Maintenance

2-STAGE MAST

PART NO. 550088524 4000 YRM 1647

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE 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 re-
move 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
Series Code / Model Designation Reference Table ..................................................................................................1
General ..................................................................................................................................................................... 1
Description And Operation ........................................................................................................................................1
Mast System .........................................................................................................................................................1
Tilting .................................................................................................................................................................... 1
Lifting .................................................................................................................................................................... 2
Operation ......................................................................................................................................................... 2
Pilot Operated Check Valves ........................................................................................................................... 3
Gland Lubrication ............................................................................................................................................. 4
Emergency Lowering Valve ............................................................................................................................. 4
Operation ..................................................................................................................................................... 4
Lift Chains ........................................................................................................................................................ 5
Elongation Through Wear ............................................................................................................................5
Speed of Wear .............................................................................................................................................5
Plate Height Wear ........................................................................................................................................6
Lubrication ................................................................................................................................................... 6
Restoring The Oil Film ................................................................................................................................. 6
Maintenance ................................................................................................................................................ 6
Maintaining The Presence of Oil ..................................................................................................................7
Corrosion Protection .................................................................................................................................... 7
Requirements for Chain Lubricant ............................................................................................................... 7
Load Rollers ..................................................................................................................................................... 8
Bearing Blocks ................................................................................................................................................. 8
Carriage ................................................................................................................................................................9
Standard Carriage with Manual Fork Positioning .............................................................................................9
Standard Carriage with Hydraulic Fork Positioning ..........................................................................................9
Dual Function Side Shift and Fork Positioning (DFSSFP) Carriage .............................................................. 10
Integral Side Shift ...........................................................................................................................................10
Carriage Valve ............................................................................................................................................... 11
Alternating Pressure and Tank (P & T) ...................................................................................................... 11
Fixed Pressure and Tank (P & T) .............................................................................................................. 11
Flow Divider for Simultaneous Fork Positioning .............................................................................................11
Valve for Dual Function with Side Shift and Fork Positioning (DFSSFP) .......................................................13
Fixed Pressure and Tank System (Fixed P & T) ............................................................................................15
Forks .............................................................................................................................................................. 17
Safety Procedures When Working Near Mast ....................................................................................................18
Before Starting Repairs to the Hydraulic System, Always: .................................................................................19
Remove and Replace ............................................................................................................................................. 19
Forks ...................................................................................................................................................................19
Remove ..........................................................................................................................................................19
Install ..............................................................................................................................................................20
Fork Guide And Fork Pin .................................................................................................................................... 21
Remove ..........................................................................................................................................................21
Install ..............................................................................................................................................................21
Carriage ..............................................................................................................................................................22
Remove ......................................................................................................................................................22
Install ..........................................................................................................................................................23
Carriage Bearing Blocks ................................................................................................................................ 24
Remove ......................................................................................................................................................24
Install ..........................................................................................................................................................25

©2016 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Carriage Load Rollers .................................................................................................................................... 25
Replace ......................................................................................................................................................25
Side Shift Cylinder ..........................................................................................................................................27
Remove ......................................................................................................................................................27
Disassemble .............................................................................................................................................. 27
Clean And Inspect ......................................................................................................................................28
Assemble ................................................................................................................................................... 28
Install ..........................................................................................................................................................29
Fork Positioner Cylinder .................................................................................................................................29
Remove ......................................................................................................................................................29
Disassemble .............................................................................................................................................. 30
Clean and Inspect ......................................................................................................................................30
Assemble ................................................................................................................................................... 31
Install ..........................................................................................................................................................31
Carriage Valves ..............................................................................................................................................31
Remove ......................................................................................................................................................31
Install ..........................................................................................................................................................32
Valve for Fixed P & T Systems ...................................................................................................................... 32
Remove and Disassemble .........................................................................................................................32
Clean and Inspect ......................................................................................................................................34
Assemble and Install ..................................................................................................................................34
Flow Divider for Simultaneous Fork Positioning Valve ...................................................................................35
Restrictor Valve and Relief Valve Replacement ........................................................................................ 35
Dual Function Valve for Side Shifting and Fork Positioning ...........................................................................35
Solenoid Valve Replacement .....................................................................................................................35
Relief Valve Replacement ..............................................................................................................................36
Remove ......................................................................................................................................................36
Install ..........................................................................................................................................................36
Mast ....................................................................................................................................................................36
Lift Chains and Top Chain Anchor ................................................................................................................. 36
Remove ......................................................................................................................................................36
Install ..........................................................................................................................................................36
Chain Anchor On Carriage .............................................................................................................................37
Remove ......................................................................................................................................................37
Install ..........................................................................................................................................................37
Chain Sheave .................................................................................................................................................38
Remove ......................................................................................................................................................38
Install ..........................................................................................................................................................38
Header Hoses ................................................................................................................................................ 39
Remove ......................................................................................................................................................39
Install ..........................................................................................................................................................41
Electric Mast Cable ........................................................................................................................................ 41
Remove ......................................................................................................................................................41
Install ..........................................................................................................................................................41
Hose Sheave ..................................................................................................................................................42
Remove and Disassemble .........................................................................................................................42
Assemble and Install ..................................................................................................................................42
Mast Assembly ...............................................................................................................................................43
Remove ......................................................................................................................................................43
Disassemble .............................................................................................................................................. 45

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Assemble ................................................................................................................................................... 46
Install ..........................................................................................................................................................47
Inner Mast Load Rollers ................................................................................................................................. 49
Replace ......................................................................................................................................................49
Mast Bearing Blocks ...................................................................................................................................... 50
Remove ......................................................................................................................................................50
Install ..........................................................................................................................................................50
Lift Cylinders .......................................................................................................................................................51
Remove ..........................................................................................................................................................51
Disassemble ...................................................................................................................................................54
Clean and Inspect .......................................................................................................................................... 54
Assemble ....................................................................................................................................................... 54
Install ..............................................................................................................................................................55
Tilt Cylinders .......................................................................................................................................................56
Remove ..........................................................................................................................................................56
Disassemble ...................................................................................................................................................57
Clean and Inspect .......................................................................................................................................... 57
Assemble ....................................................................................................................................................... 57
Install ..............................................................................................................................................................58
Checks and Adjustments ........................................................................................................................................ 59
General Checks ..................................................................................................................................................59
Mast Condition Check .................................................................................................................................... 59
Mast Operation Check ................................................................................................................................... 60
Counterbalance Valve Check (for Only) E876 and E877................................................................................60
Fork Inspection and Adjustment .....................................................................................................................60
Lift Chain Inspection .......................................................................................................................................61
Lift Chain Lubricant Requirements .................................................................................................................62
Lift Chain Lubrication Procedure ....................................................................................................................62
Leak Checks .................................................................................................................................................. 62
Mast Vertical Creep ................................................................................................................................... 62
Mast Tilt Drift ..............................................................................................................................................63
Adjustments ........................................................................................................................................................63
Lift Cylinder Shimming ................................................................................................................................... 63
Lift Chain and Fork Height Adjustment .......................................................................................................... 65
Header Hose Tension Adjustment ................................................................................................................. 67
Electric Mast Cable Tension Adjustment ....................................................................................................... 67
Counterbalance Valve Adjustment .................................................................................................................67
Tilt Cylinder Backward Tilt Angle Adjustment ................................................................................................ 68
Mast Support Pad Adjustment ....................................................................................................................... 68
Troubleshooting ...................................................................................................................................................... 69
Introduction .........................................................................................................................................................69
No Hydraulic Movement With Engine Running .................................................................................................. 69
Initial Basic Check ..........................................................................................................................................69
Electrical Supply .............................................................................................................................................70
Hydraulic Supply ............................................................................................................................................ 70
Fault Code ......................................................................................................................................................70
No Lowering Possible with Engine OFF ............................................................................................................. 71
Incorrect Movement ............................................................................................................................................71
Irregular (shaking) Movement or Slight Carriage Movement When Starting Engine ..................................... 71
Unequal Movement of Left And Right Tilt Cylinder ........................................................................................ 71

iii
Table of Contents

TABLE OF CONTENTS (Continued)

Insufficient Lifting Speed ................................................................................................................................ 71
Insufficient Lifting Capacity ............................................................................................................................ 72
Incorrect Lowering Speed .............................................................................................................................. 72
Lift Cylinder Creep ......................................................................................................................................... 72
Tilt Cylinder Creep ......................................................................................................................................... 72

This section is for the following models:

iv
4000 YRM 1647 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table

This section is for the following models:

Series Code European Model Americas Model

D876 GDP/GLP80-120DB GP/GDP/GLP170-280DB
D877 GDP/GLP130-160EB GP/GDP/GLP300-360EB
E876 GDP80DC, GDP90DC, GDP100DC, GDP190DC, GDP210DC, GDP230DC,
GDP100DCS, GDP120DC GDP230DCS, GDP250DC, GDP280DC)
E877 GDP130EC, GDP140EC, GDP160EC GDP300EC, GDP330EC, GDP360EC
F876 GDP80-120DC, GDP100DCS GDP190-280DC, GDP230DCS
F877 GDP130-160EC GDP360-360EC
G876 GDP80-120DC, GDP100DCS GDP190-280DC, GDP230DCS
G877 GDP130-160EC GDP360-360EC

General

This manual contains the description and repair procedures for the two stage mast and its components. The com-
ponents of the mast include the inner and outer mast, tilt and lift cylinders, carriage and forks.

Description And Operation

MAST SYSTEM TILTING

The function of the mast assembly is to lift a load ver-
tically. It consists of an outer mast, inner mast and a
carriage. The outer mast is attached to the truck
frame. Inside the channels of the outer mast, the inner
mast moves up and down, guided by rollers. Inside
the channels of the inner mast, the carriage moves up
and down guided by rollers. The forks or an attach-
ment are mounted on the carriage.
The vertical movement of the inner mast and carriage
is provided by two lift cylinders and lift chains. For-
ward and backward tilting of the mast is provided by
the tilt cylinders. Different carriage options are availa-
ble for side shifting, fork positioning or for attach-
ments.
The mast pivots on pins, which are bolted to the outer
mast. The pins rotate in bushings that are installed in
the mast mounts at the front of the frame. By extend-
ing or retracting the tilt cylinders, the mast tilts forward
or backward. The maximum tilt angles are determined
by the end stroke positions of the tilt cylinders. The
length of the two tilt cylinders must be adjusted to pre-
vent the tilt cylinders from twisting the mast in the
maximum back tilted position.
The hydraulic pressure in the tilt cylinders is deter-
mined by the combined weight of the mast assembly
and the load, and by the horizontal distance between
the mast pins and the combined point of gravity of
mast and load.

The masts for GDP80-120DC and H300-360HD2 A valve is installed in the connection with the rod side
trucks are similar, and only differ in the dimensions of of the tilt cylinders to improve control of tilt cylinder
their components. movement. This valve can be a counterbalance valve
or a relief valve.

1
Description And Operation 4000 YRM 1647

A counterbalance valve is installed on E876 and E877
units produced before November 2012. The counter-
balance valve has no oil flow restriction when tilting
backward. The counterbalance valve acts as a
35 MPa (5076 psi) relief valve as pressure builds up
at the rod side of the tilt cylinders. When tilting for-
ward, supply pressure at the piston side opens the
counterbalance valves and relieves pressure at the
rod side of the tilt cylinders. To prevent racking of the
mast, the counterbalance valves must be adjusted to
obtain equal pressures in the two cylinders when tilt-
ing forward.
The lowering control valve is a pressure compensated
valve. It allows an increasing flow with increasing
pressure until a preset maximum flow is reached. The
result is that similar lowering speeds are obtained for
loaded and unloaded conditions. The primary function
of the lowering control valve is to limit the lowering
speed in case of a malfunction of the supply/return
connection. The different lift height capacities are de-
termined by the dimensions of the various mast as-
semblies. The lowest position of the forks is deter-
mined by the adjustment of the chain anchors.

A relief valve is installed on lift trucks manufactured

after November, 2012. When tilting forward, additional
oil pressure must be applied at the piston side, above
the pressure which is required for tilting. This addi-
tional oil pressure is required to open the
14 MPa (2031 psi) relief valves.

LIFTING

The lift cylinders are supported at the base of the

outer mast. When the cylinders extend, they push the
inner mast upwards. The chains are attached to the
outer mast and carriage, and they run over the chain
sheaves at top of inner mast. When inner mast moves
upwards, chains pull the carriage upwards to twice
the distance that the lift cylinders have extended. See
Figure 1.

Operation

The lift cylinders extend when hydraulic pressure ap-

plied is sufficient to lift the combined weight of the
load, forks, carriage and inner mast. Lowering is ach-
ieved by releasing hydraulic pressure, which is in- 1. LIFT CYLINDERS
2. OUTER MAST
duced by the weight resting on the rod of the lift cylin- 3. INNER MAST
ders. 4. CHAIN SHEAVE
5. LIFT CHAIN
Lifting speed and lowering speed are controlled by the 6. CARRIAGE
moved position of lift spool in the main control valve.
Figure 1. Operation of a Two-Stage Mast
Maximum lifting speed is determined by maximum
pump supply. Maximum lowering speed is determined
by the lowering control valve at the bottom of each lift
cylinder.

2
4000 YRM 1647
Pilot Operated Check Valves
The lift spool in the main control valve does not seal
completely in the neutral position. To obtain zero leak-
age, a pilot operated check valve is mounted in the
main control valve between lift spool and lift cylinder.
See Figure 2.
When raising the mast, oil supply will pass through a
check valve in the pilot operated check valve. To
lower mast, the pilot operated check valve must be
moved into the open position. The position of the pilot
operated check valve, is determined by oil pressure at
the cylinder side of the check valve, and by the com-
bined force of a spring and oil pressure at pilot side of
check valve. Spring force will keep the check valve
closed when equal pressures exist at the pilot side
and cylinder side of the check valve.
1. PILOT OPERATED CHECK VALVE
2. EMERGENCY LOWERING VALVE (IN LH LIFT
SECTION ONLY)
Figure 2. Pilot Operated Valves – Schematic
Description And Operation
The pilot operated check valve opens when pressure
at the cylinder side of valve exceeds the combined
force of spring and oil pressure at the pilot side. Oil
pressure at the pilot side of the check valve reliefs to
tank by opening the pilot operated selector valve. The
pilot operated selector valve is opened by pilot pres-
sure from the lift spool, when the lift spool has moved
into the lowering position.
Lowering the lift cylinders can be interrupted by re-
turning the lift spool into the neutral position, which in-
terrupts pilot supply to the pilot operated selector
valve, causing the selector valve to close. The closed
selector valve allows lift cylinder pressure to build up
at the spring side of the check valve, causing the pilot
operated check valve to close as well. See Figure 2.
3. PILOT SIDE
4. PILOT OPERATED SELECTOR VALVE
5. CYLINDER SIDE
3
Description And Operation
Gland Lubrication
To provide lubrication to the seals in the gland, the
rod side inside the lift cylinder is filled with hydraulic
oil. When the cylinder extends to highest position,
some of the oil moisturizes the gland seals.
The area between shell and rod is closed off by a
1 MPa (145 psi) check valve, which is located at the
lower cross member of outer mast. The function of the
1 MPa (145 psi) check valve is to retain air pressure
at the rod side.
When the cylinder extends, the increasing air pres-
sure between shell and rod pushes the oil through the
holes into the inside of the rod. When the cylinder re-
tracts, the reducing air pressure at the shell side al-
lows oil to return from the rod inside to the highest
possible position on the rod outside.
Emergency Lowering Valve
The lift cylinders will NOT lower if lift cylinder pressure
is insufficient to overcome the combined force of the
spring and the oil pressure at the pilot side of check
1. EMERGENCY LOWERING CONTROL VALVE
Figure 3. Emergency Lowering Control Valve - Location
4
4000 YRM 1647
valve. This situation occurs for instance, when the
weight of carriage has been removed from lift cylin-
ders. The emergency lowering valve provides the
possibility to manually relieve lift cylinder pressure to
tank.
The emergency lowering valve combines three func-
tions in one assembly. The anti-cavitation valve opens
when lift cylinder pressure is lower than tank pres-
sure. The shock valve opens when (under extreme
conditions) lift cylinder pressure exceeds
35 MPa (5076 psi). Turning the hand wheel clock
wise, opens the shock valve against spring force. See
Figure 3.
Operation
The emergency lowering valve is located at the left
hand side of the main control valve. See Figure 3. Ini-
tial turning of the hand wheel CLOCKWISE will re-
move play between spindle and shock valve. Contin-
ued turning clockwise opens the shock valve against
spring force and allows oil from the lift cylinders to
drain to tank. See Figure 4.
4000 YRM 1647 Description And Operation

A. TO TANK
B. FROM CYLINDER
1. SHOCK VALVE 1. OUTER PLATES
2. ANTI-CAVITATION VALVE 2. LINK PIN (RIVETED TO OUTER PLATES
3. SHOCK VALVE SPRING 3. INTERMEDIATE PLATES
4. ANTI-CAVITATION SPRING 4. INNER PLATES
5. SPINDLE 5. OUTER LINK
6. HAND WHEEL 6. INNER LINK
Figure 4. Emergency Lowering Valve Assembly Figure 5. Chain Components

The emergency lowering valve closes by turning the

Elongation Through Wear
hand wheel COUNTER CLOCKWISE. After the spin-
dle loses contact with the shock valve, continue to
When the chain articulates, the inner plates rotate
turn the hand wheel counter clockwise as far as it
over the link pin and cause wear. Wear reduces the
goes. This allows the Anti-Cavitation Valve to open
pin diameter and enlarges the hole in the plate, which
when necessary. Immediately after, turn the hand
results in chain elongation. When elongation has
wheel one turn back to prevent damage in case an
reached 3%, the entire chain must be replaced.
operator is not familiar with the correct direction of
hand wheel rotation.
Speed of Wear
Lift Chains
The speed of wear of link pin and inner plates de-
pends on the following factors:
The lift chains are leaf type chains. A leaf chain con-
sists of link pins and plates that are made of special • Load and impact load. The chain load de-
steel. Heat treatment and mechanical processing give pends on the weight lifted and the weight of the
the pins and plates their final strength, but they also carriage and forks. Impact loads occur, when
make these components more vulnerable to fatigue the truck drives over uneven surfaces. The
fractures, if pin and plate surfaces are damaged. forces generated by an impact load can be a
multiple of those of normal chain load.
The link pins are riveted into the outer plates. The • Number of link movements. The number of
press fit of the link pins in the outer plates is essential link movements directly relates to the number
for the integrity of the chain. of times the chain passes over the sheave
when the mast is raised or lowered. Chain
The inner plates have a tight sliding fit for an opti- elongation must therefore be measured at that
mized carrying area that also allows rotation over the chain section that runs over the sheave most
link pin. See Figure 5. often. The chain section close to the carriage
will have the lowest number of articulations and
The chains are connected to the carriage and outer is irrelevant for measuring chain elongation.
mast through chain anchors. The pin between chain
anchor and chain is secured with a snap ring.

5
Description And Operation
• Lubrication. An oil film at the contact area be-
tween link pin and inner plates reduces wear
and preserves the smooth surface of this con-
tact area. The oil film is particularly important
for new chains, when the contact areas are be-
ing broken in. Therefore, it is essential that new
chains are lubricated with oil before they are
put into service.
See Figure 6.
A. CONTACT AREA
Figure 6. Contact Area Between Link Pin and
Inner Plates.
Plate Height Wear
The chain plates also wear at the contact area be-
tween chain and chain sheave. When the chain
moves onto the sheave, the plates rotate slightly to
follow the radius of the sheave. In combination with
the high pressure between chain plates and sheave,
this movement causes wear, which affects the
strength of the plates. The maximum allowed wear is
5% of the original link plate height.
Lubrication
An oil film at the contact area between link pin and in-
ner plates reduces wear and preserves the smooth
surface of this contact area. See Figure 6.
The oil film between pin and plates is pushed away
under load conditions and must be allowed to restore
daily by removing the load and allowing oil to pene-
6
4000 YRM 1647
trate again. Restoring the oil film is effected by the ca-
pillary action of oil. This process is to be considered
separately from applying new oil to the chain.
Restoring The Oil Film
The capillary action of oil allows restoring the oil film
between chain pin and inner plates, provided that suf-
ficient free flowing oil is present between the plates,
and provided that chain tension is as low as possible
during a certain time.
The required time to maintain this low chain tension
varies with chain cleanliness and availability of free
flowing oil between the plates. This time can be as
short as 30 minutes or extend infinitely when condi-
tions are unfavorable.
Chain tension should not exceed the own weight of
the chain when restoring the oil film. This means that
chains must be slack.
Interruption of the oil film between pin and chain out-
side reduces the capillary action, but also allows entry
of humidity. Humidity activates the formation of corro-
sion products, making it even more difficult for oil to
reach the pin contact area. This means that new fresh
oil must be applied to the chain before the oil film on
the outside is interrupted.
Maintenance
The purpose of applying new oil to chain is to replen-
ish free flowing oil and restore outside oil film. Adding
new oil will extend the proper conditions for restoring
the oil film at the pin area.
The interval for applying new oil depends on load ap-
plied, the number of chain articulations, and ambient
conditions like rain, temperature, presence of dust
and dirt.
In many cases the simple application of oil on the
chains is sufficient to cover the period until the next
planned service interval. Main pre-condition is that
contamination has not progressed too far, which
would prevent oil to penetrate.
Periodically the chains will have to be removed from
the truck for cleaning, inspection and re-lubrication by
immersion in oil. Cleaning must allow thorough visual
inspection and must be aimed at the removal of wear
particles and used oil at pin contact area.
4000 YRM 1647
Maintaining The Presence of Oil
Insufficient lubrication permanently damages the
smooth contact area between chain pin and inner
plates. Re-lubricating a damaged contact area after-
wards, will not restore the smooth finish of the contact
area. A damaged contact area causes accelerated
wear and increased friction.
Increased friction may allow the inner plates to rotate
the pin in the outer plates. Once the pin has rotated in
outer plate, integrity of the chain structure is lost. Ro-
tation of a pin in the outer plate is visible when the
beveled end of a pin no longer runs parallel to the
length of chain. A chain must be replaced if a pin is at
an angle or if a pin has protruded.
Sufficient lubrication is particularly important for new
chains, which require a breaking in of the contact
area. Proper breaking in also requires low load condi-
tions during initial lifting and lowering. At least avoid
lifting high capacity loads initially.
Corrosion Protection
Link pins and chain leaves are made of a steel type
that is vulnerable to corrosion. Corrosion causes pits
which are the starting point for fatigue fractures. Cor-
rosion preventing coatings, e.g. paint or grease, can-
not be applied to the chain as these would obstruct
the penetration of oil for re-lubrication.
Therefore, the applied lubricating oil must also serve
as a protection against corrosion. This outside oil film
must always remain intact to make sure that humidity
does not reach the components of the chain, and cer-
tainly not the contact area between pin and plate.
Circumstances like temperature, dust and rain will dic-
tate the frequency of re-application of oil to the chain
to restore a protecting film. Re-apply oil before the oil
film is interrupted.
Description And Operation
Requirements for Chain Lubricant
The chain lubricant must be a mineral or synthetic en-
gine oil. Oil viscosity must match the ambient temper-
ature, so that the oil remains viscous and can pene-
trate contact area between link pin and intermediate
link.
• Use SAE 20W to 30W oil in ambient tempera-
tures of −30 to 5°C (−22 to 41°F)
• Use SAE 40 oil in ambient temperatures of 5 to
45°C (41 to 113°F)
• Use SAE 50 oil in ambient temperatures above
45°C (113°F)
DO NOT use the following lubricant types:
• Lubrication products that contain solids such
as graphite or molybdenum disulfide. Solids
will not penetrate between the plates, and over
time, they will form a barrier that prevents oil
penetration.
• Grease or lubrication products that stiffen or
form a greasy film.
Stiffening products do not penetrate suffi-
ciently. Grease does not penetrate at all. Stiff-
ening products and grease form a barrier that
prevents penetration of oil for re-lubrication.
Without proper lubrication, the service life of a
lift chain is minimized.
• Penetrating fluids or aerosol spray lubricants
containing penetrating fluids do not provide ad-
equate lubricity, adhesion or corrosion protec-
tion, and they do not form a film.
NOTE: If an aerosol spray lubricant is used, always
check that it deposits an engine oil equivalent mini-
mum viscosity after the dispersing agent has evapora-
ted.
7
Description And Operation
Load Rollers
Movement of the inner mast within the outer mast,
and movement of the carriage in the inner mast are
guided by load rollers to reduce friction. The load on
the carriage causes forces on the load rollers in differ-
ent directions. The lower load rollers are pushed
against the rear of the mast channels. The upper load
rollers are pushed against the front of the mast chan-
nels. See Figure 8.
When the mast is tilted completely backward and the
carriage is raised, it is possible that the upper load
rollers of the inner mast start traveling on the rear side
of the outer mast channel, instead of the front side. To
reduce this backward movement of the inner mast in-
side the outer mast, mast support pads are installed
at the top of the outer mast. See Figure 7.
1. OUTER MAST
2. INNER MAST
3. LIFT CYLINDER
4. MAST SUPPORT PAD
Figure 7. Mast Support Pads
8
4000 YRM 1647
Bearing Blocks
The carriage and inner mast are equipped with bear-
ing blocks. These absorb sideways forces, which can-
not be absorbed by the load rollers. The bearing
blocks are shimmed close to mast channels. Re-shim-
ming is required when sideways movement causes
shocks that affect load handling.
The bearing blocks on the carriage are located just
above the load rollers. On the mast the lower bearing
blocks are located above the lower rollers on the inner
mast. The upper bearing blocks are at the upper
channel end of the outer mast. See Figure 8.
1. LOAD ROLLER
2. BEARING BLOCK
3. INNER MAST
Figure 8. Bearing Blocks and Load Rollers on
Inner Mast
4000 YRM 1647 Description And Operation

CARRIAGE Standard Carriage with Hydraulic Fork

Three types of carriages are available for different
combinations of side-shifting and fork positioning.
• The standard carriage can have manual or hy-
draulic fork positioning.
• The carriage with integral side shifting has a
separate apron, which carries a pin type car-
riage.
• The dual function carriage is provided with fork
carriers, which allow side shifting under load.
Positioning
The pin-type forks are positioned by fork guides that
are attached to fork positioning cylinders. By activat-
ing the directional control valve the cylinders move
the guides and forks individually or simultaneously.
See Figure 10.
Sufficient grease must be present on fork pin and
lower carriage bar to reduce wear and friction during
fork positioning.

Standard Carriage with Manual Fork

Positioning

The pin-type forks are kept in position by two locking

pins. A spring ball keeps the pins in place. An attach-
ing cable keeps the pins from being lost. Each side of
the carriage has four holes to enable securing forks at
three different positions. The forks are repositioned
manually after releasing the locking pins from the car-
riage. See Figure 9.

1. CARRIAGE
2. FORK GUIDE
3. FORK
4. FORK POSITIONING CYLINDERS

Figure 10. Standard Carriage with Hydraulic Fork

Positioning

1. CABLE
2. LOCKING PIN
3. CARRIAGE
4. FORK
Figure 9. Standard Carriage with Manual Fork
Positioning

9
Description And Operation 4000 YRM 1647

Dual Function Side Shift and Fork Positioning
(DFSSFP) Carriage
Forks and fork guides for DFSSFP carriages are de-
signed to side shift under loaded conditions. For this
purpose the fork has a bushing at the fork eye and
each fork guide has a bearing block where it touches
the lower carriage bar. Both the bushing and bearing
block are serviceable components. See Figure 11.
Integral Side Shift
The carriage with integral side shift has a separate
apron, which carries the forks. By activating the side
shift cylinder the entire apron is moved over the apron
pins. To reduce friction during side shifting the apron
has bushings at the apron bracket and bearing blocks
between apron and carriage. It is possible to have an
apron with or without hydraulic fork positioning. Con-
struction and functionality of such aprons is similar to
the above described carriages. See Figure 12.

1. CARRIAGE
2. FORK GUIDE
3. FORK 1. CARRIAGE
4. FORK POSITIONING CYLINDERS 2. APRON PIN
3. APRON BRACKET
Figure 11. DFSSFP Carriage 4. FORK POSITIONING CYLINDER
5. SIDE SHIFT CYLINDER
6. FORK

Figure 12. Integral Side Shift

10
4000 YRM 1647
Carriage Valve
Different types of Valves can be installed depending
on the number and type of hydraulic functions on the
carriage. Oil supply is through header hoses, for ei-
ther a Fixed Pressure and Tank (P & T) system or for
an Alternating Pressure & Tank system. An electrical
cable is routed over hose sheaves, parallel with
header hoses. For header hose connections see sec-
tion Step 4.
Alternating Pressure and Tank (P & T)
Alternating P & T is applied when a limited number of
functions allow the control valve on the truck to deter-
mine direction of oil flow. Examples are: one single
function, Simultaneous Fork Positioning only, and
Dual Function with Fork Positioning only.
For alternating P & T systems there are two header
hoses, which are marked with two colored straps.
• Green-Yellow is connected with control valve
port Aux A.
• Green-Green is connected with control valve
port Aux B.
For alternating P & T systems, two different carriage
control valves are used:
• Flow divider for simultaneous Fork Positioning
• Valve for Dual Function with Side Shift and
Fork Positioning (DFSSFP)
Fixed Pressure and Tank (P & T)
Fixed P & T systems are applied when control valve
on the carriage determines the direction of oil flow to
different functions.
Description And Operation
Fixed P & T systems require three header hoses,
which have the following strap marking:
• Green is connected with control valve port Aux
A.
• Yellow is connected with control valve port T3.
• White-Yellow is connected with control valve
port T Aux.
NOTE: Nomenclature for the right and left fork posi-
tioner cylinder can be confusing. The right fork posi-
tioner cylinder moves the right fork, however, the right
fork positioner is located at the left side of the car-
riage. See Figure 13.
Flow Divider for Simultaneous Fork
Positioning
Simultaneous cylinder movement of the fork posi-
tioner cylinders is controlled by a flow restrictor and
two relief valves in the Flow Divider Manifold. The
flow restrictor provides an equal oil volume to the pis-
ton side of fork positioner cylinders. The relief valves
maintain an equal pressure at rod side of the cylin-
ders when they extend. When the cylinders retract,
equal movement is controlled by flow restrictors only.
Differences in mechanical resistance of the two fork
positioners and / or leakages may result in unequal
cylinder extension positions. Correction of the cylinder
end positions is obtained by a continued activation of
this function until both cylinders have reached their
end positions. See Figure 13 and Figure 14.
11
Description And Operation 4000 YRM 1647

A. TO MAIN CONTROL VALVE PORT AUX B E. TO ROD SIDE RH FORK POSITIONER CYLIN-
B. TO MAIN CONTROL VALVE PORT AUX A DER
C. TO PISTON SIDE RH FORK POSITIONER CYL- F. TO ROD SIDE LH FORK POSITIONER CYLIN-
INDER DER
D. TO PISTON SIDE LH FORK POSITIONER CYL-
INDER
1. FLOW RESTRICTOR 2. RELIEF VALVE

Figure 13. Flow Divider Port Connections - Schematic

12
4000 YRM 1647 Description And Operation

Valve for Dual Function with Side Shift and

Fork Positioning (DFSSFP)

Fork positioning is controlled by simultaneous activa-

tion of the Auxiliary spool in the main control valve
and activation of a fork positioner solenoid in the
valve for Dual Function with Side Shift and Fork Posi-
tioning (DFSSFP). Pressure will be applied to both
cylinders, but only the selected cylinder will be able to
move as its return oil escapes through the selected
solenoid.

The direction of cylinder movement is controlled by

selecting the A-side or B-side of the Auxiliary spool in
main control valve.

Side shifting is controlled by connecting the piston

A. TO MAIN CONTROL VALVE PORT AUX B
B. TO MAIN CONTROL VALVE PORT AUX A
C. TO PISTON SIDE RH FORK POSITIONER CYL-
INDER
D. TO PISTON SIDE LH FORK POSITIONER CYL-
INDER
E. TO ROD SIDE RH FORK POSITIONER CYLIN-
DER
F. TO ROD SIDE LH FORK POSITIONER CYLIN-
DER
1. FLOW RESTRICTOR
2. RELIEF VALVE
Figure 14. Valve for Simultaneous Fork
Positioning
sides of both cylinders and pressurization of one of
the cylinders at rod side. Oil extruding from the pres-
surized cylinder will move the piston of the second
cylinder. Activation of the Auxiliary A-spool activates
side shifting to the left until one of the cylinders has
reached its end-position. Activation of the B-spool ac-
tivates side shifting to the right.
Two relief valves limit supply pressure to
20 MPa (2901 psi) for each of the supply lines. Each
solenoid valve has impact relief valves to protect the
system against pressure peaks. See Figure 15 and
Figure 16.

13
Description And Operation 4000 YRM 1647

A. TO MAIN CONTROL VALVE PORT AUX B E. TO PISTON SIDE RH FORK POSITIONER CYL-
B. TO MAIN CONTROL VALVE PORT AUX A INDER
C. TO ROD SIDE LH FORK POSITIONER CYLIN- F. TO ROD SIDE RH FORK POSITIONER CYLIN-
DER DER
D. TO PISTON SIDE LH FORK POSITIONER CYL-
INDER
1. SIDE SHIFT SOLENOID 3. RH FORK POSITIONER SOLENOID
2. LH FORK POSITIONER SOLENOID 4. RELIEF VALVE

Figure 15. Schematic for Dual Function Valve

14
4000 YRM 1647 Description And Operation

Fixed Pressure and Tank System (Fixed P &

T)

Fixed P & T systems use a directional control valve

which can have up to four valve sections to operate
the different functions through solenoid valves. The
electric signal is provided by one wire harness for all
versions of this type of control valve. Unused harness
connectors are folded back against the wire harness
and taped in. See Table 3 for the identification of
functions, connectors and wire numbers.

Hydraulic operation of the directional valve is similar

to operation of the main control valve. The difference
in this directional valve is the absence of a line sens-
ing connection with the pump, the addition of a two
stage relief valve and addition of a pilot pressure sup-
ply valve.

The function of the two stage relief valve is to main-

tain supply pressure just above the required pressure
1. SIDE SHIFT SOLENOID (SS) - CONNECTOR as signaled by the internal LS line. Oil supply pres-
CPS 153 sure is regulated by relieving excess pressure through
2. LH FORK POSITIONER SOLENOID - CONNEC- port T3 in the main control valve. Maximum supply
TOR CPS 155
3. RELIEF VALVE pressure is regulated by the 19.5 MPa (2828 psi) re-
4. RH FORK POSITIONER SOLENOID - CONNEC- lief valve, which reliefs through Port T Aux in main
TOR CPS 154 valve.
5. PORT LEFT A - TO ROD SIDE RH FORK POSI-
TIONER The function of the pilot pressure supply valve is to
6. PORT RIGHT A - TO ROD SIDE LH FORK POSI-
TIONER maintain oil supply to a maximum pressure of
7. PORT LEFT B - TO PISTON SIDE RH FORK PO- 1.5 MPa (218 psi) for operation of auxiliary spools.
SITIONER See Figure 17 and Figure 18.
8. PORT RIGHT B - TO PISTON SIDE LH FORK
POSITIONER
9. PORT A1 - FROM CONTROL VALVE AUX A
10. PORT B1 - FROM CONTROL VALVE AUX B
Figure 16. Valve for Dual Function with Side Shift
and Fork Positioning (F876/F877 Shown)

15
Description And Operation 4000 YRM 1647

1. HYDRAULIC FUNCTION 4. PILOT PRESSURE SUPPLY VALVE

2. INLET MODULE 5. SOLENOID
3. RELIEF VALVE 6. CYLINDER
Figure 17. Schematic for Fixed P& T Directional Control Valve

16
4000 YRM 1647 Description And Operation

Forks

Two different fork constructions are used, depending

on type of carriage. The standard pin type fork is used
when the fork will not be moved under load. The ap-
plication is for different versions of fork positioning.
The dual function fork has a bushing to allow side
shifting under load. See Figure 19.

1. PORT B
2. PORT A
3. PORT T0 = CONNECTS WITH T AUX
4. PORT T = CONNECTS WITH T3
5. PORT P = CONNECTS WITH A AUX
6. INLET MODULE
7. 3RD FUNCTION
8. 4TH FUNCTION 1. STANDARD PIN TYPE FORK
9. 5TH FUNCTION 2. DUAL FUNCTION FORK

Figure 18. Directional Control Valve, Fixed P & T Figure 19. Fork Types
Systems

17
Description And Operation
SAFETY PROCEDURES WHEN WORKING
NEAR MAST
The procedures below must be followed, when in-
specting or working near the mast. Additional precau-
tions and procedures can be required when repairing
or removing the mast. Follow the repair procedures in
this section.
WARNING
Mast parts are heavy and can move. Distances be-
tween 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 place any part of the body into or un-
der the mast or carriage unless all parts are
completely lowered or a safety chain is in-
stalled. Also make sure that the power is
OFF and the key is removed. Place a DO
NOT OPERATE tag in the operators com-
partment.
• 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 can require disassembly and
removal of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push
the lift/lower control lever forward and make sure
there is no movement in the mast. Make sure that
all parts of the mast that can move are fully low-
ered.
OR
2. If parts of the mast must be in raised position, in-
stall a safety chain to restrain the moving parts of
the mast. Connect moving parts to a part that
does not move.
18
4000 YRM 1647
Follow these procedures:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom cross-mem-
ber of the inner mast with a cross-member on
the outer mast. See Figure 20.
c. Use a 1/2 inch minimum safety chain with a
hook to fasten the crossmembers together so
the movable member cannot lower. Put the
hook on the back side of the mast. Make sure
the hook is completely engaged with a link in
the chain. Make sure the safety chain does not
touch lift chains or chain sheaves, tubes, ho-
ses, fittings, or other parts on the mast.
d. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (two-
stage, full free-lift, and three-stage masts only)
is completely retracted. If running, stop the en-
gine. Apply the 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 and a crossmember on the outer
weldment.
3. Apply the parking brake. After lowering or re-
straining the mast, shut off the power and remove
the key. Place a DO NOT OPERATE sign in the
operator's compartment.
1. OUTER 2. HOOK
Figure 20. Mast Safety Chains
4000 YRM 1647 Description And Operation

BEFORE STARTING REPAIRS TO THE
HYDRAULIC SYSTEM, ALWAYS:
1. Place the lift truck on a solid, level surface.
2. Apply the parking brake.
3. Tilt the mast completely forward.
4. Lower the carriage and inner mast completely.
Make sure the lift cylinders are completely retrac-
ted.
7. Operate the lift and tilt levers completely forward
and backward to remove any trapped hydraulic
pressure.
8. Apply the brake pedal until the brake lights do not
longer come ON when the brake pedal is fully de-
pressed.
9. Turn the key switch to the OFF position.
10. Place blocks against both sides (front and back)
of the tires to prevent movement of the lift truck.

5. Turn engine OFF.

6. Turn the key switch to the ON position.

Remove and Replace

FORKS 2. Position forks in front of hoist chains.

3. Place a pallet on a hydraulic jack or hand pallet

Remove
wagon. Place pallet under one of the forks. Lift
pallet at least 5 cm (2 in.) off ground.
WARNING
4. Place mast in a vertical position and lower mast
The mast assembly and its components are
until fork is stable on pallet.
heavy. To avoid causing damage or injuries, a lift-
ing device must be used during all service proce- 5. Attach fork guide to a lifting device. The fork guide
dures. weighs 12 kg (26.4 lb). Put tension on lifting de-
vice until it carries the weight of fork guide.
1. On carriages with manual fork positioning: re-
move retainer pins that secure forks.

Table 1. Fork Sizes And Weights

Model Type Fork Size Shortest Shortest Longest Longest

Fork Length Fork Weight Fork Length Fork Weight
GDP80-90DC Pin 65 x 200 mm 1220 mm 176 kg 2440 mm 266 kg
(GDP190-210DC) (2.6 x 7.8 in.) (48 in.) (388 lb) (96 in.) (586 lb)
GDP80-120DC Pin 75 x 200 mm 1220 mm 214 kg 2440 mm 336 kg
(GDP190-280DC) (3 x 7.8 in.) (48 in.) (472 lb) (96 in.) (741 lb)
Pin, PFT* 75 x 200 mm 1220 mm 187 kg 1825 mm 228 kg
(3 x 7.8 in.) (48 in.) (412 lb) (71.9 in.) (503 lb)
DFSSFP 70 x 200 mm 1220 mm 208 kg 2440 mm 422 kg
(2.8 x 7.8 in.) (48 in.) (459 lb) (96 in.) (930 lb)
GDP130-160EC Pin 90 x 200 mm 1370 mm 292 kg 2440 mm 422 kg
(GDP300-360EC) (3.5 x 7.8 in.) (54 in.) (644 lb) (96 in.) (930 lb)
DFSSFP 90 x 200 mm 1830 mm 374 kg 2440 mm 447 kg
(3.5 x 7.8 in.) (72 in.) (825 lb) (96 in.) (985 lb)
The approximate weight for alternative fork lengths can be calculated by extrapolation between shortest and
longest fork lengths. The indicated weights are for one fork. *PFT = Polished Fully Tapered

19
Remove and Replace 4000 YRM 1647

6. Remove capscrews and bracket that retain fork
pin in carriage. See Figure 21.
WARNING
Only remove the fork pin when the fork is properly
supported and when there is no tension on the
fork pin or damage and personal injury may oc-
cur.
NOTE: The fork pin weighs 55 kg (121.2 lb). For fork
weights, see Table 1.
7. Use a hydraulic jack or hand pallet wagon to re-
lieve tension from fork pin and move fork pin until
its end has reached the fork.
a. For carriages with manual fork positioning,
attach a lifting device to fork pin with a
sling and move fork pin out of fork.
b. For carriages with hydraulic fork position-
ing, move fork pin just out of fork, but still
inside side plate of fork guide.
8. Lower pallet with fork and move fork away from
truck.
Move pin until there is sufficient space to
install fork.
b. For carriages with hydraulic fork position-
ing, move fork pin out of carriage until its
inner end is still inside the side plate of fork
guide.
5. Place each fork on a separate pallet.
6. Use a hydraulic jack or hand pallet wagon to posi-
tion a fork in fork guide, while the back of fork
touches carriage.
7. Lift fork on pallet until fork pin aligns with the pin
tube of fork.
8. Slide fork pin through fork pin tube to its final
mounting position in carriage.
9. Install bracket with four capscrews that retain fork
pin to carriage. Tighten bolts to 66 N•m (49 lbf ft).
10. Repeat Step 1 through Step 9 to install remaining
fork.
11. Remove lifting devices.

9. Return fork pin to its assembled position and in-

stall retainer bracket. Remove lifting strap from
fork guide.

10. Repeat Step 4 through Step 9 to remove remain-

ing fork.

Install
1. Put mast in a vertical position and lower carriage
almost completely.

2. Position fork guides in front of hoist chains.

3. Attach a lifting strap and lifting device to fork

guide. The fork guide weighs 12 kg (27 lb). Put
tension on lifting strap until it carries weight of fork
guide.

NOTE: The fork pin weighs 55 kg (121.2 lb). The fork

weighs between 180 kg (396.8 lb) and
270 kg (595.2 lb).

4. Remove capscrews and bracket that retain fork 1. CAPSCREWS

2. WASHER
pin to carriage. See Figure 21. 3. BRACKET
a. For carriages with manual fork positioning, 4. FORK PIN
attach a lifting device to fork pin with a 5. RETAINER PIN
sling about one foot from inner end of the Figure 21. Fork - Remove
pin.

20
4000 YRM 1647 Remove and Replace

FORK GUIDE AND FORK PIN
Remove
1. Position forks in front of hoist chains.
2. Attach a lifting device at rod side of fork positioner
cylinder.
3. Remove securing pin and pin that connects the
cylinder rod to fork guide. See Figure 22.
4. Put a layer of grease on wear pad to attach it to
DFSSFP fork guide.
NOTE: The fork guide weighs 10 kg (22 lb) for fork
positioners. The fork guide weighs 16 kg (35 lb) for
DFSSFP carriages.
5. Use a lifting device to position one ear of fork
guide onto fork pin.
6. Install fork. See section Forks, Install.

NOTE: The fork guide weighs 10 kg (22 lb) for fork
positioners. The fork guide weighs 16 kg (35 lb) for
Dual Function Side Shift and Fork Positioning
(DFSSFP) carriages.
7. Install pin and securing pin that connect cylinder
rod of fork positioner cylinder to fork guide.
8. Remove lifting device.

4. Attach a lifting device to fork guide.

5. Remove fork. See section Forks, Remove.

6. Remove DFSSFP guide by sliding it off pin, lower-

ing hanger approximately two inches and then
move guide on ground. Take care to not loosen
wear pad at back of guide.

7. Remove standard guide for fork positioning by

sliding it off fork pin and putting it on ground.

NOTE: The fork pin weighs 55 kg (121.2 lb).

8. Attach a lifting device to fork pin at carriage out-

side.

9. Have fork pin supported at both ends before it is

removed entirely from carriage.

10. Remove fork pin and lower lifting device to put

fork pin on a pallet.
1. CAPSCREWS
Install 2. WASHERS
3. BRACKET
NOTE: The fork pin weighs 55 kg (121.2 lb). 4. FORK PIN
5. FORK GUIDE
1. Use a lifting device to lift fork pin. 6. CARRIAGE
7. FORK
2. Install one end of pin into carriage until it is in
front of hoist chains. Figure 22. Fork Guide And Pin

3. For Dual Function Side Shift and Fork Positioning

(DFSSFP) fork guides, use a new wear pad if pad
thickness is 20 mm (0.79 in.) or less. Minimum al-
lowable pad thickness is 15 mm (0.59 in.).

21
Remove and Replace 4000 YRM 1647

CARRIAGE 11. Attach a lifting device to carriage. Make sure that

lifting device is correctly positioned to pull car-
Remove riage in lifting direction of mast only.

NOTE: Carriage removal is necessary for inspection
and replacement of load rollers and bearing blocks.
All other serviceable carriage components can be re-
placed with carriage installed in mast.
1. Remove forks. See section Forks, Remove.
12. Operate lifting device until lift chains of mast are
slack.
13. Disconnect lift chains from anchor chain. Remove
split pin and washer from chain pin, support chain
anchor and remove chain pin.

2. Place lift truck on a solid, level surface. 14. Attach a strap through lower end of each chain.

3. Apply parking brake.
4. Tilt mast slightly backwards.
5. Turn engine OFF.
6. Turn key switch to ON position.
7. Operate lift and tilt levers completely forward and
backward to remove any trapped hydraulic pres-
sure.
8. Apply brake pedal until brake lights do not longer
come ON when brake pedal is fully depressed.
9. Turn key switch to OFF position.
10. Place blocks at front and back of all tires to pre-
vent movement of lift truck.
15. Attach straps around inner mast below two upper
mast roller stubs.
16. Connect a rope between strap at chain and inner
mast. The ropes must have twice length of car-
riage height.
17. Disconnect electric mast cable from carriage
bracket and remove cable clamp. Place caps on
all open electrical connectors.
18. Tag and disconnect header hoses at carriage
bracket. Place plugs and caps at open fittings.
19. Attach a 4 m (13 ft) long rope to header hoses
and tie rope to upper part of inner mast. This is to
prevent hoses from being pulled over the sheave,
and to give them sufficient slack when inner mast
goes up.

Table 2. Carriage Weights

Model Type Weight

GDP80-90DC (GDP170-210DC) Standard 762 kg (1680 lb)
Standard with fork positioner 970 kg (2138 lb)
Side shift carriage 1266 kg (2791 lb)
Side shift with fork positioner 1358 kg (2987 lb)
GDP100-120DC, GDP100DCS Standard 912 kg (2994 lb)
(GDP230-280DC, GDP230DCS) Standard with fork positioner 1160 kg (2552 lb)
Side shift carriage 1311 kg (2557 lb)
Side shift with fork positioner 1429 kg (3150 lb)
GDP130-160EC (GDP300-360EC) Standard 1382 kg (3047 lb)
Standard with fork positioner 1450 kg (3197 lb)
Side shift carriage 1784 kg (3993 lb)
Side shift with fork positioner 3485 kg (7683 lb)

22
4000 YRM 1647
20. Start engine and operate lift cylinders to raise in-
ner mast until mast channels are well above up-
per bearing blocks of carriage.
21. Move lifting device with carriage away from mast
and put carriage on blocks on the ground with
load rollers facing up.
22. Lower mast completely and shut down engine.
Install
1. Place blocks at front and back of all tires to pre-
vent movement of lift truck.
WARNING
Use caution when removing or installing the snap
rings used to fasten the load rollers to the stub
shafts. The snap rings can come loose with force
if not properly removed or installed. Wear eye and
face protection when the snap rings are removed
or installed.
2. Inspect rollers on carriage. If replacement is re-
quired, remove snap ring and load roller from stub
shaft. Install a new load roller and snap ring. See
section Load Rollers, Replace.
3. Verify correct shimming of bearing blocks.
a. Measure distance between outer faces of bear-
ing blocks on carriage.
b. Measure distance between inside of left and
right hand channel of inner mast. Measure en-
tire length of inner mast to establish shortest
distance. Establish shortest distance with an
accuracy of 0.5 mm (0.02 in.). See section
Mast Bearing Blocks, Install.
c. Calculate actual play between inner mast and
bearing blocks by deducting distance between
outer faces of bearing blocks (3a), from dis-
tance between mast channels (3b).
d. Determine number of additional shims by de-
ducting another 0.15 to 1.0 mm (0.006 to
0.039 in.) from actual play as calculated in (3c).
e. Loosen four bolts that hold bracket to allow in-
serting required shims.
Remove and Replace
f. When dividing shims, make sure that left and
right hand blocks extend a similar distance
from vertical carriage frame plates. Make sure
that this distance is the same at the same
plate.
g. Install a new bearing block if more than 5
shims are required for correct shimming.
h. When reinstalling a bearing block, tighten se-
curing bolt to 9 N•m (79.7 lbf in).
i. After bearing block assembly is correctly shim-
med, tighten four bracket bolts to
44 N•m (32.5 lbf ft).
4. Attach a lifting device to carriage.
5. Lift carriage and move it in front of mast. Verify
that upper and lower load rollers are parallel with
mast. Correct carriage position as necessary.
6. Start engine and operate lift cylinders to raise in-
ner mast until mast channels are well above up-
per bearing blocks. Tilt mast backward until mast
and carriage have same tilt position.
7. Move carriage to position upper bearing blocks
into inner mast channels.
8. Use the emergency lowering valve to lower mast
slowly. DO NOT damage bearing blocks when
they enter mast channel. See Figure 3.
9. Lower mast further until lower load rollers and
lower bearing blocks have entered. Lower mast
completely.
10. Reconnect lift chains to chain anchors.
11. Lower lifting device, detach and remove from car-
riage.
12. Adjust chain length. See section Lift Chain, Lift
Chains Adjustment.
13. Use rope to lower header hoses and electric ca-
ble. Remove rope.
14. Remove caps and plugs and install header hoses
to fittings on carriage bracket.
15. Maintain tension on electric mast cable while
tightening cable clamp. See Figure 23.
23
Remove and Replace 4000 YRM 1647

16. Attach electrical connector. See Figure 23.

17. Start engine and operate hydraulic functions on

carriage. Make sure that functions operate cor-
rectly. Check for leaks.

18. Remove blocks that have been placed at both

sides of tires.

1. CAPSCREW
2. WASHER
3. CARRIAGE
4. SHIM
5. BEARING BLOCK

Figure 24. Carriage Bearing Block

1. HEADER HOSES
2. ELECTRICAL CONNECTOR CLAMP
3. ELECTRIC MAST CABLE CONNECTOR

Figure 23. Carriage Bracket

Carriage Bearing Blocks

Remove
1. CAPSCREW
1. Remove carriage. See section Carriage, Remove. 2. WASHER
3. SHIM
2. If necessary, remove four capscrews and wash- 4. BEARING BRACKET
ers that retain bearing block bracket and shims to 5. BEARING BLOCK
carriage. See Figure 24. 6. SPACER
7. WASHER
3. Remove button head capscrew and nut that retain 8. BUTTON HEAD CAPSCREW
bearing block to bearing block bracket. See Fig-
Figure 25. Bearing Block Assembly
ure 25.

24
4000 YRM 1647 Remove and Replace

Install
NOTE: Install bearing blocks with curved side to-
wards load roller.

1. Measure distance between inside of left hand and

right hand channel of inner mast. Measure entire
length of inner mast to establish shortest dis-
tance. Establish shortest distance with an accu-
racy of 0.5 mm (0.02 in.). See Figure 26.

A. DISTANCE BETWEEN THE OUTER FACES OF

THE BEARING BLOCKS

Figure 27. Bearing Block Measurement

A. DISTANCE BETWEEN INNER MAST CHAN-
NELS

Figure 26. Inner Mast Channel Measurement Carriage Load Rollers

2. Temporarily place new bearing blocks for carriage
in bearing block brackets and measure distance
between outer faces of bearing blocks. See Fig-
ure 27.
3. Determine number of required shims by deducting
distance as established in Step 2 from distance
as established in Step 1.
4. To obtain required clearance between mast and
carriage deduct another 0.5 to 1.0 mm (0.02 to
0.04 in.) from distance as established in Step 3.
NOTE: A maximum of five shims can be added be-
hind bearing block in case bearing block is reused. If
more than five shims are required, replace bearing
blocks.
Replace
Starting 2014, the masts have been provided with
greasable load rollers, which are retained by three
bolts. Masts built before 2014 have non-greasable
load rollers, which are retained by a snap ring.
1. Remove carriage. See section Carriage, Remove.
2. Remove dirt to allow inspection of load rollers. Do
not clean.
3. Inspect rollers. The seals must be in good condi-
tion. Axial bearing play must be less than
0.7 mm (0.028 in.). Grease must still be present in
bearing. The roller must allow smooth rotation.

5. Divide shims equally between left and right bear-

ing blocks. Shims are available in thicknesses of
0.5 mm (0.02 in.), 1.5 mm (0.06 in.), and
3.0 mm (0.12 in.).

25
Remove and Replace 4000 YRM 1647

Legend for Figure 28

WARNING
Use caution when removing or installing the snap 1. SNAP RING
2. LOAD ROLLER
rings used to fasten the load rollers to the stub 3. STUB SHAFT
shafts. The snap rings can come loose with force
if not properly removed or installed. Wear eye and
face protection when the snap rings are removed
or installed.

4. Remove the bolts or the snap ring from the stub

shaft and remove the load roller. See Figure 28
and Figure 29.

5. Install a new load roller, install the bolts or a new

snap ring.

6. Tighten the bolts to 40 N•m (29.5 lbf ft).

7. Install the carriage. See section Carriage, Install.

1. GREASE FITTING
2. BOLT
3. STUB SHAFT CAP
4. LOAD ROLLER
5. STUB SHAFT
6. CARRIAGE

Figure 29. Carriage Load Rollers, Greasable

Figure 28. Carriage Load Rollers, Non-Greaseable

26
4000 YRM 1647 Remove and Replace

Side Shift Cylinder 2. Remove outer snap ring on gland. See Figure 31.

3. Push gland into shell until retainer ring is ex-

Remove
posed.
1. Place lift truck on a solid level surface and apply
4. Remove retainer ring.
parking brake.
5. Pull rod assembly and gland from cylinder shell.
2. Retract side shift cylinder by side shifting to left
completely both cylinders by moving both forks to 6. Remove gland from rod.
center of truck.
7. Remove and discard the wiper, seal, back-up ring
3. Tilt mast completely backward and lower carriage and O-ring from gland.
and inner mast completely. Make sure lift cylin-
ders are completely retracted. 8. Do NOT remove piston form rod unless there is a
reason to replace seal between piston and rod.
4. Turn engine OFF.
9. Remove lock nut from rod and remove piston.
5. Turn key switch to the ON position.
10. Remove and discard seal and back-up ring from
6. Operate lift and tilt levers completely forward and piston.
backward to remove any trapped hydraulic pres-
sure. 11. Remove O-ring from rod at piston side.

7. Apply brake pedal until brake lights no longer

come ON when brake pedal is fully depressed.

8. Turn key switch to the OFF position.

9. Place blocks against both sides (front and back)

of tires to prevent movement of lift truck.

10. Disconnect two hydraulic tubes from cylinder. See

Figure 30.

11. Install caps on the fittings of cylinder and hy-

draulic tubes.

12. Connect a lifting device to side shift cylinder. The

cylinder weighs 25 kg (55 lbf).

13. Remove nut from rod side of cylinder followed by

nut at cylinder side.

14. Pull carriage to right hand side of truck and re-

move side shift cylinder.

Disassemble 1. SIDE SHIFT CYLINDER

2. HYDRAULIC CONNECTIONS
1. Place side shift cylinder on a clean, horizontal 3. LOCKNUTS
surface.
Figure 30. Side Shift Cylinder Remove

27
Remove and Replace 4000 YRM 1647

1. LOCK NUT 8. EXTERNAL SNAP RING

2. PISTON 9. RETAINER RING
3. PISTON SEAL 10. WIPER
4. PISTON BACK-UP RING 11. SEAL
5. PISTON O-RING 12. BACK-UP RING
6. CYLINDER SHELL 13. GLAND O-RING
7. CYLINDER ROD 14. GLAND

Figure 31. Side Shift Cylinder Assembly

Clean And Inspect Assemble

1. Place O-rings and seals in hydraulic oil.
WARNING
Cleaning solvents can be flammable and toxic and 2. If removed, install a new O-ring at piston end of
can cause skin irritation. When using cleaning rod.
solvents, always follow the solvent manufac-
3. Install piston on rod and tighten lock nut. Tighten
turer’s recommended safety precautions.
nut to 260 N•m (192 lbf ft).
1. Clean all parts in a cleaning solvent and dry them
4. Install a new seal and back up ring onto piston.
with compressed air.
5. Install new seals and back up rings to gland.
2. Inspect parts of side shift cylinder for damage,
rust, or wear. 6. Apply hydraulic oil to inside of gland and slide it
onto rod.
3. Inspect rod surface closely to make sure it is free
of dents and scratches. 7. Apply hydraulic oil to outer diameter of piston and
gland and carefully slide piston and gland into
4. Make sure that internal stroke surface of cylinder
shell.
shell and grooves for seals do not show any
nicks, scratches, or other damage. 8. Push gland into shell until retainer ring can be in-
stalled.
5. Replace parts as needed.

28
4000 YRM 1647 Remove and Replace

9. Install a new retainer ring and pull rod with piston
out of shell until gland stops on retainer ring and
snap ring groove is exposed.
10. Install snap ring on retainer.
Install
8. Turn key switch to OFF position.
9. Place blocks against both sides (front and back)
of tires to prevent movement of lift truck.
10. Disconnect two hydraulic tubes from cylinder. See
Figure 32.

1. Inspect and if necessary replace spherical bush- 11. Install caps on fittings of cylinder and hydraulic
ing at rod side of cylinder. tubes.

2. Slide washer and spherical bushing on cylinder 12. Connect a lifting device to positioner cylinder. The
rod. cylinder weighs 25 kg (55 lb).

3. Connect a lifting device to cylinder. The cylinder 13. Remove split pin and pin retaining rod side of cyl-
weighs 25 kg (55 lb). inder to fork guide.

4. Lift cylinder and insert rod at apron side of car- 14. Remove split pin and pin retaining rod side of cyl-
riage and install nut. DO NOT tighten nut. inder to carriage.

5. Move apron and insert stud at cylinder end into 15. Remove straps and hose from cylinder.
carriage. 16. Remove cylinder and repeat Step 12 through
6. Install washer and nut, rotate cylinder into correct Step 15 to remove other cylinder.
position and tighten nut to 300 N•m (221 lbf ft).

7. Tighten nut at rod side to 300 N•m (221 lbf ft).

8. Connect two hydraulic tubes to cylinder.

9. Start engine and operate hydraulic system. Make

sure that side shift cylinder works correctly.

Fork Positioner Cylinder

Remove
1. Place lift truck on a solid level surface and apply
parking brake.

2. Retract both cylinders by moving both forks to

center of truck.

3. Tilt mast completely backward and lower carriage

and inner mast completely. Make sure lift cylin-
ders are completely retracted.

4. Turn engine OFF. 1. FORK POSITIONER CYLINDER

2. SPLIT PIN
5. Turn key switch to ON position. 3. PIN
4. HYDRAULIC CONNECTIONS
6. Operate lift and tilt levers completely forward and 5. STRAPS
backward to remove any trapped hydraulic pres-
sure. Figure 32. Fork Positioner Cylinder

7. Apply brake pedal until brake lights no longer

come ON when brake pedal is fully depressed.

29
Remove and Replace 4000 YRM 1647

Disassemble 6. Remove gland from piston rod.

1. Place fork positioner cylinder on a clean, horizon-
tal surface.
2. Insert a pin face spanner into bores in gland and
remove gland from cylinder shell. See Figure 33.
CAUTION
Keep the piston rod aligned with the center line of
the cylinder shell during removal to avoid damage
to the cylinder parts.
3. Carefully pull piston rod out of cylinder shell.
4. Remove locking nut from piston retaining piston to
piston rod.
5. Remove piston from piston rod.
7. Remove and discard piston seal from piston.
8. Remove and discard wiper, seal, back-up ring
and O-ring from gland.
Clean and Inspect
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety precautions.
1. Clean all parts in a cleaning solvent and dry them
with compressed air.

1. CYLINDER SHELL 7. PISTON SEAL

2. CYLINDER ROD 8. ROD SEAL
3. PISTON 9. WIPER
4. RETAINER 10. BACK-UP RING
5. NUT 11. O-RING
6. SPACER

Figure 33. Fork Positioner Cylinder Assembly

30
4000 YRM 1647
2. Inspect parts of cylinder for damage, rust, or
wear. Inspect rod surface closely to make sure it
is free of dents and scratches.
3. Make sure that internal stroke surface of cylinder
shell and grooves for seals do not show any
nicks, scratches, or other damage.
4. Replace parts as needed.
Assemble
1. Place O-rings and seals in hydraulic oil.
2. Install wiper, seal, back-up ring and O-ring to
gland.
3. Install seal to piston.
4. Lubricate piston rod with hydraulic oil and install
gland onto piston rod.
5. Install spacer onto piston rod.
6. Install piston onto piston rod.
7. Install locking screw that retains piston to piston
rod. Tighten nut to 260 N•m (192 lbf ft).
CAUTION
Keep the piston rod aligned with the center line of
the cylinder shell during installation to prevent
damage to the parts.
8. Carefully slide piston rod and gland into cylinder
shell.
9. Insert a pin face spanner into holes of gland and
install gland into cylinder shell. Tighten gland to
300 N•m (221.5 lbf ft).
Install
1. Connect a lifting device to cylinder.
2. Position cylinder onto carriage.
3. Install pin and split pin that retain rod side of cylin-
der to fork guide.
4. Install pin and split pin that retain cylinder side to
carriage.
5. Connect two hydraulic tubes to cylinder.
6. Repeat Step 1 through Step 5 for other cylinder.
Remove and Replace
7. Start engine and operate hydraulic system. Make
sure that side shift and fork positioner cylinders
work correctly.
Carriage Valves
Remove
NOTE: Most serviceable components can be re-
placed without removing the carriage valve. For re-
placement of a section in a fixed Pressure & Tank (P
& T) valve, it is necessary to remove and disassemble
the entire valve.
1. Place lift truck on a solid, level surface.
2. Apply parking brake.
3. Tilt mast completely forward.
4. Lower carriage and inner mast completely. Make
sure lift cylinders are completely retracted.
5. Turn engine OFF.
6. Turn key switch to ON position.
7. Operate lift and tilt levers completely forward and
backward to remove any trapped hydraulic pres-
sure.
8. Apply brake pedal until brake lights no longer
come ON when brake pedal is fully depressed.
9. Turn key switch to OFF position.
10. Place blocks against both sides (front and back)
of tires to prevent movement of lift truck.
11. Tag and disconnect electrical connectors from
solenoids on the valve.
• For Fixed P & T Valves, see Figure 34.
• For Simultaneous Fork Positioner Valves,
see Figure 37.
• For Dual Function Side Shift and Fork Po-
sitioning (DFSSFP) Valves, see Figure 38.
12. Tag and disconnect hydraulic supply and return
hoses from hoses that connect to the directional
control valve. Plug openings of hoses and valve.
13. The valve for DFSSFP carriages is mounted on
bottom carriage bar. Remove three capscrews
under bottom carriage bar to remove valve.
31
Remove and Replace 4000 YRM 1647

14. All other valves are mounted on a bracket at the
top carriage bar. Remove the two nuts and wash-
ers at the upper side of the bracket. Lift the
bracket with the valve vertically over the mounting
studs, to remove from the carriage. See Fig-
ure 35.
Install
1. Mount the valve on the bracket with Torx screws.
2. Position the valve in the center on the top of the
carriage.
3. Install the two cap screws and washers that retain
the valve to the carriage. See Figure 35.
4. Remove plugs and caps from the hydraulic lines
and ports.
6. Connect the hydraulic hoses between the valve
and the hydraulic functions.
7. Connect the electrical connectors to the solenoids
on the valve. See Figure 35.
Valve for Fixed P & T Systems
Remove and Disassemble
1. Remove four torx screws that retain the P & T
valve to bracket.
2. Place the valve on a clean, horizontal surface.
3. Remove four capscrews that retain electrical end
cap to mid-section. See Figure 36.
4. Remove electrical end cap from mid-section.

5. Connect the supply and return hoses. 5. Repeat Step 2 and Step 3 to remove remaining
electrical end caps.

6. Remove four capscrews that retain the valve end

cap to mid-section.

7. Remove the valve end cap from mid-section.

1. PORT B
2. PORT A
3. PORT TO = CONNECTS WITH T AUX
4. PORT T = CONNECTS WITH T3
5. PORT P = CONNECTS WITH A AUX
6. INLET MODULE
7. 3RD FUNCTION 1. NUT
8. 4TH FUNCTION 2. WASHER
9. 5TH FUNCTION 3. BRACKET
4. P & T VALVE
Figure 34. Fixed P & T Valve Connections
Figure 35. Bracket for Fixed P & T Valve

32
4000 YRM 1647 Remove and Replace

8. Repeat Step 5 and Step 6 to remove remaining 11. Separate mid-sections and the end section.
valve end caps.
12. Remove the O-rings from the mid-sections and
9. Remove the three nuts from the tie-rods. the end section. See Figure 36.

10. Carefully remove the tie-rods from the valve. See

Figure 36.

A. PORT T0 = T AUX - ON MAIN CONTROL VALVE D. PORT A

B. PORT T = T3 - ON MAIN CONTROL VALVE E. PORT B
C. PORT P = A AUX - ON MAIN CONTROL VALVE
1. INLET MODULE 5. O-RING
2. END MODULE 6. VALVE HOUSING
3. TIE-ROD 7. SPOOL
4. SOLENOID 8. END CAP

Figure 36. Fixed P & T Valve Assembly

33
Remove and Replace 4000 YRM 1647

Clean and Inspect

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. If using cleaning sol-
vents, always follow the solvent manufacturer’s
recommended safety precautions. Compressed
air can move particles and cause injury to the
user or to other personnel. Make sure com-
pressed air path is away from all personnel. Wear
eye protection.
WARNING
Be careful not to damage the threads of the tie-
rods during assembly of the mid-sections and
end-sections.
3. Carefully place a mid-section over the three tie-
rods against the end section.
4. Carefully place the remaining mid-sections over
the three tie-rods against the first installed mid-
section.

1. Clean all parts of the fixed P & T valve with sol-
vent and carefully dry the parts with compressed
air.
2. Check the valve end caps and bores for defects.
If a valve end cap or bore is damaged, replace
the valve section that contains the damaged part
or parts. Make sure the bores and grooves for O-
rings are smooth and do not contain dirt or have
defects.
3. Check the electrical end caps for damage and re-
place the damaged electrical end caps.
4. Check each tie-rods and nuts for thread damage
and replace the damaged tie rods and nuts.
5. Carefully place the second end section against
the mid-section.
6. Install the three nuts onto the tie-rods and tighten
to 26 to 30 N•m (230 to 266 lbf in).
7. Position a valve end cap to a mid-section.
8. Install the four cap screws that retain the valve
end cap to the mid-section and tighten to 7.5 to
8.5 N•m (66.6 to 75.4 lbf in).
9. Repeat Step 7 to install the remaining valve end
caps.
10. Position the electrical end cap against a mid-sec-
tion.

Assemble and Install
NOTE: Lubricate all parts using hydraulic oil before
assembly.
1. Install new O-rings to the valve housing and end
caps. See Figure 34.
2. Place the three tie-rods in an end section.
11. Install the four cap screws that retain the electrical
end cap to the mid-section and tighten to7.5 to
8.5 N•m (66.6 to 75.4 lbf in).
12. Repeat Step 10 and Step 11 to install the remain-
ing electrical end caps.
13. Install the fixed P & T valve to the bracket using
the four Torx screws.

Table 3. Spool Identification for Fixed P & T Systems

Function Hydraulic Connector Code Electrical Wire Numbers

Identification Identification
Side Shift 3rd function CPS 149 Aux 0 703-704
Left Fork Positioner 4th function CPS 150 Aux 1 705-706
Right Fork Positioner 5th function CPS 151 Aux 2 709-710
Auxiliary 6th function CPS 152 Aux 3 702-711
NOTE: For certain configurations, the functions Side shift and Fork Positioner can be replaced by an auxiliary
function. The auxiliary function will then receive the hydraulic and electrical identification of the function that is
being replaced.

34
4000 YRM 1647 Remove and Replace

Flow Divider for Simultaneous Fork 3. If necessary clean the valve with a petroleum
Positioning Valve based solvent.

4. Use new O-rings for installation.

Restrictor Valve and Relief Valve
Replacement 5. Install the valve and tighten to 35 to 40 N•m (310
to 354 lbf in).
1. Remove valve from housing.
6. Install the coil on the valve and tighten nut to 4 to
2. Instal new O-rings. 6 N•m (35 to 53 lbf in).
3. Install valve and tighten to 220 to 230 N•m (162 to 7. Replace the harness connector.
170 lbf ft). See Figure 37.

Dual Function Valve for Side Shifting and

Fork Positioning

Solenoid Valve Replacement

1. Remove connector from coil and remove the nut
that retains the coil to the valve.

2. Inspect the valve for wear and damage.

1. SIDE SHIFT SOLENOID (SS) - CONNECTOR

CPS 153
2. LH FORK POSITIONER SOLENOID - CONNEC-
TOR CPS 155
3. RELIEF VALVE
4. RH FORK POSITIONER SOLENOID - CONNEC-
TOR CPS 154
5. PORT LEFT A - TO ROD SIDE RH FORK POSI-
TIONER
6. PORT RIGHT A - TO ROD SIDE LH FORK POSI-
TIONER
7. PORT LEFT B - TO PISTON SIDE RH FORK PO-
SITIONER
A. TO MAIN CONTROL VALVE PORT AUX B 8. PORT RIGHT B - TO PISTON SIDE LH FORK
B. TO MAIN CONTROL VALVE PORT AUX A POSITIONER
C. TO PISTON SIDE RH FORK POSITIONER 9. PORT A1 - FROM CONTROL VALVE AUX A
D. TO PISTON SIDE LH FORK POSITIONER 10. PORT B1 - FROM CONTROL VALVE AUX B
E. TO ROD SIDE RH FORK POSITIONER
F. TO ROD SIDE LH FORK POSITIONER Figure 38. DFSSFP Valve
1. FLOW RESTRICTOR
2. RELIEF VALVE
Figure 37. Valve for Simultaneous Fork
Positioning

35
Remove and Replace 4000 YRM 1647

Relief Valve Replacement 12. Follow Step 6 through Step 11 to remove other lift
chain.
Remove
Install
1. Remove relief valve from housing.
1. Attach a hook to one of the lift chains at approxi-
Install mately 1 m (3 ft) from chain end. The hook must
be strong enough to hold weight of chain. Lead
1. Use new O-rings for installation. hook through links of chain and attach hook to a
lifting device.
2. Install valve and tighten to 220 to 230 N•m (162 to
170 lbf ft). 2. Lift chain until it is in front of chain sheave.

MAST 3. Attach a rope at the end of chain and lead rope

Lift Chains and Top Chain Anchor
Remove
1. Place truck on a solid, level surface.
2. Place blocks of approximately 30 cm (1 ft) under
carriage frame and lower mast until carriage rests
on blocks.
3. Use the emergency lowering valve until the lift cyl-
inders are retracted completely and the lift chains
are slack.
4. Turn the engine OFF.
over sheave, through chain anchor hole in weld-
ment at top of mast. Pull rope to move chain end
above chain anchor hole.
4. Mount chain anchor through hole. See Figure 39.
5. Inspect chain pin for damage.
6. Install chain pin to connect lift chain to chain an-
chor. Install split pin and washer to secure chain
pin.
7. Remove rope.
8. Lower lifting device and remove hook from chain.

NOTE: Lift chains are heavy. See Table 6 for weights

of different chain lengths.

5. Attach a hook to one of the lift chains at top front

side of mast, approximately two feet below chain
sheave. The hook must be strong enough to hold
weight of chain. Lead hook through links of chain
and attach hook to a lifting device.

6. Remove split pin and washer from chain pins at

carriage chain anchors and then remove chain
pins.

7. Lift chain slightly until tension is removed from

chain pin that connects with chain anchor at top of
mast.

8. Remove split pin and washer from chain pin at top

chain anchor. See Figure 39.
1. SPLIT PIN
9. Support chain anchor and remove chain pin. 2. CHAIN PIN
3. CHAIN ANCHOR
10. Remove chain anchor.
Figure 39. Top Chain Anchor
11. Lower lifting device and put lift chain on a pallet.

36
4000 YRM 1647
9. Install chain pin at lower end of chain into carriage
chain anchor. Install washer and a new split pin.
10. Follow Step 1 through Step 9 to install other lift
chain.
11. Start engine and raise inner mast to remove
blocks under carriage.
12. Lower mast and turn key switch to OFF position.
13. Adjust chain length. See section Lift Chains, Lift
Chains Adjustment.
14. Adjust tension of header hoses. See section
Header Hose Tension Adjustment.
Chain Anchor On Carriage
Remove
1. Place truck on a solid, level surface.
2. Put blocks of approximately 30 cm (1 ft) under
carriage frame and lower mast until carriage rests
on blocks.
3. Operate lever for lowering until lift cylinders are
retracted completely and lift chains are slack.
4. Turn engine OFF.
5. Remove split pin and washer from chain pins at
carriage chain anchors, and remove chain pins.
See Figure 40.
NOTE: Before removing nut, note position of nut on
chain anchor.
6. Remove bolt that retains securing plate to car-
riage.
7. Bend securing plate and remove nuts and plate
from chain anchor.
Remove and Replace
8. Remove chain anchor from carriage.
Install
1. Position chain anchor in carriage. See Figure 40.
2. Install large nut on chain anchor. If second chain
anchor was not removed, turn large nut until it has
reached a similar position compared with nut on
second anchor chain.
3. Install securing plate to carriage and lock nut to
chain anchor.
4. Inspect chain pin for damage.
5. Connect lift chain to chain anchor by installing
chain pin. Install washer and a new split pin to se-
cure chain pin.
6. If second chain anchor was removed, repeat
Step 1 through Step 3.
7. Install securing plate to carriage and lock nut to
chain anchor.
8. Start engine and raise inner mast to remove
blocks under carriage.
9. Lower mast completely and turn key switch to
OFF position.
10. Adjust chain length. See section Lift Chains, Lift
Chains Adjustment.
11. Bend fingers of securing plate around large nut.
12. Tighten bolt to secure plate to carriage.
13. Tighten lock nut.
37
Remove and Replace 4000 YRM 1647

6. Guide a strap through opening above chain

sheave and use strap to support sheave. The
chain sheave weighs approximately
4.4 kg (9.7 lb).

7. Remove capscrew and eye bolt from chain

sheave pin. See Figure 41.

8. Remove chain sheave from mast together with

spacers by lowering strap.

Install
1. Use a strap to position chain sheave in mast and
insert spacers. See Figure 42.

2. Insert pin into sheave.

3. Install eye bolt and secure it with capscrews.

4. Reinstall lift chains and adjust chain length. See

section Bob.
1. SPLIT PIN
2. CHAIN PIN
3. WASHER
4. CHAIN ANCHOR
5. LARGE NUT
6. SECURING PLATE
7. LOCK NUT
8. NUT
9. WASHER
10. CAPSCREW

Figure 40. Chain Anchor on Carriage

Chain Sheave

Remove
1. Place truck on a solid, level surface.

2. Put blocks of approximately 30 cm (1 ft) under in-

ner mast and lower mast until inner mast rests on
blocks.

3. Operate lever for lowering until lift cylinders are 1. INNER MAST
retracted completely and lift chains are slack. 2. SHEAVE PIN
3. EYE BOLT
4. Turn engine OFF. 4. WASHER
5. CAPSCREW
5. Remove lift chains. See section Lift Chains, Re-
Figure 41. Chain Sheave
move.

38
4000 YRM 1647 Remove and Replace

6. Disconnect hydraulic hoses from fittings at lower

mast bracket. Put caps on open fittings. See Fig-
ure 44.

7. Open hose clamps which retain hoses to the right

hand lift cylinder.

8. Disconnect hydraulic hoses from fittings on car-

riage bracket. Put plugs and caps on open fittings.

9. Remove hose cap.

10. Remove hoses.

1. SHEAVE PIN
2. SHEAVE
3. EYE BOLT
4. CAPSCREW
5. SPACERS
Figure 42. Sheave Spacer Location

Header Hoses

Remove
1. Place truck on solid, level surface.

2. Put blocks of approximately 30 cm (1 ft) under 1. HOSE SHEAVES

carriage frame and lower mast until carriage rests 2. SHEAVE CAP
on blocks. 3. SHEAVE BRACKET
4. UPPER MAST BRACKET
3. Operate lever for lowering until lift cylinders are 5. CAPSCREWS AND WASHERS
retracted completely and lift chains are slack. 6. HOSE CLAMPS

Figure 43. Hose Sheaves and Clamps

4. Turn engine OFF.

5. Release hose clamps on upper mast bracket, by

removing capscrews. See Figure 43.

39
Remove and Replace 4000 YRM 1647

Item Number Description Control Valve Carriage Valve Strap Color Code
Connection Connection
1 Supply T3 T Yellow
2 Supply A (AUX) P Green
3 Drain T (AUX) T0 White/Yellow
4 Breather Hose N/A N/A White/Green
5 Electric Cable N/A N/A CRP139/ CPS148

Item Number Description Control Valve Carriage Valve Strap Color Code
Connection Connection
1 Supply Aux B B1 Green/Green
2 Supply Aux A A1 Green/Yellow
3 N/A
4 Breather Hose N/A N/A White/Green
5 Electric Cable N/A N/A CRP139/ CPS148

A. MAST SIDE B. CARRIAGE SIDE

Figure 44. Header Hose Connections

40
4000 YRM 1647 Remove and Replace

Install 2. Connect electric mast cable with connector at car-

1. Place hydraulic hoses over hose sheaves.
2. Remove plugs and caps from hose fittings at car-
riage side.
3. Connect hydraulic hoses to fittings on carriage
bracket.
4. Connect hydraulic hoses to fittings on lower mast
hose bracket.
5. Lift mast to remove blocks under carriage. Lower
carriage.
6. Put tension on hoses and reinstall clamps at up-
per mast bracket. See Figure 43.
riage bracket.
3. Install cable clamp at carriage bracket. Provide
some slack at carriage side for event that electric
mast cable has to be repositioned.
4. Insert connector at mast side in mast bracket and
install clamp ring. Reconnect mast cable with
frame harness. See Figure 44.
5. Install clamps that attach electric cable to mast.
6. Tension carriage side of cable and install clamp
on upper mast bracket.

7. Install hose clamps which retain hoses to right

hand lift cylinder.

Electric Mast Cable

Remove
1. Turn engine OFF and disconnect battery cables.

2. Disconnect electric mast cable from frame har-

ness.

3. Open hose clamps retaining electric cable to right

hand lift cylinder.

4. Remove cable clamp at upper mast bracket. See

Figure 45.

5. Remove cable from sheave.

6. Disconnect cable from carriage bracket. See Fig- 1. SHEAVE BRACKET

ure 44. 2. INNER MAST
3. UPPER MAST BRACKET
7. Remove electric cable. 4. CAPSCREWS

Figure 45. Upper Mast Bracket and Sheave

Install Bracket
1. Put middle of electric cable over sheave.

41
Remove and Replace 4000 YRM 1647

Hose Sheave

Remove and Disassemble

1. Remove header hoses and electric mast cable.
See sections Header Hoses, Remove and Electric
Mast Cable, Remove.

2. Remove capscrew, spacer, washer, and hose

sheaves.

3. Slide hose sheaves and spacers from pin. See

Figure 46.

4. Inspect sealed bearings for wear. Replace entire

sheave if damaged.

Assemble and Install

1. Apply multipurpose grease to sheave pin.

2. Slide hose sheaves and spacers on pin. Both

spacers and hose sheaves can be installed either 1. CAPSCREW
way. 2. WASHER
3. SHEAVE PIN
3. Put additional grease at end of pin and install cap- 4. SHEAVE BRACKET
screw with washer. Tighten capscrew to 5. SHEAVES AND SPACERS
120 N•m (88 lbf ft). 6. SPACER

4. Install header hoses and electric mast cable. See Figure 46. Hose Sheaves
sections Header Hoses, Install and Electric Mast
Cable, Install.

42
4000 YRM 1647 Remove and Replace

Mast Assembly 9. Tag and disconnect hoses that lead to header

hose bracket.
Remove
10. Place plugs and caps on hoses and fittings on
1. Remove carriage. See section Carriage, Remove. header hose bracket. See Figure 44.

2. Lower inner mast and make sure lift cylinders are 11. Tag and disconnect hydraulic hose at base of
completely retracted. each lift cylinder.

3. Turn engine OFF.
4. Turn key switch to ON position.
5. Operate the lift and tilt levers completely forward
and completely backward to remove any trapped
hydraulic pressure.
6. Apply and release the brake pedal until the brake
lights do not longer come ON when the brake
pedal is fully depressed.
7. Turn key switch to OFF position.
8. Disconnect mast lights harness from the mast
harness connector and disconnect the frame har-
ness from the mast harness connector at header
hoses bracket. See Figure 44.
12. Install plugs and caps on fittings at base of lift cyl-
inders and in hydraulic hoses.
NOTE: See Table 6 for the correct weights of the
mast. Make sure the lifting device has the proper ca-
pacity rating.
13. Strap lift chains and header hoses to lift cylinders
to prevent them from moving while lowering mast.
14. Connect a lifting device to lifting eyes on outer
mast. Position lifting device above lifting eyes. Put
tension on lifting device to have it carry weight of
mast. See Figure 47.

Table 6. Mast Component Weights

Unit Lift Height Mast Assembly Inner Mast Weight Outer Mast Weight
Weight
GDP80-90DC 3686 mm (145.0 in.) 1510 kg (3328.9 lb) 509 kg (1122.1 lb) 677 kg (1492.5 lb)
(GDP190-210DC) 4586 mm (180.5 in.) 1670 kg (3681.7 lb) 578 kg (1274.3 lb) 728 kg (1604.9 lb)
5336 mm (210.0 in.) 1840 kg (4056.4 lb) 621 kg (1369.0 lb) 838 kg (1847.4 lb)
GDP100-120DC, 3686 mm (145.0 in.) 2060 kg (4541.5 lb) 762 kg (1679.9 lb) 817 kg (1801.2 lb)
GDP100DCS 4586 mm (180.5 in.) 2270 kg (5004.4 lb) 838 kg (1847.4 lb) 894 kg (1970.9 lb)
(GDP230-280DC,
GDP230DCS) 5336 mm (210.0 in.) 2510 kg (5533.5 lb) 902 kg (1988.5 lb) 1121 kg (2471.3 lb)
6130 mm (241.5 in.) 2670 kg (5886.2 lb) 970 kg (2138.5 lb) 1188 kg (2619.0 lb)
6630 mm (261.0 in.) 2780 kg (6128.7 lb) 1012 kg (2231.0 lb) 1231 kg (2713.8 lb)
GDP130-160EC 3660 mm (144.0 in.) 2506 kg (5524.7 lb) 938 kg (2067.9 lb) 1217 kg (2682.9 lb)
(GDP300-360EC) 4560 mm (179.5 in.) 2771 kg (6108.9 lb) 1068 kg (2354.5 lb) 1309 kg (2885.8 lb)
5310 mm (209.0 in.) 3118 kg (6873.9 lb) 1144 kg (2522.0 lb) 1561 kg (3441.4 lb)
6110 mm (240.5 in.) 3313 kg (7303.8 lb) 1225 kg (2700.6 lb) 1649 kg (3635.4 lb)
6610 mm (260.3 in.) 3439 kg (7581.6 lb) 1276 kg (2813.1 lb) 1704 kg (3756.6 lb)

43
Remove and Replace 4000 YRM 1647

g. Completely retract tilt cylinders and stop en-

gine.

16. Remove capscrews and washers from mast

mounting pins that connect mast to frame. See
Figure 49.

17. Use a soft hammer to remove the mast mounting

pins.

18. Lift mast away from truck.

19. Lower mast on blocks so mast mounts and tilt cyl-

inder mounts are facing up.

20. Place blocks under outer mast so that inner mast

can move.

1. LIFTING EYE

Figure 47. Lifting Eyes

WARNING
DO NOT push the cylinder pins out with your fin-
gers. DO NOT permit the tilt cylinders to drop and
cause damage or personal injury.

15. Disconnect tilt cylinders from mast as follows:

a. Put a wooden block between front fender and

tilt cylinder to support tilt cylinder.

b. At rod end, remove capscrew and eye bolt to

unlock pin that retains tilt cylinder to mast. See
Figure 48. 1. TILT CYLINDER
2. ROD END
c. Make sure wooden blocks are placed correctly 3. CAPSCREW
4. ANCHOR PIN
on front fender and support the tilt cylinder. 5. GREASE FITTING
6. EYE BOLT
d. Use a soft hammer to remove the tilt cylinder 7. WASHER
pin out of the tilt cylinder and the mast bracket. 8. LOCKING BOLTS
9. RELIEF VALVE (F876 ONLY)
e. Repeat Step a through Step d to disconnect 10. HYDRAULIC LINES
other tilt cylinder from mast. 11. PLUG

f. Start engine. Figure 48. Tilt Cylinder Connections

44
4000 YRM 1647 Remove and Replace

10. Remove isolator blocks at rear top side of outer

mast.

11. If installed, remove bearing block assemblies at

top of outer mast. See Figure 51.

12. Support lift cylinders to prevent them from falling

or moving.

13. Remove capscrews and washers that secure lift

cylinders to top of inner mast. See Figure 50.

14. Attach a lifting device to top cross member of in-

ner mast and pull inner mast half way out of outer
mast.

15. Attach any shim to cylinder if found installed at

top of cylinder. Apply right hand and left hand
markings to cylinders according their installation.

16. Remove securing bolt at bottom of lift cylinders.

17. Attach a lifting device to lift cylinders and remove

1. MAST them from outer mast.
2. CAPSCREWS
3. GREASE FITTING
4. SHIM WARNING
5. FRAME
6. BUSHING See Table 2 for the correct weight of the inner
7. MAST MOUNTING PIN mast. Make sure the lifting device has the proper
capacity rating.
Figure 49. Mast Mounted to Frame
18. Attach a lifting device to center of inner mast and
remove inner mast from outer mast.
Disassemble
1. Remove straps which temporarily retain chains
and header hoses.

2. Remove clamps that retain header hoses and

electric cable to right hand lift cylinder.

3. Remove hoses and cable. See section Header

Hoses, Remove.

4. Remove hoses connecting between lift cylinders

at top and bottom. Put caps on all open fittings.

5. Remove lowering control valve from lift cylinder

and put caps on open fittings.

6. Lead a hook through links of one of chains and at-

tach hook to a lifting device. 1. LIFT CYLINDERS
2. SMALL WASHERS
7. Remove split pin end pin to release chain from 3. WASHERS
upper chain anchor. 4. CAPSCREWS

Figure 50. Lift Cylinder Top

8. Remove chain and place it on a pallet.

9. Repeat Step 3 to Step 8 to remove other chain.

45
Remove and Replace 4000 YRM 1647

d. Determine number of additional shims by de-

ducting another 0.5 to 1.0 mm (0.02 to 0.04 in.)
from actual play as calculated in Step c.

e. Loosen four bolts for each bracket to allow in-

serting required shims.

f. When dividing shims, make sure that left and

right hand blocks extend a similar distance
from inner mast channel. Make sure that this
distance is same at same channel.

1. CAPSCREWS
2. WASHERS
3. BEARING BLOCK ASSEMBLY
Figure 51. Bearing Block Bracket

Assemble
1. TILT CYLINDER PIN
1. Inspect bushings for tilt cylinder pins in brackets 2. BUSHING
of outer mast. Replace if worn or damaged. 3. BUSHING SPLIT
4. GREASE CHANNEL
2. When reinstalling bushings, at mast side, make
Figure 52. Tilt Cylinder Bushings
sure that split in bushing is turned away by 45°
from centerline of tilt cylinder and is in virtually
highest position. See Figure 52.

3. Inspect load rollers on inner mast. If replacement

is required see instructions under Inner Mast
Load Rollers.

4. Verify correct shimming of bearing blocks.

a. Verify correct shimming of bearing blocks.

b. Measure distance between inside of left and

right hand channel of outer mast as shown in
Figure 53. Measure entire length of outer mast
to establish shortest distance. Establish short-
est distance with an accuracy of
0.5 mm (0.02 in.).
A. DISTANCE BETWEEN FACES OF OUTER
c. Calculate actual play between outer mast and MAST CHANNELS
bearing blocks by deducting distance between
outer faces of bearing blocks (Step a), from Figure 53. Outer Mast Channel Measurement
distance between mast channels (Step b).

46
4000 YRM 1647
g. Install a new bearing block if more than 5
shims are required for correct shimming.
h. When reinstalling a bearing block, tighten se-
curing bolt to 9 N•m (80 lbf in).
i. Do not yet install bearing block at top of outer
mast.
j. After bearing block assembly is correctly shim-
med, tighten four bracket bolts to
44 N•m (32.5 lbf ft).
WARNING
See Table 6 for the correct weight of the inner
mast. Make sure the lifting device has the proper
capacity rating.
5. Attach a lifting device to center of inner mast and
install inner mast into outer mast until it is approxi-
mately 1 m (3 ft) from completely retracted posi-
tion.
6. Attach a lifting device to lift cylinders and install
lower end into bottom cross member of outer
mast.
7. Install securing washer with bolt at bottom of cyl-
inders. Tighten bolt to 35 N•m (26 lbf ft).
8. Install bearing blocks at top of outer mast with
correct number of shims for a total play of 0.5 to
1.0 mm (0.02 to 0.04 in.).
9. Support lift cylinder to align its top end with
mounting hole in inner mast.
10. Install shims on lift cylinder if originally installed. If
a different cylinder is installed, establish correct
shimming. See section Lift Cylinder, Install.
11. Retract inner mast to seat both lift cylinders.
12. Install securing washer with bolt at top of lift cylin-
der. Tighten bolt to 200 N•m (148 lbf ft). See Fig-
ure 50.
13. Install and shim isolator blocks to obtain a play of
0.5 to 1.5 mm (0.02 to 0.06 in.) between blocks
and inner mast channel. Tighten nut to
53 N•m (39 lbf ft).
14. Position hoist chains at top of mast and lead one
chain end over sheave to top chain anchor.
Remove and Replace
15. Connect lift chain by installing chain pin and se-
curing it with washer and a new split pin.
16. Install lowering control valve at bottom of lift cylin-
ders.
17. Install hoses connecting between lift cylinders at
top and bottom.
18. Install header hoses and electric cable provision-
ally over sheave and secure with straps.
Install
NOTE: Inspect mast pins and bushings for wear prior
to install. Replace if required.
1. Install the bushings, grease the mast pin and in-
sert the pin with the grease fitting pointing to the
center of the truck.
2. Apply grease to the mast shims to stick them
against the RH hanger. Position one shim at the
inside and two or three shims at the outside of the
RH hanger. Turn the shims with their opening fac-
ing up. Do NOT install shims at the LH hanger.
3. See for the correct weight of mast. Make sure lift-
ing device has proper capacity rating.
4. Connect a lifting device to lifting eyes on outer
mast. See Figure 48.
5. Lift and position mast in front of lift truck.
6. Lower mast hangers on mast pins.
7. Connect mast pins with hangers using 4 cap-
screws.
Tighten capscrews to 435 N•m (321 lbf ft) for lift
truck models D876, E876, and F876
Tighten capscrews to 522 N•m (385 lbf ft) for lift
truck models D877, E877, and F877
8. Connect tilt cylinders to mast as follows:
a. Turn engine ON.
b. Extend tilt cylinders until rods are almost in cor-
rect position.
c. Lift tilt cylinders to align holes in rods with
holes in mast.
d. Install tilt cylinder pins with lube fittings facing
outside of truck. See Figure 54.
47
Remove and Replace 4000 YRM 1647

15. Connect mast lights harness to the mast harness

connector and connect the frame harness to the
mast harness connector at header hoses bracket.

16. Adjust tension of header hoses and electric cable

after carriage has been installed.

WARNING
DO NOT try to locate hydraulic leaks by placing
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by pres-
sure.

17. Check for leaks.

18. Remove blocks on both sides (front and back) of

tires.

19. Lubricate the bushings for the mast pivot and the
tilt cylinder.

20. Reinstall carriage. See Carriage, Install.

1. TILT CYLINDER
2. ROD END
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING
6. EYE BOLT
7. WASHER
8. LOCKING BOLTS
9. RELIEF VALVE (F876 ONLY
10. HYDRAULIC LINES
11. PLUG

Figure 54. Tilt Cylinder Connections

e. Install eye bolts and capscrews to secure tilt

cylinder pins.

9. Disconnect lifting device from lifting eyes of outer

mast.

10. Adjust backward tilt position. See section Tilt Cyl-

inder Stroke and Backward Tilt Angle Adjustment.

11. Remove plugs at end of hydraulic header hoses.

1. SHEAVE PIN
12. Remove caps from fittings at lower mast bracket. 2. SHEAVE
3. EYE BOLT
13. Install the carriage. See Carriage, Install. 4. CAPSCREW
5. SPACERS
14. Connect header hoses to mast bracket. See Fig-
ure 55. Figure 55. Sheave Location

48
4000 YRM 1647 Remove and Replace

Inner Mast Load Rollers

Replace

Starting 2014, the masts have been provided with

greasable load rollers, which are retained by three
bolts. Masts built before 2014 have non-greasable
load rollers, which are retained by a snap ring.

1. Remove carriage. See Carriage, Remove.

2. Remove inner mast. See Mast Assembly, Re-

move.

3. Remove dirt to allow inspection of the load rollers.

Do not clean.

4. Inspect rollers. The seals must be in good condi-

tion. Axial play must be less than
0.7 mm (0.028 in.). The roller must allow smooth 1. SNAP RING
rotation. Verify slight binding caused by the pres- 2. LOAD ROLLER
ence of grease. 3. STUB SHAFT

Figure 56. Mast Load Rollers, Non-Greaseable

WARNING
Use caution when removing or installing the snap
rings used to fasten the load rollers to the stub
shafts. The snap rings can come loose with force
if not properly removed or installed. Wear eye and
face protection when the snap rings are removed
or installed.

5. Remove the bolts or the snap ring from the stub

shaft and remove the load roller. See Figure 56
and Figure 57 .

6. Install a new load roller with the bolts or a new

snap ring.

7. Tighten the bolts to 40 N•m (29.5 lbf ft).

8. Install inner mast. See Mast Assembly, Install.

9. Install carriage. See Carriage, Install.

1. GREASE FITTING
2. BOLT
3. STUB SHAFT CAP
4. LOAD ROLLER
5. STUB SHAFT
6. INNER MAST

Figure 57. Mast Load Rollers, Greaseable

49
Remove and Replace 4000 YRM 1647

Mast Bearing Blocks 2. Install new bearing blocks in bearing block brack-
ets. Tighten capscrew to 9 N•m (80 lbf in). DO
Remove NOT overtighten.

1. Remove carriage. See section Carriage, Remove.
2. Remove capscrew, washer and spacer which re-
tain bearing block. Remove bearing block. See
Figure 58.
3. Measure distance between outer faces of bearing
blocks.
4. Determine number of required shims by deducting
result distance in Step 3 from result distance in
Step 1.

5. To obtain required clearance between mast and

carriage deduct another 0.5 to 1.0 mm (0.02 to
0.04 in.) from result distance in Step 4.

6. Divide shims equally between left and right bear-

ing blocks. Shims are available in thicknesses of
0.75 mm (0.03 in.).

7. Loosen four bolts which retain bearing blocks to

allow inserting correct number of shims.

8. Tighten bolts to 44 N•m (32 lbf ft).

1. BEARING BLOCK ASSEMBLY

2. SHIMS
3. CAPSCREWS
4. INNER MAST
Figure 58. Mast Bearing Block 1. CAPSCREWS
2. WASHERS
3. SHIMS
3. Remove button head capscrew retaining bearing 4. BEARING BRACKET
block and shims to bearing block bracket. See 5. BEARING BLOCK
Figure 59. 6. SPACER
7. WASHER
8. BUTTON HEAD CAPSCREW
Install
Figure 59. Bearing Block Assembly
1. Measure distance between inside of left and right
hand channel of outer mast as shown in Fig-
ure 60. Measure entire length of outer mast to es-
tablish shortest distance. Establish shortest dis-
tance with an accuracy of 0.5 mm (0.02 in.).

50
4000 YRM 1647 Remove and Replace

4. Remove fittings at top of lift cylinders.

5. Remove base hose between right hand and left

hand lift cylinder. See Figure 62.

6. Remove lowering control valve at bottom of lift

cylinders. Plug open ports.

7. Remove capscrews and washers that secure lift

cylinders to lower weldment of outer mast. See
Figure 63.

8. Attach a lifting device to top cross member of in-

ner mast.

9. Pull inner mast out of outer mast gently, until load

A. DISTANCE BETWEEN FACES OF OUTER
MAST CHANNELS rollers touch t upper mast bearing blocks.
Figure 60. Outer Mast Channel Measurement
WARNING
LIFT CYLINDERS The lift cylinder weight varies between 100 and
250 kg (221 and 551 lb), depending on the truck
Remove model. Make sure the lifting device has the proper
capacity rating.
1. Remove mast. See section Mast Assembly, Re-
move. 10. Attach a lifting device to one of the lift cylinders.

2. Unstrap chains and hoses from lift cylinders. 11. For high lift masts, remove top bracket at upper
weldment. See Figure 64.
3. Remove bleeder hoses from lift cylinders. See
Figure 61.

1. BALANCE LINE
2. LOWERING CONTROL VALVE
3. LIFT CYLINDERS
1. BLEEDER HOSES
Figure 61. Bleeder Hoses Figure 62. Lift Cylinder Base - Hoses

51
Remove and Replace 4000 YRM 1647

12. Remove capscrew and washers that retain cylin-

der at top of inner mast. See Figure 65.

13. Move cylinder towards bottom of inner mast, until

it comes out of bracket at top weldment. See Fig-
ure 64.

14. Move cylinder towards top of inner mast, slightly

twisting to inner side of mast, until lower end of
cylinder has come out of upper weldment.

15. Remove cylinder from mast.

16. Repeat Step 10 to Step 14 to remove other lift cyl-

inder.

1. CAPSCREWS
2. WASHERS
3. LIFT CYLINDERS

Figure 63. Lift Cylinder Base

52
4000 YRM 1647 Remove and Replace

NOTE: * INDICATES FOR HIGH MAST LIFT TRUCKS ONLY.

1. CAPSCREWS* 6. PLATE*
2. WASHERS* 7. OUTER MAST
3. LIFT CYLINDER* 8. INNER MAST
4. HOSE* 9. TOP BRACKET
5. BRACKET*

Figure 64. Lift Cylinder and Mast Arrangement

53
Remove and Replace 4000 YRM 1647

Legend for Figure 65

1. LIFT CYLINDERS
2. SMALL WASHERS
3. LARGE WASHERS
4. CAPSCREWS

Figure 65. Lift Cylinder Top

Disassemble
1. Place lift cylinder on clean, horizontal surface. Clean all parts in solvent and dry with compressed air.
Inspect parts of lift cylinders for damage, rust, or
2. Use a tool to remove gland from cylinder shell. wear. Carefully inspect rod surface to make sure it is
See Figure 66. free of dents and scratches. Make sure internal stroke
surface of cylinder shell and grooves for seals do not
show any nicks, scratches, or other damage. Repair
CAUTION
or replace parts as needed.
Keep the piston rod aligned in the center of the
cylinder shell during removal to avoid damage to
Assemble
the cylinder parts.
1. Apply packing lubricant and install wear band and
3. Keep rod aligned with cylinder and pull piston rod
piston seals onto piston and gland. See Fig-
out of cylinder shell.
ure 66.
4. Remove gland from piston rod. See Figure 66.
2. Apply packing lubricant and install gland onto pis-
NOTE: Mark each seal and ring location and position ton rod.
to aid in assembly.

5. Remove wear band and seal from piston rod. CAUTION

Keep the piston rod aligned in the center of the
6. Remove O-ring, backup ring, wear band, rod seal, cylinder shell during installation to prevent dam-
and wiper from gland. age to the parts.

Clean and Inspect 3. Carefully slide piston rod and gland into cylinder
shell.

WARNING 4. Use a tool to install gland into cylinder shell.

Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety procedures. Com-
pressed air can move particles so they cause in-
jury to the user or to other personnel. Make sure
that the path of the compressed air is directed
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
Tighten gland to 550 to 625 N•m (406 to
461 lbf ft).
5. Turn cylinder, until upper port faces up.
6. Lubricate gland seals by adding 7 liter (7.4 qt) of
hydraulic oil to breather port.
7. Put a plug in upper port.

54
4000 YRM 1647 Remove and Replace

Install 6. Repeat Step 1 to Step 4 to install second cylinder.

1. Extend inner mast approximately 0.9 m (3 ft).
2. Attach a lifting device to lift cylinder. Make sure
position of cylinder matches cylinder support at
bottom of mast.
3. Move top end of cylinder under top cross member
to upper cylinder bracket.
7. Lift top of cylinders to align them with upper
bracket in inner mast and retract inner mast until
both cylinders are inserted.
8. Install washers and bolts that secure the top of lift
cylinder to inner mast.
9. Tighten bolts at top and bottom of cylinder.

4. Lower bottom end of cylinder and position it into 10. Remove plugs from cylinders, use new O-rings
cylinder support at bottom of outer mast. and install fittings for bleeder hose and lowering
control valves.
5. Install large washer and capscrew provisionally at
bottom of cylinder. Make sure there is 11. Tighten lowering control valve to 150 to
2 mm (0.08 in.) play between large washer and 165 N•m (111 to 122 lbf ft).
mast support. If required, add small sized wash-
ers between cylinder cap and large washer. See 12. Install hose between left and right hand cylinder
Figure 67. base. See Figure 62.

1. CYLINDER SHELL 9. O-RING

2. LOCK RING 10. BACKUP RING
3. HYDRAULIC CONNECTION 11. NOT SERVICEABLE PART
4. ROD END 12. WEAR BAND
5. ROD SEAL 13. SEAL
6. WIPER 14. WEAR BAND
7. NOT SERVICEABLE PARTS 15. BOTTOM END
8. WEAR BANDS

Figure 66. Lift Cylinder Assembly

55
Remove and Replace 4000 YRM 1647

4. Lower carriage and inner mast completely. Make

sure lift cylinders are completely retracted.

5. Turn engine OFF.

6. Turn key switch to ON. position.

7. Operate lift and tilt levers completely forward and

backward to remove any trapped hydraulic pres-
sure.

8. Apply brake pedal until brake lights no longer

come ON. when brake pedal is fully depressed.

9. Turn key switch to OFF. position.

10. Place blocks against both sides (front and back)

of the tires to prevent movement of lift truck.

11. Disconnect hydraulic hoses from tilt cylinder. Put

caps on hydraulic lines and ports.

12. For lift truck models F876 and F877 remove relief
1. LARGE WASHER valve from tilt cylinder to prevent damage during
2. CAPSCREW removal.
3. SMALL WASHERS
4. LOWERING CONTROL VALVE 13. For lift truck models E876 and E877 remove
5. LIFT CYLINDER END CAP counter balance valve from tilt cylinder to prevent
6. CYLINDER SUPPORT
damage during removal.
Figure 67. Lift Cylinder Bottom End
WARNING
13. Install bleeder hose between lift cylinders and The tilt cylinder weighs between 39 kg (86 lb) and
connect with bleeder hose leading to check valve 45 kg (99 lb), depending on truck and mast type.
at lower cross member. See Figure 63. Verify the lifting device has the rated capacity to
lift the tilt cylinder.
14. Install mast as described in section Mast Assem-
bly, Install. 14. Install a lifting device to tilt cylinder to be removed
and allow device to carry weight of cylinder.
15. Check shimming of hoist cylinders after mast has
been installed. See section Lift Cylinder Shim- 15. At rod end, remove capscrew and eye bolt to un-
ming. lock pin that retains tilt cylinder to mast. See Fig-
ure 68.
TILT CYLINDERS
WARNING
Remove Do not push the anchor pins out with your fingers.
Do not permit the tilt cylinders to drop and cause
NOTE: The following procedure is used to service
damage.
one tilt cylinder at a time. If both cylinders are to be
serviced at once, mast must be secured with a lifting 16. Use a soft hammer to remove pin from rod end of
device. tilt cylinder.
1. Place lift truck on a solid, level surface. 17. Lift tilt cylinder into an upright position.
2. Apply parking brake.

3. Tilt mast completely forward.

56
4000 YRM 1647 Remove and Replace

18. At frame side, remove capscrew and eye bolt to

unlock tilt cylinder pin that retains tilt cylinder to
frame.
19. Use a puller tool to remove pin from cylinder end
of tilt cylinder.
20. Lift tilt cylinder away from truck.
Disassemble
1. Put tilt cylinder in a vise with soft jaws, in a hori-
zontal position.
2. Disassemble and remove rod end by removing
two locking bolts/nuts. See Figure 68.
3. Loosen gland from shell.
CAUTION
Be careful not to damage the smooth surface of
the piston rod when removing the piston rod from
the cylinder shell in a horizontal position (parallel
to the cylinder shell).
4. Pull piston rod assembly with gland out of cylinder
shell.
CAUTION
Be careful not to damage the grooves when re-
moving seals, wipers, and wear rings.
5. DO NOT remove piston from rod unless there is a
reason to replace seal between piston and rod.

6. Disassemble and remove all seals, wipers, and

wear rings.

Clean and Inspect

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety procedures. Com-
pressed air can move particles so they cause in-
jury to the user or to other personnel. Make sure
that the path of the compressed air is directed
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

Clean all parts in solvent and dry with compressed air.

Inspect parts of tilt cylinder for damage, rust, or wear.

Carefully inspect rod surface for dents and scratches.
Verify that internal stroke surface of cylinder shell and
1. TILT CYLINDER grooves for seals do not show any nicks, scratches,
2. ROD END or other damage. Replace parts as needed.
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING Assemble
6. EYE BOLT
7. WASHER NOTE: Verify that all parts are clean before assem-
8. LOCKING BOLTS bly. Always use new seals and O-rings. Lubricate all
9. RELIEF VALVES (F876 ONLY) parts with clean hydraulic oil.
10. HYDRAULIC LINES
11. LUBRICATION POINT 1. Assemble new seals, wipers, and wear rings ac-
Figure 68. Tilt Cylinder Connections cording to Figure 68.

57
Remove and Replace 4000 YRM 1647

2. If removed, install the piston on rod using a new Install

O-ring. Tighten nut to 950 to 980 N•m (700 to
725 lbf ft).
CAUTION
Be careful not to damage the smooth surface of
the piston rod when installing the piston rod into
the cylinder shell in a horizontal position (parallel
to the cylinder shell).
NOTE: Keep the piston rod in the center of the cylin-
der shell during installation to prevent damage to the
parts.
NOTE: The locking bolts on rod end of tilt cylinder
should always be on bottom side with nuts towards
center of truck. See Figure 68.
1. Inspect bushings for tilt cylinder pins in brackets
for frame and outer mast. Replace bushings if
worn or damaged.
2. When reinstalling bushings, make sure that, at
mast side, split in bushing is turned away by 45°
from centerline of tilt cylinder and is in virtually
highest position. See Figure 70.

3. Lubricate cylinder shell bore with clean hydraulic 3. Use a lifting device to move tilt cylinder to truck.
oil. Push piston rod assembly into cylinder shell.
4. Align cylinder and frame brackets.
4. Push gland onto cylinder shell. Lubricate threads
5. Grease tilt cylinder pin and insert it in frame
of cylinder shell with clean oil and tighten gland to
bracket.
550 to 600 N•m (400 to 450 lbf ft).
6. Install eye bolt and the capscrew. See Figure 69.
5. Assemble rod end onto rod.
7. Align cylinder and mast brackets.

1. ROD 7. CYLINDER SHELL

2. HOLE PLUG 8. PISTON
3. ROD WIPER 9. LOCK NUT
4. ROD SEAL 10. GUIDE RING
5. BACKUP RING 11. PISTON SEAL
6. O-RING 12. O-RING

Figure 69. Tilt Cylinder Assembly

58
4000 YRM 1647 Remove and Replace

8. Grease tilt cylinder pin and insert the pin in the 16. Apply grease to grease fittings, until grease es-
mast bracket using a soft hammer. capes from bushings.

9. Install eye bolt and capscrew. See Figure 69.

10. Tighten capscrews on both eye bolts to

165 N•m (122 lbf ft).

11. Install relief valve at rod side port of tilt cylinder.

For lift truck models (F876) and (F877), install relief

valve at rod side port of tilt cylinder.

For lift truck models (E876) and (E877), install

counterbalance valve at rod side port of tilt cylinder.

12. Connect hydraulic lines to tilt cylinder.

13. Operate tilt cylinders. Check for correct operation

and leakage. See section Lift and Tilt Cylinders
Leak Check.
1. TILT CYLINDER PIN
14. Adjust tilt cylinders as described in section Tilt 2. BUSHING
Cylinder Stroke and Backward Tilt Angle Adjust- 3. BUSHING SPLIT
4. GREASE CHANNEL
ment.
Figure 70. Tilt Cylinder Bushings
15. Tighten nuts on rod end to 66 N•m (49 lbf ft).

Checks and Adjustments

GENERAL CHECKS 1. Inspect welds on the mast and carriage for
cracks. Make sure that capscrews and nuts are
Mast Condition Check tight

2. Inspect forks. See section Forks, Fork Inspection

WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised carriage. Do not put any
part of your body in or through the lift mechanism
unless all parts of the mast are completely low-
ered and the engine is STOPPED. Before making
any repairs, use blocks and chains on the inner
and outer masts and carriage so that they cannot
move. Make sure the moving parts are attached to
a part that does not move.
and Adjustment.
3. Inspect lift chains and their adjustment. See sec-
tions Lift Chain Inspection and Step 2.
4. Inspect chain anchors and chain pins for cracks
and damage. Make sure lock nut on chain anchor
is locked.
5. Inspect rollers for wear or damage. Replace as
necessary.

6. Check for leaks. Repair as necessary.

WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by pres-
sure.
7. Check condition of hydraulic hoses and tubes.
Check hose covers for cuts, cracks or exposed
reinforcement. Replace as necessary.

59
Checks and Adjustments 4000 YRM 1647

Mast Operation Check Never repair damaged forks by heating or weld-

ing. Forks are made of special steel using special
1. Slowly raise and lower mast several times without procedures. Replace damaged forks.
a load. The mast components must raise and
lower smoothly in correct sequence. Repair as 1. Inspect forks for cracks and wear. Check that fork
necessary. tips are aligned within 3% of the length of forks.
Check that bottom of fork is not worn. See Fig-
2. Verify tensioning of header hoses and proper ure 71.
tracking over sheaves while lifting and lowering.
Re-adjust when required. 2. Replace any damaged or broken parts that are
used to keep forks locked in position.
3. Verify inner mast lowers completely. The inner
mast is lowered when lower side of inner and
outer mast channels are virtually flush with each
other.

4. Verify carriage lowers completely. The carriage is

completely lowered when forks almost touch the
ground when inner mast is completely lowered
and in a vertical position.

5. Check controls for attachment operate functions

of attachment as required. See Operating Man-
ual.

6. Verify mast and carriage do not move when lift

and tilt controls are in neutral position. Perform a
leak check (if any movement is observed), as de-
scribed in section Leak Checks.
Fork Tip Alignment
Counterbalance Valve Check (for E876 and Length of Forks 3% Dimension
E877 Only)
1220 mm (48 in.) 37 mm (1.5 in.)
1. Verify hydraulic oil is at operating temperature 1830 mm (72 in.) 55 mm (2.2 in.)
65°C (150°F).
2440 mm (96 in.) 73 mm (2.9 in.)
2. Tilt mast fully backwards.
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
3. Apply tilt forward lever 50% of its possible stroke. FORK LENGTH)
Both tilt cylinders should start moving out simulta- 2. CRACKS
3. FORK PIN DAMAGE
neously. 4. MUST BE 90% OF DIMENSION X
5. FORK WEAR
4. Adjust counterbalance valve if one tilt cylinder has
moved more than 3 mm (0.12 in.) before the other Figure 71. Check the Forks
tilt cylinder starts moving. See section Counter-
balance Valve Adjustment.

Fork Inspection and Adjustment

WARNING
Do not try to correct the alignment of the fork tips
by bending the forks or adding shims. Replace
damaged forks.

60
4000 YRM 1647
Lift Chain Inspection
WARNING
Never replace just the worn section of a chain. Re-
place the complete chain. Never replace just one
chain of a chain pair. Replace both chains. When
replacing lift chains always discard the old chain
pins at the chain anchors and replace them with
new ones.
Perform below inspections in the sequence listed. Re-
lubricate chains after all inspections are successfully
passed. See section Lift Chain Lubrication Procedure.
1. Inspect for adequate chain lubrication. Check
that the oil film is intact on the outside of the chain
and that oil at the links is still free flowing. When
the oil film is found inadequate, there is an in-
creased risk for a chain failure caused by corro-
sion and/or friction. Increase the frequency of lu-
brication.
2. Inspect chain cleanliness. Clean chains when
dirt impedes penetration of lubricating oil into the
chain, or when dirt obstructs inspection. Only par-
affin derivatives such as diesel fuel or petroleum
may be used as a cleaning agent. Use a brush to
remove dirt and sand.
3. Measure chain elongation. Load the chain with
the weight of an empty carriage and measure dis-
tance over at least 6 pitches, from pin center line
to pin center line. Measure at several locations on
the part of the chain that moves over the sheave.
Replace the chain if elongation is 3% or more. For
two inch pitch chain a 3% elongation has been
reached when pin distance over 6 links is
314 mm (12.36 in.) or more.
4. Measure remaining plate height. A reduced
plate height reduces strength of the chain. Meas-
ure the height of the plate. Replace both chains if
the height of any plate is 45.85 mm (1.80 in.) or
less.
5. Check alignment between sheave and chain.
Investigate if sheave and chain align properly. If
they do not align, one or both bearings in the
sheave, or the pin, or the sheave itself may be
damaged. Disassemble sheave, check each part
for wear and replace if necessary. See section
Step 3.
Checks and Adjustments
6. Check for chain noise. Check if the chains pro-
duce a squeaking/squalling or grinding noise as
the mast is extended and lowered. Chain lubrica-
tion has been insufficient when such noise ap-
pears. As a consequence the smooth surface be-
tween pin and plate is probably damaged. In-
crease frequency of lubrication.
7. Inspect for signs of rust or brown lubricant.
Brown lubricant indicates that corrosion has affec-
ted chain pins and / or plates. The smooth surface
between pin and plate is probably damaged.
Rapid chain wear is to be expected. When there
are signs of rust, there is an increased risk for stiff
links and displaced link pins. Remove all exterior
rust and dirt buildup with a brush and an oil based
solvent. Increase frequency of lubrication.
8. Inspect for stiff or tight chain links. Stiff articu-
lation of a chain link indicates a bent pin and/or a
serious propagation of corrosion between pin and
plate. A bent pin indicates an overload situation.
Replace both chains if any chain link suffers stiff
articulation.
9. Inspect for turned or protruding link pins.
Check if beveled ends of link pins run parallel to
length of chain. If bevels of a link pin end are at
an angle to the length of the chain, the link pin
has turned. A turned link pin indicates excessive
friction due to insufficient lubrication or an over-
load condition. If a link is turned or protrudes, the
integrity of chain is lost. Replace both chains if
any link pin is turned or protrudes. Increase fre-
quency of lubrication.
10. Inspect for broken link pins. Check that all
outer plates run parallel to each other. A link pin is
probably broken if outer plates are at an angle to
each other. A broken link pin indicates an over-
load situation. Replace both chains if any link pin
is found broken.
11. Inspect for broken or missing chain link
plates. Corrosion or an overload condition can in-
itiate fatigue fractures in plates. Replace both
chains if any plate is found broken or missing.
12. Inspect for damaged plates or pins. Impacts by
other objects may damage or deform plates or
pins. Deformation increases risk for fatigue frac-
tures. Replace both chains if any deformation ex-
ceeds 5% of the pin diameter or plate thickness.
61
Checks and Adjustments
Lift Chain Lubricant Requirements
Chain lubricant must be a mineral or synthetic engine
oil. Oil viscosity must match ambient temperature, so
that oil remains viscous and can penetrate to contact
area between link pin and intermediate link.
• Use SAE 20W to 30W oil in ambient tempera-
tures of −30 to 5°C (−22 to 41°F).
• Use SAE 40 oil in ambient temperatures of 5 to
45°C (41 to 113°F).
• Use SAE 50 oil in ambient temperatures above
45°C (113°F).
The most practical oil to use is SAE 15W-40 multi
grade engine oil.
NOTE: If an aerosol spray lubricant is used, always
check that it deposits an engine oil equivalent, with
minimum viscosity as listed under Viscosity, after the
dispersing agent has evaporated.
DO NOT use the following lubricant types:
• Lubrication products that contain solids such
as graphite or molybdenum disulfide. Solids
will not penetrate between plates, and over
time, they will form a barrier that prevents oil
penetration.
• Grease or lubrication products that stiffen or
form a greasy film. Stiffening products do not
penetrate sufficiently. Grease does not pene-
trate at all. Stiffening products and grease form
a barrier that prevents penetration of oil for re-
lubrication. Without proper lubrication, the serv-
ice life of a lift chain is minimized.
• Penetrating fluids or aerosol spray lubricants
containing penetrating fluids do not provide ad-
equate lubricity, adhesion or corrosion protec-
tion, and they do not form a film.
Lift Chain Lubrication Procedure
To achieve proper lubrication the following require-
ments must be met.
• Remove the load from chain completely. Put a
support under carriage and slacken chains.
• Clean the chain. Make sure that any debris,
grease or thick oil between chain outside and
link pin is removed.
62
4000 YRM 1647
• Dry the chains. Make sure that any trapped
water or condensation, especially at the pin
area, is removed.
• Lubricate with a mineral or synthetic based en-
gine oil. See section Lift Chain Lubricant Re-
quirements.
• Make sure applied layer of oil protects the en-
tire chain surface against corrosion.
• Allow sufficient time for oil to penetrate and fa-
cilitate oil penetration by articulating the chain
several times with the lowest possible load af-
ter oil has been applied.
Complete relaxation of chains between shifts signifi-
cantly contributes to the re-lubrication of chain pins,
provided that the oil film on outside of chain is intact.
Leak Checks
Mast Vertical Creep
1. Place a capacity load on forks and raise and
lower load several times until hydraulic oil has
reached 65°C (150°F).
2. Raise forks approximately 1 m (3.3 ft) above
ground, put lift controls in neutral position and
measure vertical creep during 10 minutes.
3. Mast Vertical Creep must be limited to
100 mm (3.94 in.) in 10 minutes for trucks up to
10 tons lifting capacity.
4. Mast Vertical Creep must be limited to
200 mm (7.87 in.) in 10 minutes for trucks above
10 tons lifting capacity.
5. If mast vertical creep exceeds maximum allowed
value, determine if an internal leak is present at
lift cylinder or at control valve.
6. Check lift cylinders for internal leaks.
7. Remove load from forks. Install a gate valve in
each of separate supply lines between lift cylinder
and control valve. Place again a capacity load on
forks, raise forks approximately 1 m (3.3 ft) above
ground and close both gate valves. If creep speed
is similar to the measurement in Step 2, lift cylin-
ders need to be resealed.
4000 YRM 1647
8. Check functionality of Emergency Lowering
Valve. Replace Emergency Lowering Valve to
verify if its replacement solves the problem. If
creep speed is still too high, replace relevant con-
trol valve section. Individual control valve section
components are not separately available.
Mast Tilt Drift
1. Place a capacity load on forks and tilt mast sev-
eral times forward and backward until hydraulic oil
has reached 65°C (150°F).
2. Attach an inclinometer to mast, put mast in a ver-
tical position, and raise load at 2.5 m (8.2 ft)
height. Put controls in a neutral position and
measure mast tilt drift. Mast tilt drift must remain
within 5 degrees during a 10 minute period. If
maximum forward tilt angle is less than 5 de-
grees, measured time period must be proportion-
ally reduced.
3. If mast tilt drift exceeds maximum allowed value,
determine if an internal leak is caused by tilt cylin-
der or by control valve.
4. Check tilt cylinders for internal leaks.
5. Remove load from forks. Install a gate valve be-
tween rod side of tilt cylinders and divider block.
Place again a capacity load on forks, raise forks
approximately 1 m (3.3 ft) above ground and
close both gate valves. If creep speed is similar to
measurement in Step 2, tilt cylinders need to be
resealed.
6. Check control valve for internal leaks.
7. Check functionality of 28 MPa (4061 psi) pressure
relief valve in tilt section of control valve. Replace
relief valve to verify if its replacement solves prob-
lem. If creep speed is still too high, replace tilt
valve section.
Checks and Adjustments
The creep and drift rates reduce with a factor of about
1.5 for every 10°C (18°F) that actual oil temperature
in cylinder is lower. Make sure to have reached re-
quired oil temperature of 65°C (150°F) in cylinders for
accurate test results.
ADJUSTMENTS
Lift Cylinder Shimming
NOTE: Lift cylinders must be shimmed to make sure
that they equally support the inner mast in the com-
pletely lowered position. The purpose is to prevent
twisting the inner mast when driving with a load in the
completely lowered position.
1. Put mast in a vertical position and lower carriage
completely. Make sure forks do not touch ground.
2. Open emergency lowering valve. See Figure 72.
3. Use a personnel lift and measure clearance be-
tween upper cylinder support and cylinder rod.
Use a pry bar to make sure that cylinder rods can-
not lower any further.
4. Shimming is required when clearance exceeds
1 mm (0.04 in.). See Figure 73.
5. Remove securing bolt and washers from cylinder,
which requires shimming.
6. Use a lifting device to lift inner mast just enough
to install shim on cylinder rod.
7. Lower inner mast and install washers and secur-
ing bolt. Tighten bolt.
8. Close emergency lowering valve.
63
Checks and Adjustments 4000 YRM 1647

A. EMERGENCY LOWERING VALVE

Figure 72. Emergency Lowering Valve Location

64
4000 YRM 1647
Lift Chain and Fork Height Adjustment
CAUTION
The carriage can be set higher and lower on the
lift chain anchor, however the carriage load rollers
must remain within the inner mast channel both in
the lowest and in the highest carriage positions to
avoid damage to the lift truck.
NOTE: The purpose of lift chain adjustment is to
align the carriage in the inner mast and to position the
forks at the required height when the carriage is com-
pletely lowered. Carriage alignment is required when
chains, chain anchors or the carriage is replaced.
Carriage alignment is also required when the carriage
does not lift and lower smoothly. A symptom is that
one of the chains has a lower tension and shows big-
ger deflection compared with the other chain. Incor-
rect carriage alignment causes premature wear of the
bearing blocks. Alignment of the carriage is obtained
by adjusting the two chain anchors individually.
A. SHIMMING GAP
1. CAPSCREW
2. SMALL WASHER
3. LARGE WASHER
4. OUTER MAST
5. INNER MAST
Figure 73. Lift Cylinder Shimming
Checks and Adjustments
1. Put mast in a vertical position and lower carriage
completely.
2. Side shift the carriage until it is at the center line
of the mast.
3. Make sure that both forks are in an equally exten-
ded position.
4. Measure the distance between the carriage bar
and the inner mast at two locations. The two loca-
tions must be at 50 cm (2 ft) from each other. See
Figure 74, measuring point (A) and (B).
5. Align the carriage if the two distances vary more
than 0.5 mm (0.025 in.).
6. Make sure that both forks have at least
1 cm (0.40 in.) clearance with the ground.
7. If adjustment is required, loosen the chain anchor
lock nut and bend the fingers of the securing plate
to release the large nut. See Figure 75.
8. Tighten the large nut of the chain anchor that is in
the lowest position to align the vertical carriage
bar with the inner mast channel.
9. Turn both large nuts with the same angle until the
required ground clearance has been obtained.
10. After adjustments are complete, bend the fingers
of the securing plates around the large nut and
tighten the lock nut.
65
Checks and Adjustments 4000 YRM 1647

A. MEASURING POINT A 1. SPLIT PIN

B. MEASURING POINT B 2. CHAIN PIN
3. WASHER
1. CARRIAGE 4. CHAIN ANCHOR
2. INNER MAST 5. LARGE NUT
3. OUTER MAST 6. SECURING PLATE
7. LOCK NUT
Figure 74. Carriage Alignment 8. SMALL NUT
9. WASHER
10. CAPSCREW

Figure 75. Chain Anchor On Carriage

66
4000 YRM 1647
Header Hose Tension Adjustment
1. Make sure that lift chains are tensioned and cor-
rectly adjusted.
2. Release hose clamp on upper mast bracket by
loosening capscrew.
3. Verify that header hoses are in good condition.
Un-tensioned hoses are to be of equal length. Re-
place any defective hose.
4. Pull and tension hoses which are clamped on
same bracket. The required elongation is between
1% and 2%.
5. Tighten capscrew to clamp hoses. See section
Step 3.
Electric Mast Cable Tension Adjustment
1. Make sure that lift chains are tensioned and cor-
rectly adjusted.
2. Loosen cable clamp at carriage bracket.
3. Pull and hold cable at same tension as header
hoses.
1. COUNTERBALANCE VALVE
2. VALVE TO ADJUST LH CYLINDER
3. VALVE TO ADJUST RH CYLINDER
Figure 76. Counterbalance Valve Adjustment
Checks and Adjustments
4. Tighten cable clamp at carriage bracket.
Counterbalance Valve Adjustment
1. Establish which tilt cylinder moves out first. See
section Counterbalance Valve Check (for E876
and E877 Only).
2. Adjust the counterbalance valve which is at the
opposite side of the valve connection for cylinder
moving out first. See Figure 76.
3. Adjust the valve by loosening the adjustment nut
one full turn and subsequently rotate the setscrew
¼ turn counter clockwise.
4. Retighten adjustment nut by using a 17 mm
wrench.
5. Check again simultaneous cylinder movement.
See section Counterbalance Valve Check (for
E876 and E877 Only).
6. Repeat adjustment procedure until both tilt cylin-
ders start moving simultaneously when tilting for-
ward.
4. LOCK NUT
5. SET SCREW
67
Checks and Adjustments 4000 YRM 1647

Tilt Cylinder Backward Tilt Angle Adjustment
1. Slowly tilt mast backward until one rod is against
its stop. Adjust opposite cylinder if it stops more
than 1.0 mm (0.04 in.) later.
2. To adjust tilt cylinder, loosen nuts on rod end and
turn cylinder rod out of rod end until both rods
stop at same time.
3. Repeat procedure to make sure cylinder rods stop
at the same time within 1.0 mm (0.04 in.).
4. Check tilt angles are correct as specified on
nameplate of lift truck. A limited tilt angle correc-
tion can be made by turning both cylinder rods the
same amount.
5. Verify thread of cylinder rod extends approxi-
mately 48 mm (1.89 in.). See Figure 77. Turn both
rods into the rod end if one of the threads extends
more than 50 mm (1.97 in.).
6. When adjustments are complete, turn rods until
wrench flats are at upper and lower side. Having
wrench flats at sides of rods increases stress
level.
7. Tighten nuts on rod end to 66 N•m (49 lbf ft).
Mast Support Pad Adjustment
1. Tilt mast slightly forward and measure clearance
between wear plate and inner mast. Clearance
should be between 0.5 and 1.5 mm (0.020 and
0.059 in.).
2. For re-shimming, remove capscrews and install
shims as necessary between wear plate and
outer mast.
3. Tighten capscrews to 60 N•m (44.3 lbf ft). See
Figure 78.

A. 6 mm (0.24 in.) MAXIMUM

NOTE: X = ROD END THREAD DISTANCE 1. OUTER MAST
2. INNER MAST
1. ROD 3. CAPSCREWS
2. WRENCH FLAT 4. PLATE
3. NUTS 5. WEAR PLATE
4. ROD END 6. SHIM
Figure 77. Tilt Cylinder Adjustment Figure 78. Mast Support Pad Adjustment

68
4000 YRM 1647 Troubleshooting

Troubleshooting

INTRODUCTION

This troubleshooting list does not cover every possible problem. It is intended to help finding the cause of problem
in the mast system.

Before searching for the cause of a problem, make sure that all daily condition checks and fluid level checks have
been performed and that required repairs have been completed. See Periodoc Maintenance YRM.

If a problem occurs directly after a repair, verify if assembly instructions have been followed correctly. If a problem
has aggravated, verify if hydraulic oil cleanliness meets 21/17/13 according ISO 4406.

For diagnosing and verification of settings, make use of the Hydraulic User Interface ProgrammeYRM. See
Hydraulic Control SystemYRM.

Follow each step in the sequence shown in one of the three main search criteria:
• No Hydraulic Movement with Engine Running
• No Lowering Possible with Engine OFF
• Incorrect Movement

If this troubleshooting list did not help solving your problem, read the Description and Operation section in this
YRM to find further possible causes of failure.

NO HYDRAULIC MOVEMENT WITH ENGINE RUNNING

Initial Basic Check

Make sure the Transmission Calibration Switch is in the OFF position.

Turn the Key Switch to the ON position to verify that all warning lights and indicator lights on the instrument panel
will light up.

After two seconds all indicator lights must be OFF, except for the Wait to Start Light, Central Warning Lights and
Brake System Low Pressure Warning Light.

Start the engine after the Wait to Start Light is OFF.

• If any of the above steps fail, follow the steps mentioned under Electrical Supply
• If the Brake System Low Pressure Warning Light is still ON after 10 seconds, follow the steps mentioned
under Hydraulic Supply.
• If the Central Warning Lights are ON and a fault code is displayed, follow the steps mentioned under Fault
Code.

69
Troubleshooting 4000 YRM 1647

Electrical Supply

Determine which fuse and/or relay connect with the failed function and replace as necessary. See DiagramsYRM
and Fuses and Relays in Electrical System YRM.
• Investigate and resolve the root cause for the failed fuse and/or relay.
• Replace the failed fuse and/or relay.

Hydraulic Supply

Operate the steering system with the engine running. Hydraulic pump supply is sufficient when steering requires
normal effort.
• If abnormal effort is required, repair the steering system and/or investigate why hydraulic pump supply is
insufficient. See Steering SystemYRM.

Make sure that the Transmission Calibration Switch is in the OFF position.

Verify that the Operator Presence System (OPS) functions correctly.

• Hydraulic functions should operate normally when the operator is seated, the engine is running and the
transmission calibration switch is in the OFF position.
• Hydraulic functions should be interrupted when the operator is not seated.
• The OPS needs repair when hydraulic functions can only be operated with the hydraulic service switch in
the ON position.
• To repair the OPS, check functionality of OPS fuse, seat switch, seat belt switch, and operator presence
relay. Replace any failed OPS component.

Fault Code

Look up the fault code and determine the location of the indicated component on the truck. See DiagramsYRM
and Electrical SytemYRM.
• Check functionality of the component and repair as required.

If a fault code suggests checking a Directional Control Valve or an Actuation Valve, verify if partial or complete
replacement is required.

Move the spool by rotating the actuator axle about 15 degrees with a spanner.
• When the spool moves smoothly, replace the failed Electrical Actuation Module only.
• When the spool sticks, disassemble and clean the spool section.
• If components of the spool section are damaged after disassembly, replace the spool section.

70
4000 YRM 1647 Troubleshooting

NO LOWERING POSSIBLE WITH ENGINE OFF

Make sure the lift cylinders are extended and the lift chains carry at least the weight of the carriage.
• If the carriage is not installed, use the emergency lowering control valve to lower the mast.

Turn the key switch to the ON position.

Move the hoist lever into the lowering position.

• If fault code H2664 is displayed, resolve the open circuit or short circuit situation for the (emergency) Low-
ering Selector Valve [B].

Attach a pressure gauge to port MPLT.

Read the pressure gauge at port MPLT with the key switch in the ON position and the hoist lever in the lowering
position.
• If pressure is lower than 1 MPa, investigate proper functioning of the Pilot Supply Valve [F] and the Lower-
ing Selector Valve [B]. Repair or replace as necessary.

INCORRECT MOVEMENT

Irregular (shaking) Movement or Slight Carriage Movement When Starting Engine

De-aerate system by operating the affected function(s) several times.

• Activate for one second and reverse cycle. Repeat a few times.
• When the problem re-occurs, search for entry of air in pump suction line.

Unequal Movement of Left And Right Tilt Cylinder

Verify and correct tilt cylinder adjustment and condition of pivot points.

Establish and repair internal leaks in the tilt cylinders.

Verify and correct relief pressure setting of the individual tilt relief valves.

Insufficient Lifting Speed

Measure pilot pressure at port MPLT.

• If pressure is above 1 MPa, verify Hydraulic Flow Control Settings and correct as required. See Hydraulic
Control SystemYRM.
• If pressure is 1 MPa or less, inspect Pilot Supply Valve [F] and replace if found defective.

Verify pump performance.

• Measure Load Sense pressures. See Hydraulic SystemYRM.
• Inspect hydraulic pump and repair as required.

71
Troubleshooting 4000 YRM 1647

Insufficient Lifting Capacity

Verify correct relief valve pressures.

• Pressure at Port MP should reach 33 +/- 0.5 MPa for Full Flow Relief Valve [G].
• Pressure at Port MLS2 should reach 22.5 +/- 0.5 MPa for Load Sense Relief Valve [H].
• Replace relief valves as necessary.

Incorrect Lowering Speed

Verify Hydraulic Flow Control Settings and correct as required. See Hydraulic Control SystemYRM.
• Replace the Lowering Control Valve(s) at the lift cylinders if hydraulic controller settings appeared to be
correct.

Lift Cylinder Creep

Follow the instructions as described under Mast Vertical Creep.

Tilt Cylinder Creep

Follow the instructions as described under Mast Tilt Drift.

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4000 YRM 1647 7/16 (2/16)(8/15)(7/15)(5/14)(11/13)