INTRODUCTION

GENERAL CARRIAGES (See FIGURE 1.)

This section has the description and repair procedures
for the Four–Stage, full free–lift (FFL) mast and the car-
riages. Checks and Adjustments and Troubleshooting
information are at the end of this section.
The mast is used to lift a load vertically. The mast has
two movements controlled by hydraulic cylinders: for-
ward and backward tilt and the lifting and lowering of
the mast weldments and carriage. The outer weldment
can move on the pivot pins at the mast mounts. The op-
eration of the tilt cylinders causes the mast to tilt forward
and backward. The tilt cylinders are fastened between
the frame of the lift truck and the outer weldment of the
mast. Hydraulic lift cylinders are installed vertically on
the mast weldments. The lift cylinders and lift chains
raise and lower the weldments and the carriage. The hy-
draulic operation of the lift cylinders and tilt cylinders is
described in the section MAIN CONTROL VALVE.
The carriage is a part of the mast assembly and moves
within the channels of the inner weldment. Forks or
other types of load handling equipment are attached to
the carriage. A load backrest extension is attached to the
carriage and adds support for a load that has multiple
pieces.
The side–shift carriage lets the operator move the forks
and load from side–to–side. This function makes it eas-
ier for the operator to align the forks with a load or align
the load with a stack. The side–shift carriage hangs on
the fork bars of the standard carriage. Special bushings
fit between the side–shift carriage and the fork bars. A
side–shift cylinder is installed on a bracket that fits on
the standard carriage. The side–shift cylinder moves the
side–shift carriage on the standard carriage.

1 5 6
2
7
2

10 8 1
9
SIDE–SHIFT
4 CARRIAGE
CARRIAGE 5. TOP BUSHING
6. TOP BAR
1. LOAD BACKREST EXTENSION 7. BOTTOM BUSHING
2. STANDARD CARRIAGE 8. BOTTOM BAR
3. FORKS 9. SIDE–SHIFT CYLINDER
4. FORK REMOVAL NOTCH 10. CYLINDER MOUNTING BRACKET

FIGURE 1. CARRIAGE AND FORKS

1
MAST MOUNTS (See FIGURE 13.)
1. OUTER WELDMENT
2. FIRST INTERMEDIATE WELDMENT
The mast can tilt forward and backward. Tilt cylinders 3. SECOND INTERMEDIATE WELDMENT
are fastened between the frame of the lift truck and the 4. INNER WELDMENT
2 3
outer weldment of the mast to change the angle of the
mast and forks. Pivot pins are installed in the drive axle 4
hangers. The pivot pins rotate in bushings in the hang-
ers. The outer weldment has mounts that fit on the pivot 1
pins. Capscrews hold the mast to the pivot pins.

MAST

Description (See FIGURE 2.)

The full free–lift, four–stage mast has four weldments:

outer, first intermediate, second intermediate and inner. 8
Two single–stage main lift cylinders and a free–lift cyl-
inder are used to raise the carriage and extend the mast
weldments. It is called a full free–lift mast because the
carriage can travel to the top of the inner weldment with-
out extending the inner weldment.

The weldments are telescopic and use load rollers and 5

strip bearings to keep them in alignment. The load roll-
ers are installed at the top of the outer, first and second
intermediate weldments. Load rollers are also used at
the bottom of the first and second intermediate weld-
ments and the inner weldment. These load rollers travel
along the flanges of the weldments. The angle of the
load rollers permits them to control the forces from the
front, back and sides of the mast. The strip bearings are
installed at the top of the outer, first and second inter-
mediate weldments and help keep the correct clearance
between the weldments. The load rollers and strip bear-
ings are adjustable with shims. 7

The two main lift cylinders are installed at the back of

the outer weldment. The base of each lift cylinder sits in
a mount at the bottom crossmember of the outer weld-
ment. The top of each main lift cylinder (cylinder rod)
fits into a guide at the top crossmember of the first inter- 6
mediate weldment. The free–lift cylinder is installed to
the inner weldment. The free–lift and left–hand main lift
7. MAIN LIFT
cylinder has an internal (secondary) lowering control CYLINDER
5. FREE–LIFT CHAINS
valve. A single external (primary) lowering control 6. FREE–LIFT CYLINDER 8. LIFT CHAIN
valve is connected by tubing and hoses to all of the lift
cylinders. FIGURE 2. FOUR–STAGE MAST
2
 chains then go over sheaves at the top of the second in-
1 3 termediate weldment and fasten at the bottom of the in-
2 ner weldment.

The free–lift chains connect at one end to the crossmem-

ber for the free–lift cylinder. Two chain sheaves are in-
stalled on a crosshead on the cylinder rod of the free–lift
cylinder. The chains then go over sheaves on the cross-
head and connect to the carriage.

4 the same time. The free–lift cylinder extends first be-
4 cause it lifts the least amount of weight. The free–lift
5 ment. After the free–lift cylinder reaches the end of its
6 10101
1. MAIN LIFT CYLINDER (LEFT–HAND)
2. FREE–LIFT CYLINDER
3. MAIN LIFT CYLINDER (RIGHT–HAND)
4. LOWERING CONTROL VALVE (INTERNAL)
5. LOWERING CONTROL VALVE (EXTERNAL)
6. TO/FROM MAIN CONTROL VALVE
FIGURE 3. HYDRAULIC SCHEMATIC
One set of lift chains is connected to mounts that are near
the top of the outer weldment. The lift chains then go
over sheaves at the top of the first intermediate weld-
ment and fasten at the bottom of the second intermediate
weldment.
Another set of lift chains is connected to mounts that are
near the top of the first intermediate weldment. The lift
Operation
(See FIGURE 3., through FIGURE 6.)
The three hydraulic cylinders are connected by hoses
and tubing as shown in FIGURE 3. To extend the mast,
oil from the main control valve flows to all cylinders at
cylinder raises the carriage to the top of the inner weld-
stroke, the main lift cylinders begin to extend. As the
main lift cylinders extend, the first intermediate weld-
ment is raised by the lift cylinders. The second inter-
mediate and inner weldments are raised by the lift
chains.
The left–hand lift cylinder has a small amount of oil be-
low the piston. The free–lift cylinder has a small amount
of oil above the piston. This oil provides a hydraulic
cushion during operation. See FIGURE 5. and
FIGURE 6.
During lowering, the main lift cylinders lower first be-
cause they have a greater load. After the main lift cylin-
ders have retracted, the free–lift cylinder lowers. All oil
from the lift cylinders flows through the lowering con-
trol valves to the hydraulic tank.

3
 2 3
1 4
6
5 11 8

7 5

10
LOWERED
11
9 10 4

10101

9
3

FULLY RAISED
1

FREE–LIFT

1. MAIN LIFT CYLINDER 2

2. OUTER WELDMENT
3. FIRST INTERMEDIATE WELDMENT 8. FORK
4. SECOND INTERMEDIATE WELDMENT 9. MAIN LIFT CHAIN
5. FREE–LIFT CYLINDER 10. INTERMEDIATE LIFT
6. INNER WELDMENT CHAIN
7. CARRIAGE 11. FREE–LIFT CHAIN

FIGURE 4. OPERATION

4
 1 As the main lift cylinders retract, hydraulic oil flows out
of the cylinders through the hydraulic port (5). During
the last 20 mm (0.8 in) of the stroke, the hydraulic oil
must flow out through the small orifice (6). This action
2
causes the cylinder rod to move much more slowly at
the end of the stroke. This cushion effect prevents a
sudden stop at the end of the lowering sequence,
3 making a smoother lowering operation.
7
4

6
20 mm (0.8 in) 1. CYLINDER ROD
CUSHION 2. CYLINDER SHELL
3. PISTON
4. INTERNAL CHECK VALVE
5. HYDRAULIC PORT
8 6. ORIFICE
7. PISTON SEAL
8. CUSHION RING
LEFT–HAND LIFT CYLINDER

FIGURE 5. OPERATION, MAIN LIFT CYLINDER

There is hydraulic oil on the rod side of the piston. There

1 are two orifices in the cylinder rod, one larger than the
other, items (3) and (4). As the cylinder rod extends, the
2 hydraulic oil on the rod side flows to the base of the cylin-
der through the larger orifice (3) and the internal check
3 valve (6). When the cylinder rod extends to the last 25
mm (1.0 in) of its stroke, the retainer at the top of the cyl-
inder closes the larger orifice (3). Now, the remainder of
25 mm (1.0 in)
CUSHION the hydraulic oil must flow through the small orifice (4) to
the internal check valve (6). This action increases the
hydraulic pressure so that the main lift cylinders begin to
4 extend.
6
At the end of the free–lift stroke the oil flow through the
small orifice gives a cushion effect for the free–lift cylin-
der.
1. CYLINDER ROD 4. SMALL ORIFICE
5 2. CYLINDER SHELL 5. PISTON
3. LARGE ORIFICE 6. INTERNAL CHECK VALVE

FIGURE 6. OPERATION, FREE–LIFT CYLINDER

5
 REPAIRS
notch. See FIGURE 7. Lower the carriage further so
WARNING that the top hook of the fork is disengaged from the top
Before working on or near the mast, read SAFETY carriage bar. Move the carriage away from the fork, or
PROCEDURES WHEN WORKING NEAR THE use a lifting device to move the fork away from the car-
MAST. See FIGURE 9. riage.

FORKS
The forks are held on the carriage by hooks. The forks 1. CARRIAGE
are kept in position by latches that fit through the top BARS
fork hooks and into slots in the top carriage bar. The 2. HOOK FORK
3. BLOCKS
forks can be removed from the carriage by aligning the
forks with the fork removal notch. The fork removal 1
notch is in the bottom crossmember of the carriage. Al- 2
ways check that the latches for the forks keep the forks
in position on the carriage. Replace damaged latch parts.
ÉÉ ÉÉ
Removal ÉÉ 3
ÉÉ
WARNING
FIGURE 7. REMOVE A FORK
Do not try to remove a fork without a lifting device.
Each hook fork for these lift trucks can weigh 45 kg Installation
to 115 kg (100 to 250 lb).
Move the fork and carriage so that the top hook on the
A fork can be removed from the carriage for replace- fork can engage the upper carriage bar. Raise the car-
ment of the fork or other maintenance. Slide a hook fork riage to move the lower hook through the fork removal
to the fork removal notch on the carriage. See notch. Slide the fork on the carriage so that both upper
FIGURE 8. Lower the fork onto blocks so that the bot- and lower hooks engage the carriage. Engage the lock
tom hook of the fork moves through the fork removal pin with a notch in the top carriage bar.

6
1 6

1
2 7 7
5
5
8
8
9
9

1. LOAD BACKREST
EXTENSION
2. CARRIAGE 6. LEVER
3. FORKS 7. WASHER
4 4. FORK REMOVAL NOTCH 8. SPRING
5. LOCK PIN ASSEMBLY 9. PIN

FIGURE 8. CARRIAGE AND FORKS

6
 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)
The following procedures must be used when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast.
WARNING
Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast or the carriage.
• Never put any part of the body into or under the mast or carriage unless all parts are
completely lowered or a safety chain is installed. Also make sure that the power is off and the
key is removed. Put a “DO NOT OPERATE” tag in the operator’s compartment. Disconnect the
battery and put a tag or lock on the battery connector.
• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.
• DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on
the mast.
• DO NOT use blocks to support the mast weldments nor to restrain their movement.
• Mast repairs require disassembly and removal of parts and can require removal of the mast
or carriage. Follow the repair procedures in the this section.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely. Push the lift/lower
control lever forward and make sure there is no movement in 5
the mast. Make sure that all parts of the mast that move are 8
fully lowered. 7
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 pro-
cedures:
1
a. Put the mast in a vertical position.
2
b. Raise the mast to align the bottom crossmember of the weld-
ment that moves in the outer weldment with a crossmember on LFL
the outer weldment (1). On the LFL and FFL units, the moving
part is the inner weldment (2). On the three–stage it is the inter-
mediate weldment (3). On the four–stage it is the first intermedi-
ate weldment.
c. Use a 3/8 inch minimum safety chain with a hook (5) to fasten
the cross members together so that the movable member can
not lower. Put the hook on the back side of the mast. Make sure 6
the hook is completely engaged with a link in the chain. Make
sure the safety chain does not touch lift chains or chain sheaves, 8
tubes, hoses, fittings, or other parts on the mast.
d. Lower the mast until there is tension in the safety chain and
the free–lift cylinder (6) (FFL, three–stage and four–stage) is 1
completely retracted. If running, turn the power OFF. Apply the 7
5
parking brake. Install a “DO NOT REMOVE” tag on the safety
chain(s).
e. Install another safety chain (3/8 inch minimum) between the
top or bottom crossmember of the carriage (7) and a crossmem-
ber on the outer weldment (8).
2
• Apply the parking brake. After lowering or restraining the
mast, shut off the power and remove the key. Put a “DO NOT
OPERATE” tag in the operator’s compartment. Disconnect
the battery and put a tag or lock on the battery connector. FFL

FIGURE 9. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)

7
 mast. Make sure the chains can move freely when the in-
SAFETY PROCEDURES WHEN ner weldment is raised.
WORKING NEAR THE MAST
WARNING
Make sure that the carriage has stability when the in-
5 ner weldment is above the load rollers of the car-
6 riage.

1. CARRIAGE
2. SNAP RING
3. SHIM
4 LOAD ROLLER
7
1
1
2

3
7 5

THREE–STAGE,
FOUR–STAGE
6 2
4
FIGURE 9. SAFETY PROCEDURES WHEN
WORKING NEAR THE MAST (2 of 2) 8
2

CARRIAGES
Removal
STANDARD CARRIAGE
(See FIGURE 8. and FIGURE 10.)
1. Put a one–quarter capacity load on the forks. The load
must give the carriage stability so that the carriage can-
not fall when it is disconnected from the mast.
2. Lower the carriage and forks on blocks so that the 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 pre-
vent the lift chains from falling from the sheaves and
causing an injury or damage.
3. Remove the pin from each chain anchor at the car-
riage. Disconnect the lift chains from the carriage. Use
wire to connect the ends of the lift chains to a part of the
8
5. CHAIN ANCHOR 3
4 2
6. CHAIN PIN
7. COTTER PIN
8. ANCHOR PIN
FIGURE 10. CARRIAGE
4. Use the lift cylinders to raise the inner weldment. If
the hydraulic system cannot be used, connect a crane to
the top of the inner weldment. Carefully raise the inner
weldment until it is above the load rollers of the car-
riage.
5. Move the lift truck away from the carriage. Complete-
ly lower the inner weldment so that it cannot move.
6. Connect a lifting device to the carriage. Remove the
load from the forks with another lift truck. Lower the
carriage to the floor so that the load rollers are up.
7. If the forks are removed, use a lifting device to put the
carriage on the floor so that the load rollers are up.
SIDE–SHIFT CARRIAGE (See FIGURE 12.)
1. Lower the carriage completely and remove the forks.
2. Connect a lifting device to the lifting eye on the side– 2. Check the clearance of the load rollers. See CHECKS
shift carriage. The side–shift carriage weighs approxi- AND ADJUSTMENTS in this section.
mately 200 kg (400 lb).
3. Connect the lift chains to the chain anchors at the car-
3. Remove the two upper capscrews from the bottom riage. Use new cotter pins in the anchor pins. Adjust the
carriage bar. Slowly loosen the two bottom capscrews, lift chains as described in CHECKS AND ADJUST-
but do not remove them. The slotted holes will allow the MENTS in this section.
bottom carriage bar to move down so that the side–shift
SIDE–SHIFT CARRIAGE (See FIGURE 12.)
carriage can be removed. Carefully lift the side–shift
carriage from the standard carriage. The side–shift cyl- 1. Install the side–shift cylinder in the bracket. Use an
inder mounting bracket and cylinder will stay on the equal number of shims on both sides of the cylinder to
standard carriage. Remove the bushings. limit side–to–side movement within the bracket. Maxi-
mum movement is 0.6 mm (0.024 in). Install the bolts
4. Disconnect the hydraulic lines at the side–shift cylin-
and nuts to hold the cylinder in position. Tighten the nuts
der. Put caps on the open lines. Remove the cylinder
to 26 Nm (19 lbf ft) torque.
mounting bracket from the carriage. If necessary, re-
move the threaded rods and shims to remove the side–
shift cylinder.
4 5
Repairs (See FIGURE 10. and FIGURE 11.) 2 3
1
1. If any of the load rollers must be replaced, make a note
of the location and number of the shims. Install the 7
shims, load rollers and snap rings. See CHECKS AND 6
ADJUSTMENTS for correct adjustment of the load 1
rollers.
NOTE: The carriage has six load rollers. The shims are
installed on the bottom four rollers only.
2. Repair the side–shift cylinder as follows: 2
5 4 3
a. Remove the retainers from the shell. Pull the rod 8
from the shell.
b. Replace seals, O–rings or back–up rings as neces- 1. WIPER 5. O–RING
2. RETAINER 6. PISTON AND ROD
sary. 3. ROD SEAL 7. PISTON SEAL
c. Lubricate all internal parts with clean hydraulic oil. 4. BACK–UP RING 8. SHELL
d. Install the piston and rod in the shell. Apply Loctite FIGURE 11. SIDE–SHIFT CYLINDER
242 to the threads of the retainers. Install the retainers
and tighten them to 27 Nm (20 lbf ft) torque. 2. Install the cylinder mounting bracket on the standard
carriage, making sure it is engaged with the notch in the
Installation top carriage bar. Connect the hydraulic lines to the side–
shift cylinder. Put grease on the ends of the cylinder rod.
STANDARD CARRIAGE
3. Install the top bushing on the mounting bracket. Lu-
1. Use the hydraulic system of the lift truck or a crane to
bricate the outer surface of the bushing with multi–pur-
raise the inner weldment. If the hydraulic system cannot
pose grease.
be used, connect a crane to the top of the inner weld-
ment. Carefully raise the inner weldment until it is 4. Connect the top and bottom carriage bars by installing
above the load rollers of the carriage. Move the lift truck the two bottom capscrews. Do not tighten the cap-
toward the carriage until the inner weldment is aligned screws. Lubricate the outer surface of the bottom bush-
with the carriage rollers. Carefully lower the inner weld- ing with multi–purpose grease. Install the bottom bush-
ment until it engages all of the load rollers. ing in the bottom carriage bar.
9
 2
1
3

5 1. TOP BUSHING
4 2. CYLINDER MOUNTING
BRACKET
3. SHIM
4. SIDE–SHIFT CYLINDER
5. LIFTING EYE
6. BOTTOM CARRIAGE
10 BAR
7. BOTTOM BUSHING
9 8. TOP CARRIAGE BAR
9. GREASE FITTING
6 10. BOLT
8

FIGURE 12. SIDE–SHIFT CARRIAGE

5. Make sure the standard carriage is completely low-
ered. Connect a lifting device to the lifting eye. Install
the side–shift carriage on the standard carriage. Put
blocks under the bottom bar of the side–shift carriage so
that the bottom bushing moves tight against the standard
carriage.
6. Install the two top capscrews into the side–shift car-
riage. On the E2.00–2.75XM (E45–55XM) units, tight-
en all of the capscrews to 435 Nm (320 lbf ft) torque. On
E3.00–3.20XM (E60–65XM) units, tighten all of the
capscrews to 755 Nm (557 lbf ft) torque. Remove the
lifting device. Lubricate the top bushing at the grease fit-
tings.
MAST
Removal (See FIGURE 13.)
NOTE: If the mast must be disassembled, remove the
forks and carriage as described in the procedures for the
CARRIAGES. If only the lift cylinders need to be re-
moved, see the procedures for the LIFT CYLINDERS.
1. Before removing the mast, check the length of the lift
chains. See the procedures in Cleaning and Inspection.
2. Fully lower all of the mast weldments and the car-
riage. Tilt the mast fully forward. Use chains and con-
nect a crane to the top of the mast. Make sure all the
10
weldments are fastened together. Make sure the chains
will not damage the sheaves, tubing, or other parts of the
mast. Make sure the crane has a capacity of at least 1600
kg (3500 lb).
3. Put a drain pan under the area of the hydraulic fittings.
Disconnect the hydraulic line at the external lowering
control valve on the outer weldment.
WARNING
Use a driver, not your fingers, to push the anchor
pins from the rod ends on the tilt cylinders. The cyl-
inder or mast can move and cause serious injury.
4. Remove the cotter pins and anchor pins at the tilt cyl-
inder mounts on the mast.
5. Remove the capscrews that hold the mast to the pivot
pins at the mounts.
6. Use the crane to lift the mast assembly from the lift
truck. Put the mast on the floor so that the back of the
mast is toward the floor.
Disassembly
(See FIGURE 16. and FIGURE 17.)
NOTE: If only the lift cylinders need to be removed and
repaired, see the procedures for the LIFT CYLINDERS.
When the mast has header hoses, see the procedures for
the HEADER HOSES.
 the inner weldment from the second intermediate weld-
4 ment.
5. Disconnect the lift chains at the bottom of the second
intermediate weldment and the top of the outer weld-
3 ment. Remove the lift chains. Push the second inter-
mediate weldment toward the bottom of the mast assem-
bly until the bottom load rollers are seen.
6. Remove the strip bearings and spacers at the top of the
first intermediate weldment. Remove the load rollers at
the bottom of the second intermediate weldment. Re-
move the load rollers at the top of the first intermediate
weldment. Make a note of each shim arrangement and
2 load roller location. The shim arrangements will be ap-
proximately the same during assembly.
7. Slide the second intermediate weldment half–way out
of the top of the first intermediate weldment. Connect a
1 crane to the center of the second intermediate weldment.
See FIGURE 14. Slide the second intermediate weld-
ment out until the stub shafts are in the notches of the
1. PIVOT PIN first intermediate weldment. Remove the second inter-
2. DRIVE AXLE mediate weldment.
HANGER
(MAST MOUNT)
3. TILT CYLINDER
4. OUTER WELDMENT 12791

FIGURE 13. MAST MOUNTING

1. Disconnect and remove the hydraulic lines for the
free–lift cylinder. Remove the brackets for the free–lift
cylinder. Remove the free–lift cylinder. Disconnect the
free–lift chains at the crossmember.
2. Disconnect the lift chains at the bottom of the inner
weldment and the top of the first intermediate weld-
ment. Remove the lift chains. Push the inner weldment
toward the bottom of the mast assembly until the bottom
load rollers are seen. FIGURE 14. REMOVE A WELDMENT
8. Disconnect the hydraulic lines at the top and bottom
3. Remove the strip bearings at the top of the second in-
of the lift cylinders. Disconnect the balance line at the
termediate weldment. Remove the load rollers at the
top of the right–hand lift cylinder.
bottom of the inner weldment. Remove the load rollers
at the top of the second intermediate weldment. Make a 9. Remove the snap rings and washers at the top of the
note of each shim arrangement and load roller location. main lift cylinders. Remove the nut, bolt and spacer at
The shim arrangements will be approximately the same the mount near the top of each main lift cylinder.
during assembly. 10. Push the first intermediate weldment to disengage
4. Slide the inner weldment half–way out of the top of the lift cylinders. Remove the main lift cylinders. Keep
the second intermediate weldment. Connect a crane to the shims from the top of the right–hand lift cylinder
the center of the inner weldment. See FIGURE 14. Slide with the cylinder.
the inner weldment out until the stub shafts are in the 11. Slide the first intermediate weldment from the bot-
notches of the second intermediate weldment. Remove tom of the outer weldment approximately 30 cm (12 in).
11
Remove the strip bearings at the top of the outer weld- pitch
ment. Remove the snap rings and load rollers from both Total length of WEAR LIMIT
20 links(pitch) The maximum
weldments. Make a note of each shim arrangement and of new chain length of 20 links
load roller location. The shim arrangements will be ap-
proximately the same during assembly. mm (inch) mm (inch) mm (inch)
12.7 (0.50) 254.0 (10.0) 261.6 (10.3)
12. Slide the intermediate weldment half–way out of the 15.9 (0.63) 317.5 (12.5) 327.0 (12.9)
top of the outer weldment. Connect a crane to the center 19.1 (0.75) 381.0 (15.0) 392.4 (15.6)
of the first intermediate weldment. See FIGURE 14. 25.4 (1.00) 508.0 (20.0) 523.3 (20.6)
Slide the weldment out of the outer weldment until the
stub shafts are in the notches of the outer weldment. Re-
move the first intermediate weldment from the outer
weldment.

13. Disassemble the chain sheaves as necessary for re-

pair and cleaning. Remove the hydraulic lines and fit- 1
tings from the weldments as necessary.

Cleaning and Inspection

1. Inspect the chain sheaves and load rollers for wear or
damage. DO NOT use steam to clean the lift chains,
sheaves or load rollers. The bearings in the sheaves and
load rollers are sealed and lubricated.

WARNING
Cleaning solvents can be flammable and toxic, and
can cause severe skin irritation. When using clean- 12174
ing solvents, always follow the solvent manufactur-
1. CHAIN WEAR SCALE
er’s recommended safety precautions.
NOTE: The instructions for measuring chain
2. Clean the lift chains with solvent. Remove all dirt and wear are shown on the Chain Wear Scale.
grease. Inspect the lift chains for wear or damage. The FIGURE 15. CHECK THE LIFT CHAINS
lift chains must be installed on the mast before they can
be checked for length. A lift chain becomes longer when
it is worn. If a chain is 3% longer than a new lift chain, a
new set of lift chains must be installed. If a chain scale is WARNING
available, check the lift chain as shown in FIGURE 15. Be careful when cleaning with steam. Steam can
If a chain scale is not available, measure 20 links of the cause serious burns. Wear protective clothing and
lift chain. Compare the measurement with the lengths gloves. Never expose your skin to steam.
given in FIGURE 15. Lubricate the chains with SAE 30
engine oil. The best procedure is to soak the lift chains in 4. Clean the mast weldments with steam or solvent.
engine oil.
5. Inspect the sliding surfaces for wear or damage. In-
WARNING spect the load roller contact surfaces for wear or da-
mage. Inspect all welds for cracks.
Never replace just the worn section of a chain. Install
the complete chain. Never replace just one chain of a
chain pair. Install new chains in pairs. WARNING
Incorrect welding procedures can cause damage to
3. Inspect the chain anchors and pins. Install new parts the structure of the mast. Get information from your
for old parts that are worn or damaged. Hyster lift truck dealer before welding on the mast.
12
 3
1. OUTER WELDMENT
2. O–RING 1
2
3. SHIM(S)
4
4. STRIP BEARING 13
5. LIFT CHAIN
6. SPACER 5
7. ANCHOR PIN 7
8. COTTER PIN 6
17
8
16
9

13

10

11

12

13

14
9. CHAIN ANCHOR
10. WASHER 15
11. NUT
12. FIRST INTERMEDIATE
WELDMENT
13. SNAP RING
14. SHIMS
15. LOAD ROLLER
16. BEARING
17. CHAIN SHEAVE

FIGURE 16. OUTER AND FIRST INTERMEDIATE WELDMENTS

13
 3 1 4 6
2
5
1
7

1. SNAP RING
2. BEARING
3. CHAIN SHEAVE
4. SECOND INTERMEDIATE
WELDMENT
5. O–RING
6. SHIM(S)
7. STRIP BEARING
8. INNER WELDMENT
9. LOAD ROLLER

16 8

11

15

14

13 10
1
12 9

11

10. SHIMS
11. COTTER PIN
12. NUT
13. WASHER
14. CHAIN ANCHOR
15. ANCHOR PIN
16. LIFT CHAIN

FIGURE 17. SECOND INTERMEDIATE AND INNER WELDMENTS

14
Assembly (See FIGURE 16. and FIGURE 17.)
NOTE: The shims for the load rollers keep the weld-
ments parallel and give correct clearance. During as-
sembly, the shim arrangement will be approximately the
same as before disassembly. Check the clearance and
adjust the shims for wear or for changes caused by re-
pairs. The strip bearings are also adjusted by using
shims. See CHECKS AND ADJUSTMENTS in this
section for the adjustment procedures.
NOTE: When the mast has header hoses, see the proce-
dures for the HEADER HOSES.
10121
FIGURE 18. STRIP BEARINGS
1. Put the outer weldment on the floor with the mast piv-
ots toward the floor. Connect a crane to the center of the
first intermediate weldment. Fit the lower stub shafts of
the first intermediate weldment into the notches in the
top of the outer weldment. Slide the first intermediate
weldment into the outer weldment so that the stub shafts
are seen at the top and bottom of both weldments.
2. Install the strip bearings and the shims on the channels
of the outer weldment. See FIGURE 18. Apply grease
to the bearing surfaces.
3. Install the load rollers and the shims on the outer
weldment and at the bottom of the first intermediate
weldment. Before doing the next step, adjust the first in-
termediate weldment as described in CHECKS AND
ADJUSTMENTS. Install the chain sheaves, shims and
snap rings on the first intermediate weldment.
4. Install the main lift cylinders in the mounts at the bot-
tom of the outer weldment. Push the intermediate weld-
ment to engage the lift cylinders. Check the clearance at
the top of the lift cylinder mounts. Add or remove shims
at the top of the left–hand cylinder rod until both cylin-
ders are even. Install the keeper at the top of the right–
hand cylinder. Install the snap ring and washer at the top
of the lift cylinders. Install the nuts, bolts and spacers at
the lift cylinder mounts on the outer weldment. Tighten
the nuts to 53 Nm (39 lbf ft) torque.
5. Install the housing for the lowering control valve on
the outer weldment. Tighten the nuts for the lowering
control valve to 18 Nm (13 lbf ft) torque. Install the low-
ering control valve in the housing. Connect the hydrau-
lic lines and fittings between the lowering control valve
and the main lift cylinders.
6. Install the chain sheaves and snap rings on the second
intermediate weldment.
7. Connect a crane to the center of the second intermedi-
ate weldment. Slide the weldment into the first inter-
mediate weldment so that the stub shafts are seen at the
top and bottom of both weldments.
8. Install the strip bearings and the shims on the channels
of the first intermediate weldment. Apply grease to the
bearing surfaces. Install the load rollers and the shims on
the first and second intermediate weldments. Before do-
ing the next step, adjust the second intermediate weld-
ment as described in CHECKS AND ADJUSTMENTS.
9. Connect the lift chains to the chain anchors at the out-
er weldment. Put the lift chains over the chain sheaves
on the first intermediate weldment and connect them to
the anchors at the bottom of the second intermediate
weldment.
10. Connect a crane to the center of the inner weldment.
Slide the weldment into the second intermediate weld-
ment so that the stub shafts are seen at the top and bottom
of both weldments.
11. Install the strip bearings and the shims on the chan-
nels of the second intermediate weldment. Apply grease
to the bearing surfaces. Install the load rollers and the
shims on the second intermediate and inner weldments.
Before doing the next step, adjust the inner weldment as
described in CHECKS AND ADJUSTMENTS.
12. Connect the lift chains to the chain anchors at the top
of the first intermediate weldment. Put the lift chains
over the chain sheaves on the second intermediate weld-
ment and connect them to the anchors at the bottom of
the inner weldment.
15
13. Install the free–lift cylinder in the mounts on the in-
ner weldment. Install the brackets for the cylinder and
tighten the nuts and bolts. LOWER LOAD 2
ROLLERS
14. Install the hose sheave for the free–lift cylinder. 1
2
Install the hydraulic hose and tubing that connect the
free–lift cylinder to the right–hand lift cylinder. Install
the balance line between the two main lift cylinders. 2

15. Connect the free–lift chains to the chain anchors at

2
the inner crossmember. Attach a wire between the other
3
end of the lift chain and the bottom of the mast to control
the free–lift chain during installation of the mast. UPPER LOAD
3 ROLLERS
2
11632
Installation (See FIGURE 13.) 2

1. Lubricate the pivot pins and install them into the 1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
mounts at the drive axle hanger. 3. LOAD ROLLER

2. Connect a crane to the top of the mast using chains. FIGURE 19. LUBRICATE THE MAST
Make sure all the weldments are fastened together.
Make sure the chains will not damage the sheaves, tub- LIFT CYLINDERS
ing or other parts of the mast. Make sure the crane has a
capacity of at least 1600 kg (3500 lb).
WARNING
Before working on or near the mast, see SAFETY
3. Use the crane to install the mast assembly on the pivot PROCEDURES WHEN WORKING NEAR THE
pins. Install the capscrews that hold the mast to the pivot MAST. See FIGURE 9.
pins. Tighten the capscrews to 90 Nm (66 lbf ft) torque.
Removal
4. Connect the tilt cylinders to the mast. Install the an- MAIN LIFT CYLINDERS
chor pin and cotter pin. (See FIGURE 16. And FIGURE 22.)
NOTE: The following procedures are for the removal
5. Connect the hydraulic line to the lowering control
of the lift cylinders with the mast installed on the lift
valve.
truck.
6. Install the carriage as described in the procedures for 1. Remove the carriage as described in the procedures
the CARRIAGE. for the CARRIAGE.

7. Check the tilt cylinder adjustment as described in
CHECKS AND ADJUSTMENTS. Operate the mast
and check for leaks and correct operation. Check the lift
chains as described in CHECKS AND ADJUST-
MENTS.
8. Lubricate the sliding surfaces and the load roller sur-
faces along the full length of the channels as shown in
FIGURE 19. Apply lubricant only to the surfaces indi-
cated.
NOTE: The load rollers and sheaves have sealed bear-
ings and do not need additional lubrication.
16
2. Raise the mast until it is almost fully extended. Use a
safety chain to connect the middle crossmember of the
first intermediate weldment to the top crossmember on
the outer weldment. Lower the mast so that the safety
chain holds the weight of the weldments.
3. On the left–hand lift cylinder, remove the snap ring
from the top of the cylinder rod. On the right–hand lift
cylinder, remove the spacer and retainer from the cylin-
der rod.
4. Put a drain pan under the area of the hydraulic fittings.
Disconnect the hydraulic lines at the cylinder. Retract
the rod into the lift cylinder.
5. Remove the nut, bolt and spacer at the mounts.
6. Use a lifting device as necessary to remove the lift cyl-
inder from the mast. Keep the shims from the top of the
left–hand cylinder with the cylinder.
FREE–LIFT CYLINDER (See FIGURE 16.)
1. Remove the carriage as described in the procedures
for the CARRIAGE. Lower the mast completely.
2. Put a drain pan under the area of the hydraulic fittings.
Disconnect the hydraulic line at the cylinder.
3. Move the chains from the chain sheaves. Remove the
clamp and bracket for the free–lift cylinder. Remove the
free–lift cylinder.
4. See FIGURE 23. Remove the crosshead from the cyl-
inder rod. Disassemble the crosshead as necessary.
Disassembly
(See FIGURE 20. and FIGURE 21.)
CAUTION
Carefully disassemble the lift cylinders so that the
piston rods and sliding surfaces are not damaged.
NOTE: Disassembly of the main lift cylinders and the
free–lift cylinder is similar. All of the lift cylinders are
disassembled from the rod end of the cylinder shell.
1. Loosen the retainer with a spanner.
2. On the free–lift cylinder, do the following:
a. Remove the retainer from the shell.
b. Pull the rod and piston assembly from the shell.
Drain the hydraulic oil into a container.
3. On the main lift cylinders, do the following:
a. Pull retainer and the rod and piston assembly from
the shell. Drain the hydraulic oil into a container.
b. Remove the piston from the rod. Remove the re-
tainer from the rod.
4. Remove and discard the O–rings, seals and wear
rings.
5. On the left–hand lift cylinder and free–lift cylinder,
remove the snap ring, washer and check valve from the
base of the piston.
6. Clean all the parts. Check the sliding surfaces for
damage. Repair or install new parts as necessary.
Assembly (See FIGURE 20. and FIGURE 21.)
NOTE: Assembly of the main lift cylinders and the
free–lift cylinder is similar. All of the lift cylinders are
assembled from the rod end of the cylinder shell.
1. Lubricate all internal parts of the lift cylinder with
clean hydraulic oil or packing lubricant, Hyster Part No.
186061. Use new O–rings, seals and wear rings.
2. On the main lift cylinders, do the following:
a. Install the rod wiper and rod seal in the retainer.
Install the O–ring on the outside of the retainer. Install
the retainer on the rod.
b. Install the O–ring and back–up ring on the piston
for the right–hand cylinder. If a spacer is used, install it
on the rod. Install the piston in the rod. Tighten the pis-
ton to 170 to 200 Nm (125 to 150 lbf ft) torque.
3. Install the check valve and O–ring in the base of the
piston of the free–lift cylinder and left–hand lift cylin-
der. Make sure the arrow on the check valve is towards
the base of the piston. Install the washer and snap ring
for the check valve.
CAUTION
A difficult and important step in assembling lift
cylinders is the correct installation of the seals. Most
lift cylinder maintenance is caused by seal leaks. Do
not damage any parts during assembly.
4. Install the back–up ring, piston seal and wear ring
onto the piston. On the main lift cylinders, install the
seal ring.
5. Carefully push the piston and rod assembly into the
shell.
6. Before installing the retainer, pour 150cc (5 oz) of hy-
draulic oil into the free–lift cylinder shell.
7. On the free–lift cylinder, install the rod wiper and rod
seal in the retainer. Install the O–ring and back–up ring
on the outside of the retainer.
8. Carefully engage the threads and tighten the retainer
in the shell. Use a correct spanner. Do not hit the retainer
with a hammer and driver. Tighten the retainer on the
free–lift cylinder to 475 to 540 Nm (350 to 400 lbf ft)
torque. Tighten the retainer on the main cylinder to 340
to 410 Nm (250 to 300 lbf ft) torque.
17
 RIGHT–HAND LIFT CYLINDER

12 LEFT–HAND LIFT CYLINDER

1
3 13

2
4 5
14

5 15
3
6

5
4
7
5
8
1 6

8
9

7
10
9 12

11 10
1. ROD
2. WIPER 9. PISTON SEAL 11
3. ROD SEAL 10. WEAR RING
4. RETAINER 11. SEAL RING
5. O–RING 12. SHELL
6. SPACER 13. CHECK VALVE
7. BACK–UP RING 14. WASHER
8. PISTON 15. SNAP RING
FIGURE 20. MAIN LIFT CYLINDERS
9. Install the lowering control valve in the port at the Installation
base of the left–hand, main lift cylinder. See
FIGURE 22. Make sure the special washer and the MAIN LIFT CYLINDERS
spring are installed correctly. The special washer is next (See FIGURE 16. and FIGURE 22.)
to the cylinder shell. A wrong installation can cause the
load to lower too fast. 1. Use a lifting device to raise the mast until it is almost
fully extended. See FIGURE 9. Use safety chains to
10. Install the fitting at the base of the free–lift cylinder. connect the bottom crossmember of the first intermedi-
This is a special fitting that limits flow of the hydraulic ate weldment to a crossmember on the outer weldment.
oil. Use safety chains between the other weldments so that
18
they cannot move. Lower the mast so that the safety
chains hold the weight of the weldments. 1

2. Install the lift cylinder in the mount at the bottom of

2 9
the outer weldment. Install the nut, bolt and spacer at the
mount for the lift cylinder. Tighten the nut to 53 Nm (39
lbf ft) torque.
5

3. Install the shims at the top of the left–hand cylinder.

Use a lifting device to lower the first intermediate weld- 3 10
ment onto the lift cylinders. See the MAST–Assembly
procedures for the correct adjustment of the lift cylin- 4 11
ders. Install the snap ring at the top of the left–hand lift
cylinder. Install the retainer, fittings and tube at the top
of the right–hand lift cylinder. Tighten the nuts for the
retainer to 33 Nm (24 lbf ft) torque. 5

4. Connect the hydraulic lines at the lift cylinders. Con-

nect the hydraulic line at the tube on the right–hand lift
cylinder.

5. Install the balance line between the main lift cylin-

ders.

6
6. Connect the main lift chains as necessary and adjust
them as specified in CHECKS AND ADJUSTMENTS.

FREE–LIFT CYLINDER (See FIGURE 16.)

1. See FIGURE 23. Make sure the alignment pin is in

position, then install the crosshead mount on the cylin-
der rod. Tighten the capscrew for the mount to 435 Nm
(320 lbf ft) torque. Install the chain sheaves and nylon 4 1. WIPER 12
spacers in the mount. Install the shaft through the 2. ROD SEAL
3. RETAINER
sheaves. Install the chain guard on the mount, making 4. BACK–UP RING
sure the shaft is in the correct position. Tighten the cap- 7 5. O–RING
screws for the chain guard to 38 Nm (28 lbf ft) torque. 6. ROD AND PISTON
8 7. PISTON SEAL
8. WEAR RING
2. Install the cylinder in the mounts. Install the brackets, 9. CHECK VALVE
spacers, bolts and nuts. Tighten the bolts at the bottom 10. WASHER
bracket to 53 Nm (39 lbf ft) torque. Tighten the nuts at 11. SNAP RING
the top clamp to 38 Nm (28 lbf ft) torque. 12. SHELL

3. Connect the hydraulic line at the cylinder. FIGURE 21. FREE–LIFT CYLINDER

4. Install the carriage as described in the procedures for

the CARRIAGE.
19
 1. BALANCE LINE
2. SNAP RING 2
3. SHIM
4. FITTING AND O–RING 1
5. MAIN LIFT CYLINDER, LEFT–HAND 3
6. LOWERING CONTROL VALVE
FITTING
4

10
5
12

4
8

11 6

7. HOUSING
8. HOSE
9. LOWERING CONTROL VALVE
10
9 10. MAIN LIFT CYLINDER, RIGHT–HAND
11. SPACER
12. RETAINER

FIGURE 22. INSTALLATION OF MAIN LIFT CYLINDERS

HEADER HOSE ARRANGEMENTS
Some lift trucks are equipped with auxiliary hydraulic
functions that are fastened to the carriage. Examples of
these auxiliary functions are a side–shift carriage or a
roll clamp. These auxiliary functions require header
hoses for their operation.
NOTE: Before installing the header hoses, make sure
you know the lift height of the mast. The tension on the
header hoses is adjusted according to lift height. The lift
height is on the nameplate of the lift truck and on the
right–hand side of the outer weldment.
Installation, Header Hoses (See FIGURE 24.
through FIGURE 26. and TABLE 1.)
WARNING
Before working on or near the mast, see SAFETY
PROCEDURES WHEN WORKING NEAR THE
MAST. See FIGURE 9.
NOTE: This procedure is for the four function option.
The three function option will have hoses “A” and “B”
only.
NOTE: The carriage height must be correct before the
header hoses can be adjusted. See ADJUST THE LIFT
CHAINS for the carriage adjustment procedure.
NOTE: If the header hoses were removed, use this pro-
cedure to install the Type “A” or Type “B” header hoses.
See TABLE 1. If the mast components have not been as-
sembled, assemble the mast as described in the previous
procedure.
1. Raise the carriage so that the free–lift chains are not
tight. Raise the inner channel so that the main–lift chains
are not tight. Install chains to prevent the inner channel
and carriage from moving. The chains must not be in the
path of the header hose.

20
 2 3 4 5
1

8 9
18 8

10

9
7

5 11
12

13

1. HOSE
2. HOSE SHEAVE
3. STUB SHAFT WELDMENT
4. WASHER
5. CAPSCREW
6. CHAIN GUARD
7. SPACER 14
8. CHAIN SHEAVE
9. SNAP RING
10. PIN
11. CROSSHEAD
12. ALIGNMENT PIN
13. FREE–LIFT CYLINDER
14. STRAP 15
15. TUBE SPACER
16. BRACKET
17. LOWERING CONTROL
VALVE FITTING
18. BEARING

17 16

FIGURE 23. CROSSHEAD AND FREE–LIFT CYLINDER ASSEMBLY

2. Install all hose sheaves loosely. Do not tighten caps- 3. Make sure the replacement header hose is the correct
crews and nuts until header hoses are installed. part number for your mast assembly. Make sure the

21
header hoses are straight on a flat surface. Mark header FIGURE 25.:
hose at points ”E” and “G” (mm) as shown in TABLE 1. a. Put a coating of multi–purpose grease on the stub
Measure from the end of the hose with the small fitting. shafts before assembly.
4. Loosely assemble the hose sheaves as shown in

2
1 3 5
4
DC B A

3
DC B A

6
5
DC BA
1 4

2 8

DC B A
A B C D = HOSES

1372390 2/3 R7
DC BA
1. CARRIAGE
6
1 2. MAST ASSEMBLY
7 3. CHAIN AND HOSE SHEAVES
DC B A AT FREE–LIFT CYLINDER
4. REAR HOSE SHEAVES
5. FRONT HOSE SHEAVES
2 6. MIDDLE HOSE SHEAVES
D A 7. MIDDLE HOSE CLAMP
8. CABLE MOUNT BLOCKS
CB 9. BOTTOM HOSE CLAMP
DC BA ASSEMBLIES
9 8
8

FIGURE 24. HOSE SHEAVES AND ROUTING

22
 TABLE 1. STANDARD FOUR–STAGE HOSE DIMENSIONS
Channel
Lift Height Length Dimension “E” Dimension “G”
(Reference)
mm in mm mm in mm in
4839 190.5 1735 1351 53.2 4750 187.0
5143 202.5 1811 1426 56.1 4971 195.7
5450 214.6 1888 1501 59.1 5192 204.4
5754 226.5 1964 1576 62.1 5414 213.1
6058 238.5 2040 1651 65.0 5635 221.9
6364 250.6 2141 1751 68.9 5930 233.5
6670 262.6 2243 1851 72.9 6225 245.1
6977 274.7 2345 1951 76.8 6520 256.7
7274 286.4 2446 2051 80.8 6815 268.3
7583 298.5 2548 2151 84.7 7110 279.9
7886 310.5 2649 2251 88.6 7405 291.6
8192 322.5 2751 2351 92.6 7701 303.2
8496 334.5 2853 2452 96.5 7996 314.8
8799 346.4 2954 2552 100.5 8291 326.4
9108 358.6 3056 2652 104.4 8586 338.0

Dimension “G”
Dimension “E”

TYPE A

Dimension “G”
Dimension “E”

TYPE B 1372025 1/1 R1

“E” = (0.985 x channel length in mm) –358.2 “G” = (2.905 x channel length in mm) –291.0

b. The nuts for the sheave capscrew (axle) must be
on the inside of each assembly.
c. Do NOT tighten any of the nuts or capscrews.
They must be loose to allow installation of the
hoses on the hose sheave.
5. Install the plate at the middle hose clamp and tighten
the capscrews to 8 Nm (6 lbf ft) torque.
6. Install the bottom hose clamps as shown in
FIGURE 24. Put some grease on the bottom of the
brackets so that the hoses can slip to equalize the pres-
sure. Tighten the capscrews and nuts of the bracket to 18
Nm (13 lbf ft) torque. Do NOT tighten the capscrews
and nuts for the strap clamps at this time.
7. If the crosshead of the free –lift cylinder does not have
hose guides, remove the chain guard brackets, chains
and chain sheaves. Install hose guides (flare towards
outside) and snap rings to the chain sheaves. Install the
free–lift sheaves, chains and chain guard brackets as
shown in FIGURE 24. and FIGURE 26.
23
 17 16

14
1. CARRIAGE CLAMP
2 15 2. WASHER
29 15 3. HOSE SHEAVE
4. STUB SHAFT
3 5. STUB SHAFT
27 WELDMENT
4 6. SNAP RING
18 7. HOSE GUIDE
8. CLAMP, C–D
3 14
29 9. PLATE
10. CLAMP, A–B
11. HOSE BRACKET
24 12. GUIDE BRACKET
13. STRAP
26 5 14. HOSE GUARD
15. STUB SHAFT
2 16. TUBE
14 15 17. ROLLER
3 18. CABLE ROLLER
18 16 6 19. CABLE ASSEMBLY
17 20. NUT
7
25 21. BLOCK
14 22. PIN
15 9
14 23. COTTER PIN
17 8
24. HEADER HOSE
25. HOSE MOUNT
16
26. HOSE CLAMP
27. CLAMP, C–D
19 28. SPRING
6
18 29. SPACER
28 2 2
26 23
20 28
10
20

22 19
2
25
21 2

24
11 11
1

12
13

FIGURE 25. HEADER HOSES

24
 D C B A

8 9

C B

D A 10

D 4

BACK VIEW 5 SIDE VIEW

1. HOSE SHEAVE NO. 1 6. GUIDE BRACKET

2. HOSE SHEAVE NO. 2 7. CLAMP, C–D
3. FLOATING SHEAVE ASSEMBLY 8. CLAMP, C–D
4. CLAMP, A–B 9. CLAMP, A–B
5. CABLE MOUNT 10. FREE–LIFT CROSSHEAD

FIGURE 26. HEADER HOSE ARRANGEMENT

25
8. Install hoses over the free–lift cylinder with marks
“E“ aligned with the top edge of the clamp of the middle
hose clamp assemblies. Tighten the capscrews and nuts
of the clamps to 8 Nm (6 lbf ft) torque.
9. Pass the hoses under the lower hose clamps and install
the strap clamps on the hoses. Align marks “G“ to the
bottoms of the lower hose clamps. Tighten the caps-
crews and nuts of the strap clamps to 18 Nm (13 lbf ft)
torque.
10. Install the hoses on hose sheaves (items 5 & 4 of
FIGURE 24.) with loops long enough to install on the
floating hose sheaves. Tighten the axle capscrews and
nuts of sheaves 4 & 5 to 53 Nm (39 lbf ft) torque.
11. Partially assemble the floating sheaves (6) as shown
in FIGURE 24. and FIGURE 25. Install the loops of the
hoses under the sheaves (6). Then install the roller guide
assemblies over the hoses and between the hose guards.
See FIGURE 24. and FIGURE 26. Tighten the roller
guide capscrews and nuts to 8 Nm (6 lbf ft) torque.
12. Fasten the looped ends of the cables of the floating
sheaves to the cable mount blocks. Use the pins, wash-
CHECKS AND ADJUSTMENTS
CHECK FOR LEAKS IN THE LIFT AND
TILT SYSTEM
WARNING
During the test procedures for the hydraulic system,
use chains to fasten the load to the carriage to pre-
vent it from falling. Keep all people away from the
lift truck during the tests.
Do not try to find hydraulic leaks by putting your
hand on hydraulic components under pressure. Hy-
draulic oil can be injected into the body by the pres-
sure.
Check The Lift Cylinders For Leaks
1. Operate the hydraulic system. Put a capacity load on
the forks. Use a safety chain to hold the load to the car-
riage. Raise and lower the load several times. Lower the
load and tilt the mast forward and backward several
times. Check for leaks.
26
ers, and cotter pins to fasten the cable loops. See
FIGURE 25. If necessary, install the mount blocks on
the bottom crossmember of the intermediate channel us-
ing the capscrews and washers. Tighten the capscrews
to 18 Nm (13 lbf ft) torque.
13. Make sure the cables are in the grooves of the idler
wheels and under the formed feature of the hose guards
of the floating sheaves. Install the ends of the cables in
the brackets so that there is spring tension on the cables.
Make sure the axle capscrews and nuts of the sheaves
are tightened to 53 Nm (39 lbf ft) torque.
14. Slowly operate the hydraulic system so that the lift
chains are tight. Remove the chains that fasten the car-
riage and channel weldment. Slowly raise the carriage
using the hydraulic system. Make sure the hoses move
through all the sheaves correctly.
15. Slowly operate the mast through a few cycles to
make sure the hoses track correctly. Tighten the strap
clamps at the bottom hose clamps to 18 Nm (13 lbf ft)
torque. Fasten the hose assemblies to the main cylinders
using hose clamps and screw clamps as shown in
FIGURE 24. and FIGURE 25.
2. Raise the carriage and load one meter (3 ft). If the car-
riage slowly lowers when the control valve is in the Neu-
tral position, there are leaks in the hydraulic system. The
maximum speed that the carriage is allowed to lower is
50 mm (2 in) per 10 minutes when the hydraulic oil is
30°C (90°F). If the oil temperature is 70°C (160°F), the
maximum speed that the carriage can lower is 150 mm
(6 in) per 10 minutes.
3. Check the lift cylinders for internal leaks. Remove the
load from the forks. Install a gate valve in the supply line
between the main control valve and the mast. Put a ca-
pacity load on the forks again. Raise the carriage one
meter (3 ft). Close the gate valve. If the carriage or mast
weldments lower slowly, the seals in the lift cylinders
have leaks.
4. If the carriage does not move, open the gate valve and
check the movement again. If the carriage lowers when
the gate valve is open, check for leaks in the hydraulic
lines and fittings. If no leaks are found, the main control
valve can be worn or damaged. Remove the load from b. Slowly tilt the mast backward until one rod end just
the forks. contacts the spacer. Add shims to fill the gap at the op-
posite rod end until both rod ends contact the spacers
Check The Tilt Cylinders For Leaks within 0.5 mm (0.02 in).
1. Put a capacity load on the forks. Use a safety chain to c. After the adjustments are complete, tighten the
hold the load to the carriage. Raise the load approxi- capscrews on the rod ends.
mately 2.5 m (8 ft). Put the mast in a vertical position. d. Tilt the mast fully backward and measure the tilt
angle. (See Nameplate for tilt angles.) If necessary,
2. Measure the distance that the rod for the tilt cylinder
add an equal number of shims to both rods for the cor-
extends from the shell. Check the distance the rod
rect angle.
moves in five or ten minutes. The maximum tilt rate
with the oil at 20°C (68°F) is 1.0 mm/min (0.04 in/min).
The maximum tilt rate with the oil at 60°C (140°F) is 6.8 1
mm/min (0.30 in/min). 2 3
4
3. If the tilt rate is greater than the specifications, lower
5
the mast and remove the load from the forks. Install a
valve between the port at the front of the tilt cylinder and
the hydraulic line. Put the load on the forks again. Close
the valve. Tilt the mast forward just past the vertical
position. If the mast continues to tilt slowly forward, the
seals on the piston are leaking. 2
4. If the mast does not move, open the gate valve and
check the movement again. If the mast moves forward
when the gate valve is open, check for leaks in the hy-
draulic lines and fittings. If no leaks are found, the main
control valve can be worn or damaged. Remove the load
from the forks when the checks are complete.

ADJUST THE TILT CYLINDERS

(See FIGURE 27.) DIMENSION “A” = 15 mm (0.60 in)
WARNING 1. MAST
When the tilt cylinders have tilt limit spacers, make 2. ROD END 4. TILT LIMIT SPACER
sure they are installed during installation proce- 3. SHIMS 5. TILT CYLINDER
dures. Without the tilt limit spacers, the mast can tilt FIGURE 27. TILT CYLINDER ADJUSTMENTS
too much and cause an accident or serious injury.
LIFT CHAIN ADJUSTMENTS
Check the tilt cylinder stroke by slowly tilting the mast
fully forward and backward several times. Both tilt cyl- WARNING
inders must stop their stroke at the same time. Adjust the When working on or near the mast, see SAFETY
rod ends to dimension A for all tilt cylinders as shown in PROCEDURES WHEN WORKING NEAR THE
MAST. See FIGURE 9.
FIGURE 27. There must be no twist in the mast weld-
ments. Adjust the tilt cylinders as follows: During the test procedures for the mast, use chains to
fasten the load to the carriage to prevent it from fall-
a. Slowly tilt the mast forward until one cylinder rod ing. Keep all people away from the lift truck during
stops. On the opposite cylinder, loosen the capscrews the tests.
on the rod end. Use a wrench and turn the cylinder rod Never allow anyone under a raised carriage. Do not
IN as necessary. Repeat this procedure until both cyl- put any part of your body in or through the lift
inder rods stop at the same position within 1 mm (0.04 mechanism unless all parts of the mast are com-
in). pletely lowered and the power is OFF.
27
When the lift chains are correctly adjusted:
• The tension will be the same on each chain of the
chain set. Check tension by pushing on both
chains at the same time.
• The chain length will be correct.
• The chains must travel freely through the com-
plete cycle.
Do the following procedure to check the lift chains:
1. Put a load equal to 80 to 90% of the capacity load on
the forks. Use safety chains to hold the load to the car-
riage. Lower the forks as much as possible.
2. See FIGURE 28. Check the amount that the bottom
carriage roller extends below the inner channel of the
mast. The carriage roller must not extend more than 1/3
of the roller diameter below the inner channel. If the ad-
justment is not correct, remove the load and adjust the
chain anchors. Make sure each chain anchor is adjusted
the same amount. Put the mast in a vertical position and
adjust the chain anchors so that the lower edge of the
bottom carriage bar is 82.5 mm (3.25 in) above the floor.
3. Adjust the lift chains at the outer weldment so that the
top of the second intermediate weldment is even with
the top of the outer weldment within 1.5 mm (0.06 in).
4. Adjust the lift chains at the first intermediate weld-
ment so that the top of the inner weldment is even with
the top of the outer weldment within 1.5 mm (0.06 in).
5. When the chain adjustments are complete, make sure
that the threads on the nuts of the chain anchors are com-
pletely engaged. Make sure that all of the adjustment is
not removed from the chain anchors. The chain anchors
must be able to move in their sockets.
6. Check the clearance of the carriage when the mast is
fully extended. The carriage stops must not touch the
stop on the top crossmember of the inner weldment. The
chains are too tight if the carriage touches the
crossmember.
7. Lower the mast completely and put a capacity load on
the forks. Tilt the mast fully backward and do Step 2
again.
MAST ADJUSTMENTS (See FIGURE 29.)
NOTE: Shims are installed on both sides of the load
rollers. Do not add or remove shims from the stub shafts.
To change the position of the roller on the stub shaft,
28
move the shims from one side of the load roller to the
other.
1
3
4
4691
2
1. TILT MAST FULLY BACKWARD
2. CARRIAGE ROLLER
3. FORK
4. CARRIAGE ROLLER MUST NOT
EXTEND MORE THAN 34 mm (1.3 in)
BELOW THE MAST CHANNEL
FIGURE 28. ADJUST THE LIFT CHAINS
During assembly, the shim arrangement will be approxi-
mately the same as before disassembly. Check the clear-
ance and adjust for wear or change because of repairs.
1. The load rollers control the alignment of the weld-
ments. The alignment conditions are given on a list be-
low with the most important condition first. See
FIGURE 29.
a. The weldments must be parallel to each other.
b. Use shims to adjust the load rollers so that there is
zero clearance between the load roller and the channel
at the point of tightest fit.
c. The number of shims under a load roller must be
approximately the same as the stub shaft in the oppo-
site side of the weldment. The weldments will be ap-
proximately in the center.
2. Do the following steps to adjust the mast load rollers:
a. Use a crowbar to move the weldments from side
to side to measure the movement. Measure the
movement in a minimum of three different posi-
tions of the weldments.
b. Separate the mast weldments and change the
shim arrangements as required. Assemble the
weldments. Slide the weldment all the way to the
top and bottom to find the tightest fit.
 c. Repeat Steps a and b until there is zero clearance
at the point of the tightest fit.
d. Measure the distance between the channels of the
weldments on the top and bottom. Change shims
to keep the distance equal between the top and
bottom so that the mast weldments are parallel.
Also make sure that the weldments are parallel
within 1.5 mm (0.060 in).
3. Adjust the strip bearings. See FIGURE 30. Insert
shims under the strip bearing. Adjust the clearance until
there is less than 0.8 mm (0.030 in) at the tightest fit. See
FIGURE 29.
CARRIAGE ADJUSTMENTS
(See FIGURE 29.)
1. Install the six load rollers on the carriage. Install the
shims for the rollers in the same sequence on the stub
shaft before disassembly.
2. Use a lifting device to raise the carriage up the inner
channel. Find the point of tightest fit between the load
rollers and the inner channels.

TOP VIEW MAST CARRIAGE

FRONT VIEW FRONT VIEW

6
1
7

2
9

10

3
11

4 5

5 8
8

1. CHANNEL 7. ZERO CLEARANCE AT 10. PUT SPACER ON OUTSIDE

2. LOAD ROLLER POINT OF TIGHTEST FIT OF TOP LOAD ROLLER,
3. STUB SHAFT 8. EQUAL SPACE ± 1.5 mm UNDER SNAP RING
4. SNAP RING (0.060 in) 11. SHIM FOR ZERO
5. SHIMS 9. PARALLEL CLEARANCE AT POINT OF
6. PARALLEL TIGHTEST FIT
USE SHIMS TO KEEP CARRIAGE AND MAST WELDMENTS PARALLEL, TO GIVE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND WELDMENTS AND TO GIVE ZERO CLEAR-
ANCE AT POINT OF TIGHTEST FIT. 4690

FIGURE 29. MAST ADJUSTMENTS

29
3. Remove the carriage from the mast. Adjust the shim
arrangement for each roller for clearance between the
roller and the inner channel. Repeat Steps 1 and 2 until
there is zero clearance at the point of tightest fit.
4. Keep the shim arrangement on each side of the car-
riage approximately equal. Also keep the shim arrange-
ment on each side of the carriage approximately equal.
The carriage must run parallel with the inner weldment
within +1.5 mm (0.060 in.
5. After adjustment, lubricate the channels with a thin
layer of grease. Adjust the hydraulic hoses and make
sure the connections are correct if the carriage is
equipped with hydraulic attachments.
CAUTION
Too much grease will cause the rollers to slide and
wear flat areas on the rollers.

3
2
3
2
1.STRIP BEARING
2. LOAD ROLLER
3. WELDMENT
4. SHIMS
5. O–RING 1
4
1
4

3
3 3 10106
5

FIGURE 30. ARRANGEMENT OF THE STRIP BEARINGS

30
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE
Slow or no movement of lift Air is in the hydraulic system.
or tilt cylinders. The hydraulic pump is worn or dam-
aged.
Restriction in the hydraulic lines.
Cylinder seals are damaged.
Load is greater than capacity.
Linkage is disconnected or damaged.
Pressure relief valve(s) is not adjusted
correctly or is damaged.
Large leaks between spool and bore.
Spool is not fully extended or re-
tracted.
Rough movement of the mast Air is in the hydraulic system.
assembly. Lift cylinder(s) is damaged.
Mast weldments are damaged or not
aligned.
Mast weldments are not lubricated
correctly.
Lift or tilt cylinders retract Check valve for the lift spool is dam-
when the spool is in the NEU- aged.
TRAL position. Cylinder seals have leaks.
Hydraulic lines have leaks.
Leaks between the lift spool and the
bore.
Tilt cylinders extend when the Cylinder seal have leaks.
tilt spool is in the NEUTRAL Oil leaks between control valve spool
position. and bore.
Hydraulic lines have leaks.
PROCEDURE OR ACTION
Remove air from hydraulic system.
Repair or replace hydraulic pump.
Repair hydraulic lines.
Repair cylinders.
Reduce load.
Repair and adjust linkage for control
levers.
Repair or adjust relief valve(s).
Replace valve section.
Adjust linkage to spool.
Remove air from hydraulic system.
Repair cylinder(s).
Repair or adjust mast weldments.
Lubricate mast correctly.
Replace check valve.
Repair lift cylinders.
Repair or tighten lines or fittings.
Replace valve section.
Repair tilt cylinders.
Replace valve section.
Repair or tighten lines or fittings.
31