resistant
2018 AND AFTER gloves when handling hydraulic oil. Thoroughly
This section applies to lift truck modelsERC22-35VG wash oil from exposed areas of skin as soon as
(ERC045-070VG) (A968), GLC20-35VX (GC/ possible. The hydraulic oil is hot at normal
GLC40-70VX) (C910), and GP/GLP/GDP040-070VX operating temperatures. Be careful when draining
(D875) equipped with an integral sideshift carriage the oil.
and manufactured after December, 2016.
Remove WARNING
1. Lower carriage completely. Remove forks. See Never check for leaks by putting hands on
Fork Replacement for removal procedures. hydraulic lines or components under pressure.
2. Remove four capscrews, washers, nuts, and load the skin.
WARNING 4. Disconnect hydraulic hoses from sideshift
Before disconnecting the hydraulic hoses, relieve cylinder. Put caps and plugs on open lines and
the pressure in the hydraulic system. Serious cylinder ports. See Figure 98.
hoses.
100
NOTE: PARTS OF CARRIAGE OMITTED FOR CLARITY.

NOTE: CLASS III INTEGRAL SIDESHIFT CARRIAGE SHOWN. CLASS II INTEGRAL SIDESHIFT CARRIAGE
IS SIMILAR.
1. HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

2. HYDRAULIC HOSES 4. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY
Figure 85. Integral Sideshift Carriage Hydraulic Hoses
5. Remove lower mounting hooks by removing four 7. Use a crane with a capacity of at least
capscrews and washers securing the hooks. See 48 kg (106 lb) to lift outer frame away from inner
Figure 86. frame. Lay outer frame flat on a pallet or work
101

2. LUBE FITTING 11. LOAD ROLLERS
7. LOWER MOUNTING HOOK 16. CHAIN ANCHOR PIN
8. INTEGRAL SIDESHIFT CYLINDER 17. WASHER
9. UPPER BEARINGS 18. NUT
Figure 86. Integral Sideshift Component Parts
Disassemble
frame. See Clean and Inspect section for
procedures.

3. Dissemble the integral sideshift cylinder. See

102

and ends are flush. If carriage bars have any

for wear as follows:

the inner frame. See Figure 88. See Assemble
section to install new upper bearings.

inner frame. See Figure 88. See Assemble
section to install new lower bearings.
NOTE: OUTER FRAME SHOWN MAY BE DIFFER-
ENT FROM WHAT IS ON YOUR LIFT TRUCK. HOW- 3. Inspect sideshift cylinder. See Cylinder Repair
EVER, REMOVING THE OUTER FRAME FROM THE (Mast S/N F507, F508, F562, F563)
INNER FRAME IS THE SAME. 2100YRM1668 for procedures.
1. OUTER FRAME 4. Inspect load rollers for wear or damage (see

2. LIFTING HOOK Figure 86). If load rollers must be replaced, make
3. LIFTING DEVICE
Figure 87. Remove Outer Frame shims, load rollers and snap rings. See section
Carriage Adjustments for correct adjustment.
Clean and Inspect 5. Clean and inspect chain anchors and chain
anchor pins. Check chain anchors and anchor
CAUTION pins for wear and serviceability. Discard worn or
Improper welding procedures can damage the unserviceable chain anchors and chain anchor
structure of the mast or cause incorrect function pins. Discard used cotter pins. See Figure 86.
103
A. MINIMUM THICKNESS 2.5 mm (0.1 in.)

2. CARRIAGE BARS
*Bold Arrows Indicate Which Side To Apply Grease.

1. Assemble the integral sideshift cylinder. See lower carriage bar and tap bearing into place
Cylinder Repair (Mast S/N F507, F508, F562, on lower carriage bar using a rubber or brass
F563) 2100YRM1668 for procedures. hammer. See Figure 88.
Install
NOTE: Use a wood block or a plastic hammer to fully See Mast 4000YRM1664 for procedures.
hook clearance requires the upper bearings be fully 2. Use a crane with a capacity of at least
seated. 48 kg (106 lb) and install outer frame onto inner
3. Apply a 1 mm (0.040 in.) layer of multipurpose
3. Install lower mounting hooks using four
Install upper and lower bearings onto the inner
frame.
150 to 180 N•m (108 to 132 lbf ft).
a. To install new upper bearing, align the pins on
4. Connect hydraulic hoses, as noted during
the bottom side of bearing to notches on top
removal, to sideshift cylinder. See Figure 85.
carriage bar and slide into place on top
carriage. See Figure 88. 5. Install load backrest to sideshift carriage. Tighten
104
6. Install forks. See Fork Replacement section for Never check for leaks by putting hands on
procedures. hydraulic lines or components under pressure.
FORK POSITIONER CARRIAGE, LIFT the skin.
TRUCKS MANUFACTURED PRIOR TO
DECEMBER, 2016
CAUTION
Remove Protect the hydraulic system from dirt and
NOTE: The fork positioner can be removed from the contaminants when servicing the hydraulic
integral sideshift carriage with the integral sideshift system.
positioner is removed with the integral sideshift
carriage on the mast. If integral sideshift carriage must CAUTION
be removed from mast first, go to Integral Sideshift DO NOT bend tube assemblies during removal.
2016 in this section. NOTE: Tag all hydraulic hoses, lines, and fittings prior
to removal to aid in installation.
procedures. 3. Disconnect and cap tube assemblies (8,
backrest from carriage. See Figure 75. 4. Remove capscrews and washers and remove
lower hooks and bracket weldments from
carriage. See Figure 90 and Figure 92.
WARNING
Before disconnecting the hydraulic hoses, relieve 5. Install lifting eye in hole (see Figure 90 ) on
the pressure in the hydraulic system. Serious integral sideshift carriage and use lifting device to
injury can occur if pressure is not relieved from lift outer frame up.
hoses.
Figure 90.
WARNING NOTE: Make note of shims used to aid in reassembly.

wash oil from exposed areas of skin as soon as 8. Remove fork positioner from outer frame.
possible.
WARNING
105

(CLOSED) 8. TUBE ASSEMBLY
HOSES
4. FORK POSITIONER
5. OUTER FRAME
106
NOTE: RIGHT OUTER FRAME BAR REMOVED FOR CLARITY.


2. SHIM 6. LOWER HOOK
4. FORK CARRIER
For procedures to repair the fork positioner cylinder, 2. Install second lockwasher and capscrew. Tighten
see Cylinder Repair (Mast S/N F507, F508, F562, both capscrews to 65 N•m (50 lbf ft). See
F563) 2100YRM1668 Figure 90.
Install 3. Connect fork positioner hydraulic hoses to fork

1. Place fork positioner cylinders onto outer frame. 21 N•m (186 lbf in). See Figure 89.
hand tighten capscrew. See Figure 90. Add shims 4. Thread fork positioner hydraulic hoses through
as follows: hose guides. See Figure 89.
NOTE: The maximum number of shims per side is 5. Install outer frame, with fork positioner, to inner
five. The maximum difference in the number of shims frame.
per side is two. The maximum gap allowed before
tightening capscrews is 0.50 mm (.020 in.). 6. Using a lifting device, position outer frame at the
a. Measure gap at opposite side and determine same height of inner frame and 150 mm (6 in.)
the number of shims required. away.

107


are in line with inner frame retainer plates. See
Figure 91.
9. Using washer and capscrew, install bracket

weldment to lower hook and hand tighten
capscrew. Install lower hook on retainer plate with
washer and capscrew and tighten capscrews to
10. Position bracket weldment over fork positioner

hydraulic hoses (see Figure 89) and adjust so
that bracket weldment makes contact with fork
positioner hoses. Tighten capscrew to

hoses to 42 N•m (31 lbf ft).
WARNING 1. RETAINER PLATE

DO NOT try to install a fork without a lifting device. 2. INNER FRAME
45 to 115 kg (99 to 254 lb). Figure 91. Inner Frame Retainer Plates
CAUTION
Remove fork latch pins (see Figure 3) if adding a
fork positioner attachment. Damage to forks and
other carriage components can occur if fork latch
pins are not removed prior to using a fork
positioner attachment.
NOTE: Before proceeding to Step 12 and Step 13,

12. Install forks to outer fork carriers. Secure inner
fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to

Figure 92. Bracket Weldment and Lower Hook

Assembly
108
Legend for Figure 92. 2. Fork positioner hoses are correctly adjusted when
1. BRACKET WELDMENT the integral sideshift carriage and do not contact
2. RETAINER PLATE mast channels under all conditions.
3. WASHER
4. LOWER HOOK
5. CAPSCREW (LOWER HOOK) 3. Move fork positioner and check to ensure fork
6. CAPSCREW (BRACKET WELDMENT) carriers clear fork positioner relief tubes through
Adjustment capscrews to 195 N•m (144 lbf ft). See Figure 75.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. LARGE HEX NUT

2. FORK POSITIONER HYDRAULIC HOSE 6. TUBE ASSEMBLY
(CLOSE) 7. RELIEF TUBE ASSEMBLY
3. MANIFOLD 8. INTEGRAL SIDESHIFT HYDRAULIC HOSES
4. SMALL HEX NUT
Figure 93. Fork Positioner Hydraulic Hose Adjustment
109
FORK POSITIONER CARRIAGE, LIFT Never check for leaks by putting hands on
TRUCKS MANUFACTURED DECEMBER, hydraulic lines or components under pressure.
2016 THROUGH LATE JUNE, 2018 the skin.
This section applies to lift truck modelsERC22-35VG
(ERC045-070VG) (A968), GLC20-35VX (GC/
GLC40-70VX) (C910), and GP/GLP/GDP040-070VX CAUTION
(D875) equipped with a fork positioner on an integral Protect the hydraulic system from dirt and
sideshift carriage and manufactured after December, contaminants when servicing the hydraulic
2016. system.
Remove
NOTE: The fork positioner can be removed from the CAUTION
integral sideshift carriage with integral sideshift DO NOT bend tube assemblies during removal.
positioner is removed with integral sideshift carriage NOTE: Tag all hydraulic hoses, lines, and fittings prior
on the mast. If integral sideshift carriage must be to removal to aid in installation.
removed from mast first, go to Integral Sideshift 3. Disconnect and cap tube assemblies (8,
Carriage, Lift Trucks Manufactured December, 2016 Figure 94) from header hoses.
Through Late June, 2018 in this section for
procedures. 4. Remove capscrews and washers and remove
1. Remove forks. See Fork Replacement section for lower hooks from retainer plates on inner frame.
procedures. See Figure 95.
2. Remove four capscrews, washers, nuts, and load 5. Install lifting eye in hole (7, Figure 95) on outer
backrest from carriage. See Figure 75. frame of integral sideshift carriage. Use a lifting
device, with a capacity of 62 kg (136 lb), to lift
outer frame with fork positioner attached. See
WARNING Figure 83.
Figure 94.
hoses. NOTE: Make note of shims used to aid in reassembly.
WARNING
Always wear the proper protective equipment 8. Remove fork positioner from outer frame.
gloves when handling hydraulic oil. Thoroughly For procedures to repair the fork positioner
wash oil from exposed areas of skin as soon as cylinder, see Cylinder Repair (Mast S/N F507,
possible. F508, F562, F563) 2100YRM1668.
WARNING
110

NOTE: CLASS III INTEGRAL SIDESHIFT CARRIAGE WITH FORK POSITIONER SHOWN. CLASS II INTE-
GRAL SIDESHIFT CARRIAGE WITH FORK POSITIONER IS SIMILAR.

HOSES 10. MANIFOLD
5. OUTER FRAME
111

4. FORK CARRIER
Disassemble and Assemble side is two. The maximum gap allowed before
tightening capscrews is 0.50 mm (.020 in.).
F563) 2100YRM1668 for procedures to disassemble a. Measure gap at opposite side and determine
and assemble fork positioner cylinder. the number of shims required.
Clean and Inspect b. Install shims on both sides of the fork

F563) 2100YRM1668 for cleaning and inspection 2. Install second lockwasher and capscrew. Tighten
procedures of fork positioner cylinder. both capscrews to 65 N•m (50 lbf ft). See
Figure 95.
Install
as follows: 4. Thread fork positioner hydraulic hoses through
112


away.


are in line with retainer plates on inner frame. See
Figure 96.

10. Tighten fork positioner hydraulic tubes to header 1. RETAINER PLATES

hoses to 42 N•m (31 lbf ft). 2. OUTER FRAME (FORK BAR)
3. INNER FRAME

CAUTION Frame
adding a fork positioner attachment. Damage to Fork Positioner Hydraulic Hose
forks and other carriage components can occur if Adjustment
fork positioner attachment. 1. To adjust the fork positioner hydraulic hoses, hold
NOTE: Before proceeding to Step 11 and Step 12, towards the load face of the carriage (towards the
adjust the fork positioner hydraulic hoses. See Fork forks). See Figure 97.
11. Install forks to outer fork carriers. See Fork
Replacement section for procedures.

113

FORK POSITIONER CARRIAGE, LIFT 2. Remove four capscrews, washers, nuts, and load
TRUCKS MANUFACTURED AFTER LATE backrest from carriage. See Figure 75.
JUNE, 2018
This section applies to lift truck modelsERC22-35VG WARNING
sideshift carriage and manufactured after December, hydraulic system prior to disconnecting hydraulic
2016. hoses.
Remove
2016 in this section for procedures.
procedures.
114

See Figure 99.
hydraulic lines or components under pressure. device, with a capacity of 62 kg (136 lb), to lift
Hydraulic oil under pressure can be injected into outer frame with fork positioner attached.
the skin.
CAUTION Figure 98.
system. 7. Remove capscrews, lockwashers, and shims

CAUTION
DO NOT bend tube assemblies during removal. For procedures to repair the fork positioner
cylinder, see Cylinder Repair (Mast S/N F507,
NOTE: Tag all hydraulic hoses, lines, and fittings prior F508, F562, F563) 2100YRM1668 .
to removal to aid in installation.
115

NOTE: CLASS III INTEGRAL SIDESHIFT CARRIAGE WITH FORK POSITIONER SHOWN. CLASS II INTE-
GRAL SIDESHIFT CARRIAGE WITH FORK POSITIONER IS SIMILAR.

HOSES 10. MANIFOLD
5. OUTER FRAME
116

4. FORK CARRIER
Disassemble and Assemble side is two. The maximum gap allowed before
tightening capscrews is 0.50 mm (.020 in.).
F563) 2100YRM1668 for procedures to disassemble a. Measure gap at opposite side and determine
and assemble fork positioner cylinder. the number of shims required.
Clean and Inspect b. Install shims on both sides of the fork

F563) 2100YRM1668 for cleaning and inspection 2. Install second lockwasher and capscrew. Tighten
procedures of fork positioner cylinder. both capscrews to 65 N•m (50 lbf ft). See
Figure 98.
Install
as follows: 4. Thread fork positioner hydraulic hoses through
117


away.


are in line with retainer plates on inner frame. See
Figure 100.

165 N•m (122 lbf ft).
10. Tighten fork positioner hydraulic tubes to header 1. RETAINER PLATES

hoses to 42 N•m (31 lbf ft). 2. OUTER FRAME (FORK BAR)
3. INNER FRAME

CAUTION Frame
adding a fork positioner attachment. Damage to Fork Positioner Hydraulic Hose
forks and other carriage components can occur if Adjustment
fork positioner attachment. 1. To adjust the fork positioner hydraulic hoses, hold
NOTE: Before proceeding to Step 11 and Step 12, towards the load face of the carriage (towards the
adjust the fork positioner hydraulic hoses. See Fork forks). See Figure 101.
11. Install forks to outer fork carriers. See Fork
Replacement section for procedures.

118
4000 YRM 1669 Three-Stage FFL Mast Repair

Three-Stage FFL Mast Repair

Remove CAUTION
WARNING damage the sheaves, tubing, or other parts of the
The mast is heavy. The mast can weigh mast.
lifting devices (hoists, cables, chains, slings, etc.) NOTE: If mast needs to be disassembled, remove the
are suitable and of adequate capacity to lift the forks and carriage. see the sections Fork Replacement
mast. and Carriages Repair, Three-Stage FFL Mast in this
service manual for procedures. If only the main lift
cylinders need to be removed for repair, the mast does
not need to be removed from the lift truck. See the
WARNING
section Cylinder Repair (Mast S/N F507, F508, F562,
Mast weldments can slide when the mast is F563) 2100YRM1668 for procedures to remove the
moved. A weldment that slides can cause serious main lift cylinders.
injury.
119
Three-Stage FFL Mast Repair 4000 YRM 1669
NOTE: The length of the lift chains must be checked

before the mast is removed. See Lift Chains
Adjustment section in this manual for procedures.
1. Fully lower all of mast weldments. Tilt mast fully
forward. Connect a crane with a capacity of at
least 907 kg (2000 lb) to the top of the mast using
chains to support the mast in an upright position
when the tilt cylinders are disconnected. See the
section Safety Procedures When Working Near
Mast in this manual.
WARNING
possible.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of the lift
pump or disconnecting any hoses.
temperatures. Be careful when draining the oil. 1. O-RING 7. PIVOT PIN
2. SPACER 8. GREASE FITTING
4. NUT 10. CAPSCREW
CAUTION 5. WASHER 11. ROD END
Protect the hydraulic system from dirt and 6. CAPSCREW
system. Figure 102. Mast Mounting, Tilt Cylinder Without
Optional Boot
2. Position a drip pan under area of hydraulic
fittings. Disconnect hydraulic line at the external
lowering control valve on the outer mast. See
Figure 107.
WARNING
injury.

tilt cylinders, remove the capscrews, washers,
anchor pins, and pivot pins at the tilt cylinder
mounts on the outer mast. See Figure 102.
120
NOTE: Allow the mast to tilt forward enough to gain

access to the mast mount capscrews.
5. Disconnect lower mast mounts from the lift truck
by removing the capscrews that hold the mast
pivot pins to the mounts on the drive axle. See
Figure 105 and Figure 106.
WARNING
mast.
6. Use the crane to lift the mast assembly from the

lift truck. Position the mast across wooden beams
on the floor with the carriage side up.
NOTE: If mast mounting bushing needs to be

replaced in Step 7, go to Step 8 for procedures.
7. Check the mast and mounting flanges for wear or
2. PIVOT PIN 8. SHIM damage by removing the mast pivot pins from the
3. ANCHOR PIN 9. SPACER outer mast. Check that the pins fit snug in the
4. ROD END 10. TILT CYLINDER outer mast. If pins can be moved up and down a
5. CAPSCREW 11. WASHER minimum of 4 mm (0.20 in.), replace bushings in
6. CLAMP 12. NUT outer mast and/or mast pivot pins as required.
See Figure 106.
Figure 103. Mast Mounting, Tilt Cylinder With
Optional Boot, Lift Truck Models ERP22-35VL 8. Remove lube fitting, lube capscrew, and washer
(ERP045-070VL (A976) from the mast mounts. See Figure 109. Use a
brass drift pin to remove mast mounting bushings
from outer mast. Discard mast mounting
bushings. See Figure 104.
Figure 104.
121

1. HANGER MOUNTS 1. MAST PIVOT PINS

122
Disassemble
CAUTION
WARNING Protect the hydraulic system from dirt and
Always wear the proper protective equipment contaminants when disconnecting hydraulic hoses
including eye protection and petroleum-resistant from the mast. If hydraulic system becomes
gloves when handling hydraulic oil. Thoroughly contaminated, damage to the hydraulic system can
wash oil from exposed areas of skin as soon as occur.
possible.
1. Disconnect free-lift chain at the crosshead. See
Figure 108.
WARNING 2. Disconnect and remove the hydraulic line from
Hydraulic oil is hot after system operation and can free-lift cylinder. Remove the brackets clamping
cause burns. DO NOT disconnect any hydraulic the free-lift cylinder. Remove the free-lift cylinder.
hoses until the oil in the system has cooled. See Figure 108.
pressure before disconnecting any hydraulic
hoses.
123
Figure 107. Main Lift Cylinder Attaching Parts
124
1. OUTER MAST 10. HOSE ASSEMBLY

2. INTERMEDIATE MAST 11. NUT
3. WASHER 12. SPACER
4. MAIN LIFT CYLINDER 13. HYDRAULIC VELOCITY FUSE
5. STRIP BEARING 14. LOWERING CONTROL VALVE
6. SHIM 15. O-RING
7. FITTING 16. SNAP RING
8. LOWERING CONTROL HOUSING 17. ISOLATOR
9. CAPSCREW
125
Figure 108. Free-Lift Cylinder Assembly and Component Parts
126
1. INNER MAST 14. RING

2. INTERMEDIATE MAST 15. CHAIN ANCHOR
3. CHAIN 16. COTTER PIN
4. HOSE ASSEMBLY 17. PIN
5. CAPSCREW 18. FREE-LIFT CYLINDER
6. CAPSCREW 19. CLAMP
7. STUBSHAFT 20. FREE-LIFT CROSSHEAD
8. FITTING 21. ROLL PIN
9. LOWERING CONTROL VALVE HOUSING 22. CHAIN SHEAVE
10. HOSE SHEAVE 23. BEARING
11. BRACKET WELDMENT 24. PLATE
12. CHAIN ANCHOR RESTRAINT 25. WASHER
13. NUT
3. Disconnect main lift chains from the chain

4. Remove strip bearings at the top of the
anchors near the top of the main lift cylinders.
intermediate mast. Remove load rollers at the
See Figure 109. Disconnect the other end of the
bottom of the inner mast. Remove load rollers at
main lift chains at the bottom of the inner mast.
the top of the intermediate mast. Make a note of
Push the inner mast toward the bottom of the
each shim arrangement and load roller location.
mast assembly until the bottom load rollers can
The shim arrangements will be the same during
be seen. See Figure 110.
assembly. See Figure 110 and Figure 111.
WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
127
Figure 109. Outer Mast Assembly
128
1. OUTER MAST 11. CHAIN ANCHOR RESTRAINT

2. STUBSHAFT 12. CAPSCREW
3. LOAD ROLLER 13. INTERMEDIATE MAST
4. SNAP RING 14. LIFT CHAIN
5. SHIM 15. WEAR STRIP
6. COTTER PIN 16. O-RING
7. PIN 17. LUBE CAPSCREW
8. CHAIN ANCHOR 18. LUBE FITTING
9. RING 19. WASHER
10. NUT
129
Figure 110. Inner Mast Assembly
130
1. INNER MAST 7. PIN

2. STUBSHAFT 8. COTTER PIN
3. SNAP RING 9. RING
5. SHIM 11. LIFT CHAIN
6. CHAIN ANCHOR
131
1. INTERMEDIATE MAST 6. CHAIN SHEAVE

2. STUBSHAFT 7. BEARING
3. LOAD ROLLER 8. LIFT CHAIN
4. SNAP RING 9. STRIP BEARING
5. SHIM 10. SPACER
Figure 111. Intermediate Mast Assembly
132
5. Slide intermediate mast halfway out of the top of

WARNING the outer mast. Connect a crane with a capacity
The mast is heavy. The mast can weigh of at least 907 kg (2000 lb) to the center of the
approximately 907 kg (2000 lb). Make sure all intermediate mast. See Figure 112. Slide the
lifting devices (hoists, cables, chains, slings, etc.) intermediate mast out of the outer mast until the
are suitable and of adequate capacity to lift the stub shafts are in the notches of the outer mast.
mast. Remove the intermediate mast from the outer
mast.
1. Slide inner mast halfway out of the top of the
intermediate mast. Connect a crane with a 6. Disassemble chain sheaves as necessary for
capacity of at least 907 kg (2000 lb) to the center repair and cleaning. See Figure 108 and
of the inner mast. See Figure 112. Slide the inner Figure 111. Remove hydraulic lines and fittings
mast out of the intermediate mast until the stub from mast weldments as necessary.
shafts are in the notches of the intermediate
mast. Remove the inner mast from the
intermediate mast.
WARNING
or installation with enough force to cause an
injury. Always use the correct snap ring pliers, and
wear eye and face protection during removal or
installation.
2. Remove capscrews and isolator near the top of

each main lift cylinder. Remove snap rings and
washer from top of each main lift cylinder.
Disconnect main lift cylinder at the mounts. See
Figure 112. Connecting a Crane
Figure 107.
3. Push intermediate mast to disengage the main lift Clean and Inspect
cylinders. Remove the main lift cylinders.
CAUTION
4. Slide intermediate mast from the bottom of the
outer mast 30 cm (12 in.). Remove the strip DO NOT use steam or high-pressure water to clean
bearings at the top of the outer mast. Remove the the load rollers or the lift chains. Steam and high-
snap rings and load rollers from both weldments. pressure water can remove the lubrication from
Make a note of each shim arrangement and load the bearings in the load rollers. Water in the
roller location. The shim arrangements will be bearings of the sheaves and the link pins of chains
approximately the same during assembly. See can also shorten the service life of these parts.
1. Inspect chain sheaves and load rollers for wear or
damage. See Figure 109, Figure 110, and
Figure 111. DO NOT use steam to clean lift chain
WARNING sheaves or load rollers. The bearings in the
The mast is heavy. The mast can weigh sheaves and load rollers are sealed and
approximately 907 kg (2000 lb). Make sure all lubricated.
mast.
133
WARNING WARNING
Cleaning solvents may be flammable and toxic and Never replace only the worn section of a chain.
can cause severe skin irritation. When using Replace the complete chain. Never replace only
commercial cleaning solvents, always comply with one chain of a chain pair. Replace both chains.
solvent manufacturer's recommended safety Damage to the lift truck and serious injury can
precautions. occur if lift chains are not replaced correctly.
NOTE: The chains must be inspected in the area of

WARNING chain that passes over the chain sheave during the
wear.
Make sure that the path of the compressed air is 3. Inspect the lift chains for wear and damage. A lift
away from all personnel. Wear protective goggles chain becomes longer when it is worn. If a chain
or a face shield to prevent injury to the eyes. is 3% longer than a new lift chain, the lift chain
must be replaced.
2. Clean the lift chains by soaking in solvent for 30
chains up and remove solvent using compressed
air.
134
12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20. in.) 523.3 mm (20.6 in.)


are worn or damaged.
WARNING
your skin to steam.
135
6. Clean mast weldments with steam or solvent.
WARNING
of the mast which can result in serious injury to
personnel. Consult your lift truck dealer for more
7. Inspect sliding surfaces for wear or damage.

Inspect load roller contact surfaces for wear or
damage. Inspect all welds for cracks.
Assemble
NOTE: Shims for the load rollers keep the weldments Figure 114. Strip Bearings
parallel and provide correct clearance. During
assembly, shims should be reinstalled in the same 3. Install the load rollers and the shims on the outer
location they were in before disassembly. Check the mast and at the bottom of the intermediate mast.
clearance and adjust the shims for wear or for Before doing Step 4, adjust the intermediate mast
changes caused by repairs. The strip bearings are and check the clearance of the load rollers as
also adjusted by using shims. Shims for strip bears described in Mast Adjustments in this manual.
should also be reinstalled in the same location they
were in before disassembly. See Mast Adjustments in NOTE: The clearance check and adjustment in Step 4
this manual for the adjustment procedures. is only an initial setup. The final check and adjustment
is done after the mast is installed on the lift truck.
1. Put the outer mast on the floor with the carriage
side up. Connect a crane with a capacity of at 4. Install the main lift cylinders. Push the
least 907 kg (2000 lb) to the center of the intermediate mast to engage the main lift
intermediate mast. Fit the lower stub shafts of the cylinders. Check the clearance at the top of the
intermediate mast into the notches in the top of main lift cylinder mounts. Add or remove washers
the outer mast. Slide the intermediate mast into at the top of the cylinder rods in the same location
the outer mast so the stub shafts are seen at the they were in before disassembly. Install the snap
top and bottom of both weldments. ring and washer at the top of the main lift
cylinders. See Figure 107.
NOTE: Load roller must be in place before strip
bearings can be shimmed. 5. Install the housing for the lowering control valve
on the outer mast. Tighten the nuts for the
2. Install strip bearings and shims on the channels lowering control valve to 18 N•m (13 lbf ft). Install
of the outer mast. See Figure 114 Apply chassis the lowering control valve in the housing. Connect
lube to the bearing surfaces. Check the clearance the hydraulic lines and fittings between the
of the strip bearings as described in Mast housing and the main lift cylinders. See
Adjustments in this manual. Figure 107.
6. Install chain sheaves at the intermediate mast.

See Figure 111.
7. Install capscrews and isolators at the mount for

main lift cylinders. Tighten capscrews to
136
8. Connect a crane with a capacity of at least 3. Install washer and lube capscrew in hole in
907 kg (2000 lb) to the center of the inner mast. bottom of outer mast. Tighten lube capscrew to
See Figure 112. Slide the inner mast into the 25 N•m (18 lbf ft). Install lube fitting onto lube
intermediate mast so the stub shafts are seen at capscrew. Tighten lube fitting to 6 N•m (53 lbf in).
the top and bottom of both. See Figure 104 or Figure 109.

Molybdenum Disulfide for normal operations. WARNING
NOTE: The load rollers must be in place before strip The mast is heavy. The mast can weigh
bearings can be shimmed. approximately 907 kg (2000 lb). Make sure all
9. Install strip bearings and shims on the channels
of the intermediate mast. See Figure 111 and
mast.
Figure 114. Apply grease to the bearing surfaces.
Install the load rollers and the shims on the 4. Connect crane to top of mast using chains. Make
intermediate and inner masts. Before doing the sure all mast uprights are fastened together.
next step, adjust the inner mast as described in Make sure chains will not damage sheaves,
Mast Adjustments in this manual. tubing, or other parts of mast. Make sure crane
10. Connect the main lift chains to the chain anchors
at the main lift cylinder mounts. Put the lift chains 5. Use crane to position mast assembly onto its
over the chain sheaves and connect them to the lower mounts. Position mast so pivot pins seat
anchors at the bottom of the inner mast. into hanger mounts on drive axle. Install
11. Install the free-lift cylinder in the mounts on the hangers. Tighten capscrews to
inner mast. Install the brackets for the cylinder 270 N•m (199 lbf ft). See Figure 105.
and tighten the nuts to 53 N•m (39 lbf ft). The nuts
are installed on the bracket side of the free-lift 6. Install new tilt rod bushings into the tilt anchors on
cylinder. See Figure 108. the outer mast. Be sure tilt bushing split is
installed at the correct angle as shown in
12. Install the chain sheave for the free-lift cylinder. Figure 104.
Tighten the capscrew for the chain sheave to
66 N•m (49 lbf ft). Install the hydraulic hose and
tubing for the free-lift cylinder.
WARNING
13. Connect free-lift chains to the chain anchors at Use a pry bar, NOT your fingers, to align the tilt
the crossmember. Attach a wire between the end cylinder clevises with the outer mast. The cylinder
of the lift chain and the bottom of the mast to or mast can shift and cause serious injury.
control the lift chain during mast installation. See
Figure 108.
1. Install new bushings into mast mounts at bottom
pins and capscrews to rod ends. Apply anti-seize
of outer mast. Be sure to align the hole in the
compound to capscrew threads and tighten
bushing with the lube fitting hole in the bottom of
38 N•m (28 lbf ft).
cylinders without optional boot.
install them into mounts at bottom of outer mast. cylinders with optional boot.
See Figure 106.
137

6. CAPSCREW
Figure 115. Mast Mounting, Tilt Cylinder Without Optional Boot, Lift Truck Models ERP22-35VL
Optional Boot (ERP045-070VL (A976)
8. Connect hydraulic line to lowering control valve.

See Figure 107.
9. Install carriage as described in Carriages Repair,

Three-Stage FFL Mast section in this manual.
WARNING
the skin.
10. Check tilt cylinder adjustment as described in

as described in Lift Chains Adjustment.
138
NOTE: Before checking for mast side kicking and NOTE: Access to some of the fittings can be difficult.
adjusting the chain anchors on the main lift cylinders, If necessary, operate the hydraulic system to move
the mast must be fully assembled to include the mast weldments or the carriage. Make sure the
carriage, forks, load backrest and any attachments if hydraulic system does not have pressure as described
the lift truck is equipped with one. in Step 1.
11. Adjust chain anchors on the main lift cylinders 1. To replace any header hoses, fully lower the
until the tops of the inner and outer mast are at carriage. Make sure the hydraulic system does
the same level within ±1.5 mm (0.06 in.). See not have hydraulic pressure. Hold the control for
Figure 109. each function in the forward position for
approximately five seconds to release the
12. Raise mast, without a load to its full height and pressure. Make sure the hydraulic pump does not
check for side kicking. Mast side kicking is when operate. Move the key or keyless switch, if
the mast moves either to the right or left as it is equipped, to the OFF position.
being raised to its full height. If the mast is side
kicking, see the Mast Adjustments section in this 2. Disconnect the battery and put a tag or lock on
manual for procedures to correct mast side the battery connector.
kicking.
3. Disconnect the header hoses and install caps on
NOTE: The load rollers and sheaves have sealed ends to prevent dirt and debris from entering the
bearings and do not need additional lubrication. hydraulic system.
along full length of channels as shown in Installation
indicated.
WARNING
possible.
the skin.
WARNING
A. UPPER LOAD ROLLERS section.
Some lift trucks are equipped with auxiliary hydraulic
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES functions that are fastened to the carriage. Examples
3. LOAD ROLLER of attachments that use these auxiliary functions are
sideshift carriages, roll clamps, and fork positioners.
Figure 117. Lubricate Mast These auxiliary functions require header hoses for
their operation.
Header Hose Installation and Adjustment
NOTE: This procedure is for the four function option.
Remove The three function option will have hoses A and B
Read and follow the Safety Procedures When Working only. See Figure 118.
Near Mast as well as all WARNINGS and CAUTIONS
before removing and header hoses.
139
NOTE: The carriage height must be correct before the 2. Clamp one end of the hose in a vise. DO NOT
header hose tension can be measured. See Carriage clamp on the threads. Pull on the other end until
Adjustments section in this manual for the carriage hose is straight. DO NOT apply enough force to
adjustment procedure. stretch the hose.
1. Before installing new header hoses, add tension
marks to each hose. See Figure 119 and
Figure 120.
140
Figure 118. Header Hose Alignment for Three-Stage FFL Mast (Sheet 1 of 2)
141

B. HEADER HOSE E. REAR VIEW (DRIVER'S VIEW)
C. HEADER HOSE F. LEFT SIDE VIEW
NOTE: The header hose tension specification is 2.0%

±1.0%. Install hose caps to marked end (truck end) of
hoses.
3. Put reference marks on each free-lift header
hoses. Starting at either end of hose, place a
mark at 400 ±10 mm (16.0 ±0.40 in.). This is
dimension FL1. See Figure 119.
4. From dimension FL1, place another mark at

500 ±2.0 mm (20.0 ±0.08 in.). This is dimension
FL2. See Figure 119.
142
A. DIMENSION = 400 ±10 mm (16.0 ±0.40 in.) A. DIMENSION = 100 ±10 mm (4.0 ±0.40 in.)
B. DIMENSION = 500 ±2.0 mm (20.0 ±0.08 in.) B. DIMENSION = 500 ±2.0 mm (20.0 ±0.08 in.)
INSTALL LENGTH HOSE TENSION INSTALL LENGTH HOSE TENSION

(FL2) (M2)
505 mm (19.8 in.) 1% 505 mm (19.8 in.) 1%
510 mm (20.1 in.) 2% 510 mm (20.1 in.) 2%
515 mm (20.3 in.) 3% 515 mm (20.3 in.) 3%
Figure 119. Free-Lift Header Hose Reference Marks Figure 120. Main Lift Header Hose Reference
Marks
5. Put reference marks on main lift header hoses.
Starting at either end of the hose, place a mark at 7. Route free-lift hoses through the crosshead and
100 ±10 mm (4.0 ±0.40 in.). This is dimension attach them to the tube assemblies. See
M1. See Figure 120. Figure 121.
6. From dimension M1, place another mark at

M2. See Figure 120.
143
A. FREE-LIFT HEADER HOSE A

B. FREE-LIFT HEADER HOSE B
C. FREE-LIFT HEADER HOSE C
D. FREE-LIFT HEADER HOSED
1. CROSSHEAD
2. TUBE ASSEMBLY
8. For three function main lift hoses (hoses A and

B), attach hoses to free-lift tube assemblies.
Route hoses through turnaround bracket and
secure hoses to turnaround bracket and
turnaround with spacer. See Figure 122.
9. Route three function main lift hoses up over hose

sheaves and secure hoses to hose sheaves with
spacer. Attach marked end of hoses to bracket on
mid-outer crossmember. See Figure 122.
10. Attach four function main lift hoses (hoses C and

D), to free-lift tube assemblies and route hoses
through turnaround bracket. See Figure 123.
Figure 121. Free-Lift Header Hose Installation
144
A. THREE-FUNCTION HEADER HOSE A B. THREE-FUNCTION HEADER HOSE B
1. FREE-LIFT HOSE TUBE 4. HOSE SHEAVE

2. SPACER 5. MID-OUTER CROSSMEMBER
3. TURNAROUND BRACKET 6. BRACKET (LOWER)
Figure 122. Three-Function Header Hose Installation
145
A. FOUR-FUNCTION HEADER HOSE C B. FOUR-FUNCTION HEADER HOSE D
1. FREE-LIFT HOSE TUBE 4. CHAIN SHEAVE

2. TURNAROUND BRACKET 5. MID-OUTER CROSSMEMBER
3. HOSE SHEAVE 6. BRACKET (LOWER)
Figure 123. Four-Function Header Hose Installation
11. Route four function hoses up and over hose c. If crosshead can not be moved, or if after
sheaves. Attached marked end of hoses to moving crosshead plate two holes in either
bracket (either upper or lower bracket) on mid- direction, header hose tension is still not
outer crossmember. See Figure 123. correct, replace the hose and re-set crosshead
plate to starting position and do Step a and
NOTE: The header hose tension specification Step b again with new hose.
between marks is 510 ±5 mm (2.0 ±1.0%).
NOTE: The header hose tension specification
Adjustments), and the forks off the ground, 13. With header hoses installed on mast and the
measure the distance between marks FL1 and carriage correctly adjusted (see Carriage
FL2 as follows: Adjustments), and the forks off the ground,
measure the distance between marks M1 and M2
a. If tension mark measurement is less than as follows:
505 mm (20.0 in.), raise crosshead plate one
hole and take measurement again to insure it
is within specifications. See Figure 124.
b. If tension mark measurement is more than

515 mm (20.3 in.), lower crosshead plate one
146
a. If tension mark measurement is less than

505 mm (20.0 in.), lower the upper bracket one
is within specifications. If tension mark
measurement is still less than
505 mm (20.0 in.), the hose has been
permanently stretched. Replace hose and re-
set upper bracket to original position and
measure again with new hose. See Figure 125.

515 mm (20.3 in.), raise the upper bracket one
hole and take the measurement again to insure
it is within specifications. If the hose has been
permanently over stretched, replace hose with
a new hose. See Figure 125.
2. LOWER BRACKET
3. UPPER BRACKET
4. CAPSCREW AND NUT
Figure 125. Main Lift Header Hose Adjustment
14. Raise and lower mast two to three times to check

for proper routing of hoses. Hoses should
smoothly go over the hose sheaves and not rub
against crossmembers or the load backrest.
1. CAPSCREW 15. Tilt the mast two to three times and check that the
2. CROSSHEAD
3. HEADER HOSE ROLLER ASSEMBLY hoses routed between truck cowl and mast move
4. CROSSHEAD PLATE freely during both forward and backward tilt.
5. HEADER HOSES
Adjustment
Figure 124. Free-Lift Header Hose Adjustment
NOTE: Tire size variations and adjusting of the lift
chains may require adjustment of free-lift and main lift
header hose tension. Lift chain adjustment for tire
wear will reduce header hose tension.
1. To adjust the free-lift header hoses, perform the

following:
a. Raise carriage at least 100 mm (4.0 in.)
147
b. Place blocks under lower carriage bar and

lower carriage onto blocks to relieve hose CAUTION
tension. Chain carriage to inner mast. See
in this manual.
mast.
c. Loosen six (three on each side) capscrews on
crosshead plate. Remove middle capscrew. NOTE: If mast needs to be disassembled, remove
See Figure 124. forks and carriage. See the sections Fork
Replacement and Carriages Repair, Three-Stage FFL
d. Move free-lift header hose roller assembly up
Mast in this service manual for procedures. If only the
to increase hose tension, and down to
main lift cylinders need to be removed for repair, the
decrease hose tension. See Figure 124.
mast does not need to be removed from the lift truck.
2. To adjust main lift header hoses, perform the See Cylinder Repair (Mast S/N F507, F508, F562,
following: F563) 2100YRM1668 for procedures to remove the
main lift cylinders.
a. Raise inner mast and place a block under inner NOTE: The length of the lift chains must be checked
mast. before the mast is removed. See Lift Chains
Adjustment section in this manual for procedures.
b. Chain inner mast weldment to outer or
intermediate mast weldment. See Safety 1. Fully lower all mast weldments. Tilt mast fully
Procedures When Working Near Mast in this forward. Connect a crane with a capacity of at
manual. least 907 kg (2000 lb) to top of the mast using
chains to support the mast in an upright position
c. Lower inner mast onto block. when the tilt cylinders are disconnected. See the
section Safety Procedures When Working Near
d. Loosen upper bracket above mid-outer Mast in this manual.
crossmember and then lower upper bracket
until correct hose tension is achieved. Tighten
nut to 18 N•m (159 lbf in). See Figure 125. WARNING
MAST WITH SERIAL NUMBER F563 including eye protection and petroleum-resistant
Remove wash oil from exposed areas of skin as soon as
possible.
WARNING Completely lower forks to relieve hydraulic
The mast is heavy. The mast can weigh pressure before disassembling any part of the lift
approximately 907 kg (2000 lb). Make sure all pump or disconnecting any hoses.
mast.
CAUTION
WARNING Protect the hydraulic system from dirt and
Mast weldments can slide when the mast is contaminants when servicing the hydraulic
moved. A weldment that slides can cause serious system.
injury.
2. Position a drip pan under the area of the hydraulic
fittings. Disconnect the hydraulic line at the
external lowering control valve on the outer mast.
See Figure 131.
148
WARNING
injury.

tilt cylinders, remove the capscrews, washers,
anchor pins, and pivot pins at the tilt cylinder
mounts on the outer mast. See Figure 126.

6. CLAMP 12. NUT

Optional Boot, Lift Truck Models ERP22-35VL
(ERP045-070VL (A976)

Figure 128.
1. O-RING 7. PIVOT PIN
2. SPACER 8. GREASE FITTING NOTE: Allow the mast to tilt forward enough to gain
3. SHIMS 9. ANCHOR PIN access to the mast mount capscrews.
4. NUT 10. CAPSCREW
5. WASHER 11. ROD END 5. Disconnect the lower mast mounts from the lift
6. CAPSCREW truck by removing the capscrews that hold the
mast pivot pins to the mounts on the drive axle.
Figure 126. Mast Mounting, Tilt Cylinder Without See Figure 129 and Figure 130.
Optional Boot
WARNING
mast.
149
6. Use the crane to lift the mast assembly from the mm (0.20 in.), replace bushings in outer mast
lift truck. Position the mast across wooden beams and/or mast pivot pins as required. See
on the floor with the carriage side up. Figure 130.
NOTE: If mast mounting bushing need to be replaced 8. Remove lube fitting, lube capscrew, and washer
in Step 7 go to Step 8 for procedures. from the mast mounts. See Figure 133. Use a
brass drift pin to remove mast mounting bushings
7. Check mast and mounting flanges for wear or
from outer mast. Discard mast mounting
damage by removing mast pivot pins from outer
bushings. See Figure 128.
mast. Check that pins fit snug in outer mast. If
pins can be moved up and down a minimum of 4

150
Disassemble
WARNING
possible.
WARNING
Hydraulic oil is hot after system operation and can
1. HANGER MOUNTS pressure before disconnecting any hydraulic
2. TRACTION MOTOR hoses.
3. DRIVE AXLE
Figure 129. Mast Mounts, Drive Axle

CAUTION
contaminants when disconnecting hydraulic hoses
contaminated, damage to the hydraulic system can
occur.
1. Disconnect free-lift chain at crosshead. See

Figure 132.
2. Disconnect and remove hydraulic line from free-

lift cylinder. Remove the brackets clamping the
free-lift cylinder. Remove the free-lift cylinder. See
Figure 132.
1. MAST PIVOT PINS

2. BUSHING
3. OUTER MAST
Figure 130. Mast Pivot Pins
151
Figure 131. Main Lift Cylinder Attaching Parts
152
1. OUTER MAST 10. HOSE ASSEMBLY

2. INTERMEDIATE MAST 11. NUT
3. WASHER 12. SPACER
4. MAIN LIFT CYLINDER 13. HYDRAULIC VELOCITY FUSE
5. STRIP BEARING 14. LOWERING CONTROL VALVE
6. SHIM 15. O-RING
7. FITTING 16. SNAP RING
8. LOWERING CONTROL HOUSING 17. ISOLATOR
9. CAPSCREW
153
Figure 132. Free-Lift Cylinder Assembly and Component Parts
154
1. INNER MAST 14. RING

2. INTERMEDIATE MAST 15. CHAIN ANCHOR
3. CHAIN 16. COTTER PIN
4. HOSE ASSEMBLY 17. PIN
5. CAPSCREW 18. FREE-LIFT CYLINDER
6. CAPSCREW 19. CLAMP
7. STUBSHAFT 20. FREE-LIFT CROSSHEAD
8. FITTING 21. ROLL PIN
9. LOWERING CONTROL VALVE HOUSING 22. CHAIN SHEAVE
10. HOSE SHEAVE 23. BEARING
11. BRACKET WELDMENT 24. PLATE
12. CHAIN ANCHOR RESTRAINT 25. WASHER
13. NUT
3. Disconnect the main lift chains from the chain

4. Remove the strip bearings at the top of the
anchors near the top of the main lift cylinders.
intermediate mast. Remove the load rollers at the
See Figure 133. Disconnect the other end of the
bottom of the inner mast. Remove the load rollers
main lift chains at the bottom of the inner mast.
at the top of the intermediate mast. Make a note
Push the inner mast toward the bottom of the
of each shim arrangement and load roller
mast assembly until the bottom load rollers can
location. The shim arrangements will be
be seen. See Figure 134.
approximately the same during assembly. See
WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
155
Figure 133. Outer Mast Assembly
156
1. OUTER MAST 11. CHAIN ANCHOR RESTRAINT

2. STUBSHAFT 12. CAPSCREW
3. LOAD ROLLER 13. INTERMEDIATE MAST
4. SNAP RING 14. LIFT CHAIN
5. SHIM 15. WEAR STRIP
6. COTTER PIN 16. O-RING
7. PIN 17. LUBE CAPSCREW
8. CHAIN ANCHOR 18. LUBE FITTING
9. RING 19. WASHER
10. NUT
157
Figure 134. Inner Mast Assembly
158
1. INNER MAST 7. PIN

2. STUBSHAFT 8. COTTER PIN
3. SNAP RING 9. RING
5. SHIM 11. LIFT CHAIN
6. CHAIN ANCHOR
159
1. INTERMEDIATE MAST 6. CHAIN SHEAVE

2. STUBSHAFT 7. BEARING
3. LOAD ROLLER 8. LIFT CHAIN
4. SNAP RING 9. STRIP BEARING
5. SHIM 10. SPACER
Figure 135. Intermediate Mast Assembly
160
5. Slide intermediate mast halfway out of the top of

WARNING the outer mast. Connect a crane with a capacity
The mast is heavy. The mast can weigh of at least 907 kg (2000 lb) to the center of the
approximately 907 kg (2000 lb). Make sure all intermediate mast. See Figure 136. Slide the
lifting devices (hoists, cables, chains, slings, etc.) intermediate mast out of the outer mast until the
are suitable and of adequate capacity to lift the stub shafts are in the notches of the outer mast.
mast. Remove the intermediate mast from the outer
mast.
1. Slide inner mast halfway out of the top of the
intermediate mast. Connect a crane with a 6. Disassemble chain sheaves as necessary for
capacity of at least 907 kg (2000 lb) to the center repair and cleaning. See Figure 132 and
of the inner mast. See Figure 136. Slide inner Figure 135. Remove hydraulic lines and fittings
mast out of intermediate mast until the stub shafts from mast weldments as necessary.
are in the notches of the intermediate mast.
Remove the inner mast from the intermediate
mast.
WARNING
or installation with enough force to cause an
injury. Always use the correct snap ring pliers, and
wear eye and face protection during removal or
installation.
2. Remove capscrews and isolator near the top of

each main lift cylinder. Remove snap rings and
washer from top of each main lift cylinder.
Disconnect main lift cylinder at the mounts. See
Figure 136. Connecting a Crane
Figure 131.
3. Push intermediate mast to disengage the main lift Clean and Inspect
cylinders. Remove the main lift cylinders.
CAUTION
4. Slide intermediate mast from the bottom of the
outer mast approximately 30 cm (12 in.). Remove DO NOT use steam or high-pressure water to clean
the strip bearings at the top of the outer mast. the load rollers or the lift chains. Steam and high-
Remove the snap rings and load rollers from both pressure water can remove the lubrication from
weldments. Make a note of each shim the bearings in the load rollers. Water in the
arrangement and load roller location. The shim bearings of the sheaves and the link pins of chains
arrangements will be approximately the same can also shorten the service life of these parts.
during assembly. See Figure 133 and Figure 135.
1. Inspect chain sheaves and load rollers for wear or
damage. See Figure 133, Figure 134, and
Figure 135. DO NOT use steam to clean lift chain
WARNING sheaves or load rollers. The bearings in the
The mast is heavy. The mast can weigh sheaves and load rollers are sealed and
approximately 907 kg (2000 lb). Make sure all lubricated.
mast.
161
WARNING WARNING
Cleaning solvents may be flammable and toxic and Never replace only the worn section of a chain.
can cause severe skin irritation. When using Replace the complete chain. Never replace only
commercial cleaning solvents, always comply with one chain of a chain pair. Replace both chains.
solvent manufacturer's recommended safety Damage to the lift truck and serious injury can
precautions. occur if lift chains are not replaced correctly.
NOTE: The chains must be inspected in the area of

WARNING chain that passes over the chain sheave during the
wear.
Make sure that the path of the compressed air is 3. Inspect the lift chains for wear and damage. A lift
away from all personnel. Wear protective goggles chain becomes longer when it is worn. If a chain
or a face shield to prevent injury to the eyes. is 3% longer than a new lift chain, the lift chain
must be replaced.
2. Clean the lift chains by soaking in solvent for 30
chains up and remove solvent using compressed
air.
162
12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20. in.) 523.3 mm (20.6 in.)


are worn or damaged.
WARNING
your skin to steam.
163
6. Clean mast weldments with steam or solvent.
WARNING
of the mast which can result in serious injury to
personnel. Consult your lift truck dealer for more
7. Inspect the sliding surfaces for wear or damage.

Inspect the load roller contact surfaces for wear
Assemble
NOTE: The shims for the load rollers keep the Figure 138. Strip Bearings
During assembly, shims should be reinstalled in the 3. Install load rollers and shims on the outer mast
same location they were in before disassembly. Check and at the bottom of the intermediate mast.
the clearance and adjust the shims for wear or for Before doing Step 4, adjust the intermediate mast
changes caused by repairs. The strip bearings are and check the clearance of the load rollers as
also adjusted by using shims. Shims for strip bears described in Mast Adjustments in this manual.
should also be reinstalled in the same location they
were in before disassembly. See Mast Adjustments in NOTE: The clearance check and adjustment in Step 4
this manual for the adjustment procedures. is only an initial setup. The final check and adjustment
is done after the mast is installed on the lift truck.
1. Put the outer mast on the floor with the carriage
side up. Connect a crane with a capacity of at 4. Install the main lift cylinders. Push intermediate
least 907 kg (2000 lb) to the center of the mast to engage the main lift cylinders. Check the
intermediate mast. Fit the lower stub shafts of the clearance at the top of the main lift cylinder
intermediate mast into the notches in the top of mounts. Add or remove washers at the top of the
the outer mast. Slide intermediate mast into the cylinder rods in the same location they were in
outer mast so the stub shafts are seen at the top before disassembly. Install the snap ring and
and bottom of both weldments. washer at the top of the main lift cylinders. See
Figure 131.
NOTE: The load roller must be in place before strip
bearings can be shimmed. 5. Install housing for the lowering control valve on
the outer mast. Tighten the nuts for the lowering
2. Install strip bearings and the shims on the control valve to 18 N•m (13 lbf ft). Install the
channels of the outer mast. See Figure 138. lowering control valve in the housing. Connect the
Apply chassis lube to the bearing surfaces. Check hydraulic lines and fittings between the housing
the clearance of the strip bearings as described in and the main lift cylinders. See Figure 131.
Mast Adjustments in this manual.
6. Install chain sheaves at the intermediate mast.
See Figure 135.
7. Install capscrews and isolators at the mount for

main lift cylinders. Tighten capscrews to
164
8. Connect a crane with a capacity of at least 3. Install washer and lube capscrew in hole in
907 kg (2000 lb) to the center of the inner mast. bottom of outer mast. Tighten lube capscrew to
See Figure 136. Slide the inner mast into the 25 N•m (18 lbf ft). Install lube fitting onto lube
intermediate mast so the stub shafts are seen at capscrew. Tighten lube fitting to 6 N•m (53 lbf in)
the top and bottom of both. See Figure 128 or Figure 133.

Molybdenum Disulfide for normal operations. WARNING
NOTE: The load rollers must be in place before The mast is heavy. The mast can weigh
bearing strips can be shimmed. approximately 907 kg (2000 lb). Make sure all
9. Install the strip bearings and the shims on the
channels of the intermediate mast. See
mast.
Figure 135 and Figure 138. Apply grease to the
bearing surfaces. Install the load rollers and the 4. Connect crane to top of mast using chains. Make
shims on the intermediate and inner masts. sure all mast uprights are fastened together.
Before doing the next step, adjust the inner mast Make sure chains will not damage sheaves,
as described in Mast Adjustments in this manual. tubing, or other parts of mast. Make sure crane
10. Connect the main lift chains to the chain anchors
at the main lift cylinder mounts. Put the lift chains 5. Use crane to position mast assembly onto its
over the chain sheaves and connect them to the lower mounts. Position mast so pivot pins seat
anchors at the bottom of the inner mast. into hanger mounts on drive axle. Install
11. Install the free-lift cylinder in the mounts on the hangers. Tighten capscrews to
inner mast. Install the brackets for the cylinder 270 N•m (199 lbf ft). See Figure 129.
and tighten the nuts to 53 N•m (39 lbf ft). The nuts
are installed on the bracket side of the free-lift 6. Install new tilt rod bushings into the tilt anchors on
cylinder. See Figure 132. the outer mast. Be sure tilt bushing split is
installed at the correct angle as shown
12. Install the chain sheave for the free-lift cylinder. Figure 128.
Tighten the capscrew for the chain sheave to
66 N•m (49 lbf ft). Install the hydraulic hose and
tubing for the free-lift cylinder.
WARNING
13. Connect the free-lift chains to the chain anchors Use a pry bar, NOT your fingers, to align the tilt
at the crossmember. Attach a wire between the cylinder clevises with the outer mast. The cylinder
end of the lift chain and the bottom of the mast to or mast can shift and cause serious injury.
control the lift chain during mast installation. See
Figure 132.
1. Install new bushings into mast mounts at bottom
pins and capscrews to rod ends. Apply anti-seize
of outer mast. Be sure to align the hole in the
compound to capscrew threads and tighten
bushing with the lube fitting hole in the bottom of
38 N•m (28 lbf ft).
cylinders without optional boot.
install them into mounts at bottom of outer mast. cylinders with optional boot.
See Figure 130.
165

6. CAPSCREW
Figure 139. Mast Mounting, Tilt Cylinder Without Optional Boot, Lift Truck Models ERP22-35VL
Optional Boot (ERP045-070VL (A976)
8. Connect hydraulic line to lowering control valve.

See Figure 131.
9. Install carriage as described in Carriages Repair,

Three-Stage FFL Mast section in this manual.
WARNING
the skin.
10. Check tilt cylinder adjustment as described in

as described in Lift Chains Adjustment.
166
NOTE: Before checking for mast side kicking and NOTE: Access to some of the fittings can be difficult.
adjusting the chain anchors on the main lift cylinders, If necessary, operate the hydraulic system to move
the mast must be fully assembled to include the mast weldments or the carriage. Make sure the
carriage, forks, load backrest and any attachments if hydraulic system does not have pressure as described
the lift truck is equipped with one. in Step 1.
11. Adjust chain anchors on the main lift cylinders 1. To replace any header hoses, fully lower the
until the tops of the inner and outer mast are at carriage. Make sure the hydraulic system does
the same level within ±1.5 mm (0.06 in.). See not have hydraulic pressure. Hold the control for
Figure 133. each function in the forward position for
approximately five seconds to release the
12. Raise the mast, without a load to its full height pressure. Make sure the hydraulic pump does not
and check for side kicking. Mast side kicking is operate. Move the key or keyless switch, if
when the mast moves either to the right or left as equipped, to the OFF position.
it is being raised to its full height. If the mast is
side kicking, see the Mast Adjustments section in 2. Disconnect battery and put a tag or lock on the
this manual for procedures to correct mast side battery connector.
kicking.
3. Disconnect header hoses and install caps on
NOTE: The load rollers and sheaves have sealed ends to prevent dirt and debris from entering the
bearings and do not need additional lubrication. hydraulic system.
along full length of channels as shown in Installation
indicated.
WARNING
possible.
the skin.
WARNING
A. UPPER LOAD ROLLERS section.
Some lift trucks are equipped with auxiliary hydraulic
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES functions that are fastened to the carriage. Examples
3. LOAD ROLLER of attachments that use these auxiliary functions are
sideshift carriages, roll clamps, and fork positioners.
Figure 141. Lubricate Mast These auxiliary functions require header hoses for
their operation.
Header Hose Installation and Adjustment
NOTE: This procedure is for the four function option.
Remove The three function option will have hoses A and B
Read and follow the Safety Procedures When Working only. See Figure 142
Near Mast as well as all WARNINGS and CAUTIONS
before removing and header hoses.
167
NOTE: The carriage height must be correct before the 2. Clamp one end of the hose in a vise. DO NOT
header hose tension can be measured. See Carriage clamp on the threads. Pull on the other end until
Adjustments section in this manual for the carriage hose is straight. DO NOT apply enough force to
adjustment procedure. stretch the hose.
1. Before installing new header hoses, add tension
marks to each hose. See Figure 143 and
Figure 144.
168
169

B. HEADER HOSE E. REAR VIEW (DRIVER'S VIEW)
C. HEADER HOSE F. LEFT SIDE VIEW
NOTE: The header hose tension specification is 2.0%

±1.0%. Install hose caps to marked end (truck end) of
hoses.
3. Put reference marks on each free-lift header
hoses. Starting at either end of hose, place a
mark at 400 ±10 mm (16.0 ±0.40 in.). This is
dimension FL1. See Figure 143.
4. From dimension FL1, place another mark at

FL2. See Figure 143.
170
A. DIMENSION = 400 ±10 mm (16.0 ±0.40 in.) A. DIMENSION M1 = 100 ±10 mm (4.0 ±0.40 in.)
B. DIMENSION = 500 ±2.0 mm (20.0 ±0.08 in.) B. DIMENSION M2 = 500 ±2.0 mm (20.0 ±0.08 in.)
INSTALL LENGTH HOSE TENSION INSTALL LENGTH HOSE TENSION

(FL2) (M2)
505 mm (19.8 in.) 1% 505 mm (19.8 in.) 1%
510 mm (20.1 in.) 2% 510 mm (20.1 in.) 2%
515 mm (20.3 in.) 3% 515 mm (20.3 in.) 3%
Figure 143. Free-Lift Header Hose Reference Marks Figure 144. Main Lift Header Hose Reference
Marks
5. Put reference marks on main lift header hoses.
Starting at either end of the hose, place a mark at 7. Route free-lift hoses through the crosshead and
100 ±10 mm (4.0 ±0.40 in.). This is dimension attach them to tube assemblies. See Figure 145.
M1. See Figure 144.
6. From dimension M1, place another mark at

M2. See Figure 144.
171
8. For three function main lift hoses (hoses A and

B), attach hoses to free-lift tube assemblies.
Route hoses through turnaround bracket and
secure hoses to turnaround bracket and
turnaround with spacer. See Figure 146.
9. Route three function main lift hoses up over hose

sheaves and secure hoses to hose sheaves with
spacer. Attach marked end of hoses to bracket on
mid-outer crossmember. See Figure 146.
10. Attach four function main lift hoses (hoses C and

D), to free-lift tube assemblies and route hoses
through turnaround bracket. See Figure 147.
A. FREE-LIFT HEADER HOSE A

B. FREE-LIFT HEADER HOSE B
C. FREE-LIFT HEADER HOSE C
D. FREE-LIFT HEADER HOSED
1. CROSSHEAD
2. TUBE ASSEMBLY
Figure 145. Free-Lift Header Hose Installation
172
A. THREE-FUNCTION HEADER HOSE A B. THREE-FUNCTION HEADER HOSE B
1. FREE-LIFT HOSE TUBE 4. HOSE SHEAVE

2. SPACER 5. MID-OUTER CROSSMEMBER
3. TURNAROUND BRACKET 6. BRACKET (LOWER)
Figure 146. Three-Function Header Hose Installation
173
A. FOUR-FUNCTION HEADER HOSE C B. FOUR-FUNCTION HEADER HOSE D
1. FREE-LIFT HOSE TUBE 4. CHAIN SHEAVE

2. TURNAROUND BRACKET 5. MID-OUTER CROSSMEMBER
3. HOSE SHEAVE 6. BRACKET (LOWER)
Figure 147. Four-Function Header Hose Installation
11. Route four function hoses up and over hose c. If crosshead can not be moved, or if after
sheaves. Attached marked end of hoses to moving crosshead plate two holes in either
bracket (either upper or lower bracket) on mid- direction, header hose tension is still not
outer crossmember. See Figure 147. correct, replace the hose and re-set crosshead
plate to starting position and do Step a and
NOTE: The header hose tension specification Step b again with new hose.
NOTE: The header hose tension specification
Adjustments), and the forks off the ground, 13. With header hoses installed on mast and the
measure the distance between marks FL1 and carriage correctly adjusted (see Carriage
FL2 as follows: Adjustments), and the forks off the ground,
measure the distance between marks M1 and M2
a. If tension mark measurement is less than as follows:
505 mm (20.0 in.), raise crosshead plate one

515 mm (20.3 in.), lower crosshead plate one
174
a. If tension mark measurement is less than

505 mm (20.0 in.), lower the upper bracket one
is within specifications. If tension mark
measurement is still less than
505 mm (20.0 in.), the hose has been
permanently stretched. Replace hose and re-
set upper bracket to original position and
measure again with new hose. See Figure 148.

515 mm (20.3 in.), raise the upper bracket one
hole and take the measurement again to insure
it is within specifications. If the hose has been
permanently over stretched, replace hose with
a new hose. See Figure 148.
1. CAPSCREW
2. CROSSHEAD
3. HEADER HOSE ROLLER ASSEMBLY
4. CROSSHEAD PLATE
5. HEADER HOSES
Figure 149. Free-Lift Header Hose Adjustment
14. Raise and lower mast two to three times to check

for proper routing of hoses. Hoses should
smoothly go over the hose sheaves and not rub
against crossmembers or the load backrest.
15. Tilt the mast two to three times and check that the
hoses routed between truck cowl and mast move
freely during both forward and backward tilt.
Adjustment
NOTE: Tire size variations and adjusting of the lift
chains may require adjustment of free-lift and main lift
header hose tension. Lift chain adjustment for tire
wear will reduce header hose tension.
1. To adjust the free-lift header hoses, perform the

2. LOWER BRACKET following:
3. UPPER BRACKET
4. CAPSCREW AND NUT a. Raise carriage at least 100 mm (4.0 in.)
Figure 148. Main Lift Header Hose Adjustment b. Place blocks under lower carriage bar and
lower carriage onto blocks to relieve hose
tension. Chain carriage to inner mast. See
in this manual.
175
Mast Adjustments 4000 YRM 1669
c. Loosen six (three on each side) capscrews on b. Chain inner mast weldment to outer or
crosshead plate. Remove middle capscrew. intermediate mast weldment. See Safety
See Figure 149. Procedures When Working Near Mast in this
manual.
d. Move free-lift header hose roller assembly up
to increase hose tension, and down to c. Lower inner mast onto block.
decrease hose tension. See Figure 149.
d. Loosen upper bracket above mid-outer
2. To adjust main lift header hoses, perform the crossmember and then lower upper bracket
following: until correct hose tension is achieved. Tighten
nut to 18 N•m (159 lbf in). See Figure 148.
a. Raise inner mast and place a block under inner
mast.
Mast Adjustments
LOAD ROLLER, ADJUST the clearance and adjust shims after repairs have
been completed.
NOTE: Shims are installed on both sides of the load
rollers. DO NOT add to or remove shims from the stub 1. The load rollers control the alignment of the mast
shafts. To change the position of the roller on the stub uprights. See Figure 150. The alignment
shaft, move the shims from one side of the load roller conditions are provided on a list below with the
to the other. most important condition first.
During assembly, the shim arrangement will be
approximately the same as before disassembly. Check
176
4000 YRM 1669 Mast Adjustments
NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO GIVE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO GIVE ZERO CLEARANCE
AT POINT OF TIGHTEST FIT.
A. TOP VIEW C. CARRIAGE FRONT VIEW

B. MAST FRONT VIEW
1. CHANNEL 7. ZERO CLEARANCE AT POINT OF TIGHTEST FIT

2. LOAD ROLLER 8. EQUAL SPACE ±1.5 mm (0.060 in.)
3. STUB SHAFT 9. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
4. SNAP RING 10. PUT SPACER ON OUTSIDE OF TOP LOAD
5. SHIMS ROLLER, UNDER SNAP RING
6. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.) 11. SHIM FOR ZERO CLEARANCE AT POINT OF
TIGHTEST FIT
Figure 150. Mast Adjustments
a. The mast uprights must be parallel to each c. The number of shims under a load roller must
other. be approximately the same as the stub shaft in
the opposite side of the upright. This ensures
b. Use shims to adjust load rollers so there is the uprights will be approximately in the center.
zero clearance between load roller and
channel at point of tightest fit. 2. Perform the following steps to adjust the mast
load rollers:
177
Mast Adjustments 4000 YRM 1669
a. Use a crowbar to move mast uprights from d. Measure distance between channels of mast
side to side to measure movement. Measure uprights on top and bottom. Change shims to
movement in a minimum of three different keep distance equal between top and bottom
positions of each mast upright. so mast uprights are parallel. Also make sure
the mast uprights are parallel within
b. Separate mast uprights and change shim 1.5 mm (0.060 in.).
arrangements as required. Assemble uprights.
Slide upright all the way to the top and bottom 3. Adjust strip bearings. See Figure 151. Insert
to find the tightest fit. shims under strip bearing. Adjust clearance until
there is less than 0.8 mm (0.030 in.) at the
c. Repeat Step a and Step b until there is zero tightest fit. See Figure 150.
clearance at the point of the tightest fit.
1. STRIP BEARING 4. SHIMS

2. LOAD ROLLER 5. O-RING
3. MAST UPRIGHT
Figure 151. Strip Bearings Arrangement
MAST SIDE KICKING, ADJUST 3. If the mast is moving to the left, shims will need to
either be added or removed from the top of the
Mast side kicking is where the mast, without a load, right main lift cylinder. If mast moves to the right,
moves either to the right or left as it is being fully shims will need to either be added or removed
raised. When this happens, it is an indication that one from the top of the left main lift cylinder. See Two-
of the main lift cylinders is raising at a faster rate then Stage LFL Mast Repair or Three-Stage FFL Mast
the other. Before checking for mast side kicking, the Repair.
mast must be completely assembled to include the
carriage, forks, load backrest, and any attachments if 4. If shims will be added, use the smallest shim size
the lift truck is equipped with one. that can be used on the mast that is being
To adjust the mast for side kicking, do the following: adjusted. See the Parts Manual for shim sizes
and part numbers.
1. Place the lift truck on a level surface and apply
the parking brake. 5. Raise the mast again and visually inspect it to
ensure that it is no longer side kicking. If side
2. Raise the mast and visually inspect it as it kicking is still present, repeat Step 3 and Step 4.
reaches its full height.
178
4000 YRM 1669 Carriage Adjustments
Carriage Adjustments
1. Install the load rollers on the carriage. Install the
shims for the load rollers onto the stubshaft in the
same sequence as when disassembled. There
are no shims under the top load rollers.
• See Figure 152 for lift trucks equipped with a
two-stage LFL mast
• See Figure 153 for lift trucks equipped with a
three-stage FFL mast
2. Use a lifting device to raise carriage. Find the

point of tightest fit between the carriage load
rollers and inner mast channels.
3. Remove carriage from mast. Adjust shim

arrangement for each roller for clearance
between roller and inner channel. Repeat Step 1
and Step 2 until there is zero clearance at the
point of tightest fit.
4. Keep shim arrangement on each side of carriage

approximately equal. The carriage must be
centered within the inner mast within
+1.50 mm (0.06 in.).
1. CARRIAGE 6. CHAIN PIN
2. SNAP RINGS 7. COTTER PIN
5. CHAIN ANCHOR
Figure 152. Carriage Adjustments, Two-Stage LFL

Mast
179
Lift Chains Adjustment 4000 YRM 1669
5. Check lateral movement of carriage:
a. Fully lower carriage to ground.
b. Place hand or small pry bar between top of

carriage side plate and the inner channel
flange. See Figure 150.
c. Move carriage back and forth and check

movement.
d. Carriage lateral movement must not be greater

than 2.5 mm (0.10 in.).
e. If carriage lateral movement is greater than

2.5 mm (0.10 in.), add or remove shims and
repeat Step a through Step d until correct
movement is achieved.
CAUTION
Too much grease will cause the rollers to slide and
wear flat areas on the rollers and introduce
1. CARRIAGE 6. CHAIN ANCHOR contamination into and on mast channels.
2. LOAD ROLLER 7. ANCHOR PIN
3. SNAP RINGS 8. CHAIN PIN
4. SHIM 9. COTTER PIN 6. After adjustment, lubricate channels with a thin
5. SPACER layer of grease. Adjust hydraulic hoses and make
sure connections are correct, if the carriage is
Figure 153. Carriage Adjustments, Three-Stage equipped with hydraulic attachments.
FFL Mast
Lift Chains Adjustment

• The tension will be the same on each chain of
the chain set. Check tension by pushing on both
WARNING chains at the same time.
When working on or near the mast, see the section
• The chain length will be correct.
Safety Procedures When Working Near Mast.
• The chains must travel freely through the
During test procedures for the hydraulic system, complete cycle.
fasten the load to the carriage with chains to
prevent it from falling. Keep all personnel away NOTE: When the lift chain adjustments are complete,
from the lift truck during the tests. make sure the threads on the nuts of the chain
anchors are completely engaged. Inspect the torque of
Never allow anyone under a raised carriage. DO the prevailing torque nut (locknut) used to adjust the
NOT put any part of your body in or through the lift chain anchor with every lift chain adjustment. After
mechanism unless all parts of the mast are carriage and or mast section(s) are adjusted for proper
completely lowered and the engine is STOPPED. ground clearance, prevent the carriage and or mast
Never check for leaks by putting hands on section(s) from fully lowering (see Safety Procedures
hydraulic lines or components under pressure. When Working Near Mast). With slack chain(s), check
Hydraulic oil under pressure can be injected into locknut torque. If 2.5 N•m (22.1 lbf in) for ½-20,
the skin. 4.5 N•m (39.8 lbf in) for 5/8-18 nuts,
6.0 N•m (53.1 lbf in) for 3/4-16 of torque cannot be
When the lift chains are correctly adjusted: reached; replace locknut. The chain anchors, after
adjustment, must be able to move on their mountings.
180
4000 YRM 1669 Lift Chains Adjustment
NOTE: Prior to performing adjustment procedures,

make sure the forklift truck is parked on a level surface
and the mast is in the vertical position.
Lift Trucks Equipped with Forks

1. Adjust the chain anchors that support the
carriage, until the bottom of the fork heel is
12 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above the
floor level. See Figure 154.
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Figure 155. Lift Chain Adjustment, Hook-Type

Carriage
Lift Trucks Equipped With Pin-Type

Carriage and Attachment Without Forks
1. MAST 1. Adjust the chain anchors, which support the
2. CARRIAGE
3. FORK carriage, until the center line of the fork pin is
4. HEEL OF FORK IS above the floor level as shown in Table 4 and
12 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) ABOVE Figure 156.
FLOOR LEVEL
Figure 154. Lift Chain Adjustment, With Forks
Lift Trucks Equipped with Hook-Type

Carriage and Attachment Without Forks
1. Adjust the chain anchors that support the
carriage, until the bottom of the lower carriage bar
is above the floor level as shown in Table 3 and
Figure 155.
Table 3. Hook-Type Carriage Chain Adjustment

Class II and III 82.5 ±3.0 mm (3.25 ±0.12 in.)
Class IV 133.5 ±3.0 mm (5.26 ±0.12 in.)
181
Hydraulic Quick Disconnect Hoses 4000 YRM 1669
Table 4. Pin-Type Carriage Chain Adjustment

4-5.5T Class III 545.0 ±3.0 mm
(21.5 ±0.12 in.)
4-5.5T Class IV 708.0 ±3.0 mm
(27.87 ±0.12 in.)
6-7T Class IV 907.0 ±3.0 mm
(35.71 ±0.12 in.)
1. LOAD BACK REST

2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR
Figure 156. Lift Chain Adjustment, Pin-Type

Carriage
Hydraulic Quick Disconnect Hoses
Some lift trucks are equipped with auxiliary tube GLP/GDP20-35VX (CP/CLP/
extensions to be used with optional equipment. The CDP040-070VX) (B875, C875, D875)
auxiliary tube extensions use quick disconnect fittings
to attach together optional equipment. Lift Trucks Equipped With E-Hydraulic
Controls
DISCONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT
WARNING
HOSES, LIFT TRUCK MODELS Before disconnecting the hydraulic hoses, relieve
GLC020-35VX (GC/GLC040-070VX, GC/ the pressure in the hydraulic system. Serious
GLC055SVX) (A910, B910, C910) AND injury can occur if pressure is not relieved from
hoses.
182
4000 YRM 1669 Hydraulic Quick Disconnect Hoses
1. Turn key switch or keyless switch to OFF position.

1. Turn key switch or keyless switch to OFF position.
2. Disconnect the battery.
2. Disconnect the battery.
NOTE: If the Quick Disconnect hose connectors
3. Disconnect the Quick Disconnect hose
cannot be disconnected, repeat Step 3 and Step 4.
connections. See Figure 158.
3. Press the plunger button, located on the top of
the pressure relief valve, and listen for the flow of
hydraulic fluid through the valve when the button
is pressed. See Figure 157.
4. Disconnect the Quick Disconnect hose

connections. See Figure 158.
1. QUICK DISCONNECT FITTINGS

2. HYDRAULIC TUBES
Figure 158. Quick Disconnect Hydraulic Hoses
CONNECTING ATTACHMENT HYDRAULIC

QUICK DISCONNECT HOSES, LIFT
TRUCK MODELS GLC020-35VX (GC/
GLC040-070VX, GC/GLC055SVX) (A910,
B910, C910) AND GLP/GDP20-35VX
(CP/CLP/CDP040-070VX) (B875, C875,
1. PRESSURE RELIEF VALVE D875)
2. PLUNGER BUTTON
Lift Trucks Equipped With E-Hydraulic
Figure 157. Pressure Relief Valve Plunger Button Controls
Lift Trucks Equipped With Manual 1. Connect the Quick Disconnect hose connectors.
See Figure 158.
Hydraulic Controls
2. Connect the battery.
WARNING
3. Turn key switch or keyless switch to the ON
position and start lift truck.
injury can occur if pressure is not relieved from 4. Move the mini lever forward and backward.
hoses.
183
Hydraulic Quick Disconnect Hoses 4000 YRM 1669
TRUCK MODELS ERC22-35VG

WARNING (ERC045-070VG) (A968) AND ERP22-35VL
Never check for leaks by putting hands on (ERP045-070VL) (A976)
Hydraulic oil under pressure can be injected into NOTE: Reconnect quick disconnect fittings as
the skin. indicated by tags.
1. Pull spring loaded quick disconnect socket head
5. Check the hydraulic system for leaks. sleeve back and press optional equipment fitting
into socket head; release quick disconnect socket
Lift Trucks Equipped With Manual head sleeve. See Figure 159.
Hydraulic Controls
2. Test connection by pulling quick disconnect and
1. Connect the Quick Disconnect hose connectors.
optional equipment fitting away from each other.
See Figure 158.
3. Repeat Step 1 and Step 2 until connection is
2. Connect the battery.
made.
3. Turn key switch or keyless switch to the ON
position.
4. Move the manual hydraulic lever forward and

backward.
WARNING
the skin.
5. Check the hydraulic system for leaks.
DISCONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT
HOSES, LIFT TRUCK MODELS
ERC22-35VG (ERC045-070VG) (A968) AND
ERP22-35VL (ERP045-070VL) (A976)
NOTE: Some lift trucks are equipped with auxiliary
tube extensions to be used with optional equipment.
The auxiliary tube extensions use quick disconnect
fittings to couple together optional equipment.
NOTE: Tag hoses before removal to aid in re-
connection.
1. Pull spring loaded quick disconnect socket head
sleeve back to disconnect fittings. See
Figure 159.
2. Remove optional equipment hose.
CONNECTING ATTACHMENT HYDRAULIC

QUICK DISCONNECT HOSES, LIFT
184
4000 YRM 1669 Hydraulic Quick Disconnect Hoses
1. DUAL EXTENSION TUBES WITHOUT QUICK

DISCONNECTS
2. SINGLE EXTENSION TUBE WITH QUICK
DISCONNECTS
3. QUICK DISCONNECT SLEEVE DIRECTION
Figure 159. Quick Disconnect and Auxiliary Tubes
WARNING
the skin.
4. Check the hydraulic system for leaks.
185
4000 YRM 1669 6/19 (1/19)(10/17)(11/16)(12/14)(4/14)

MAST REPAIR (S/N F507, F508, F562, F563) : Maintenance

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MAST REPAIR (S/N F507, F508, F562, F563) : Maintenance

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Maintenance

MAST REPAIR (S/N F507, F508, F562,

PART NO. 550093755 4000 YRM 1669

©2019 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

ERC22-35VG (ERC045-070VG) [A968];

1. MAST SERIAL NUMBER 4. MAST LIFT HEIGHT (IN MILIMETERS)

Figure 1. Mast Serial Number Location

Safety Procedures When Working Near Mast

1. Put mast in vertical position.

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

1. OUTER WELDMENT 5. FREE-LIFT CYLINDER

Figure 2. Two-Stage LFL and Three-Stage FFL Masts

2. Lower fork onto blocks (see Figure 4), so bottom

1. LOAD BACKREST 6. WEDGE

Figure 3. Carriage and Forks

1. Inspect forks for cracks and wear. Check

2. Check for smooth and proper operation of fork

3. Inspect fork wear. Ensure heel wear is not more

3. Slide fork on carriage so both upper and lower

4. Install latch pin in top hook and notch in upper

Table 1. Fork Tip Alignment

A. HEEL OF FORK (MUST BE 90% OF DIMENSION

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

See Figure 8 for lift trucks manufactured prior to

3. Lower forks onto blocks (see Figure 4) so bottom

2. Slide fork to fork removal notch in bottom bar of

1. OUTER FORK CARRIER 5. FORK POSITIONER

1. OUTER FORK CARRIER 5. FORK POSITIONER

Checks 2. Check for smooth and proper operation of the fork

Table 2. Fork Tip Alignment

A. HEEL OF FORK (MUST BE 90% OF DIMENSION

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

Figure 10. Fork Checks

Carriages Repair, Two-Stage LFL Mast

2. Remove four capscrews, washers, nuts, and load

3. Connect a lifting device to the carriage. Lift

5. Use lift cylinders to raise inner mast. If hydraulic

6. Connect a crane with a capacity of at least

Clean and Inspect

Figure 13. Standard Carriage Components

5. Install forks. See section Fork Replacement for

1. INNER FRAME 11. LUBE FITTING

Figure 14. Integral Sideshift Carriage Component Parts

Disassemble 2. If damaged, remove lube fittings from outer

a. If either upper bearing is worn to less than

b. If either lower bearing is worn to less than

4. Inspect the sideshift cylinder. See Cylinder

5. Inspect load rollers for wear or damage (see

Figure 15. Remove Outer Frame

Clean and Inspect

2. Clean and inspect carriage bars for damage and

A. MINIMUM THICKNESS 2.5 mm (0.1 in.).

1. LOWER BEARINGS 3. UPPER BEARINGS

Figure 17. Upper and Lower Bearings

Assemble 2. Use a crane with a capacity of at least

Install 6. Install forks. See section Fork Replacement, in

INTEGRAL SIDESHIFT CARRIAGE, LIFT

2. Remove four capscrews, nuts, washers, and load

NOTE: CLASS II CARRIAGE SHOWN. CLASS III CARRIAGE IS SIMILAR.

1. HYDRAULIC HOSE FITTINGS