INTRODUCTION

GENERAL
This section contains the instructions for the disassem-
bly and assembly of the masts for the E30FR-24,
E30FR, E35FR, E40FR, E45FR and E50FR series of
electric lift trucks. These lift trucks can be equipped
with the following types of masts:
The checks and adjustments are given at the end of this
section. The description and operation of the masts are in
the section, MAST DESCRIPTION, 4000 SRM 879.


The crane, slings and chains used to lift assemblies in
this section must have a minimum capacity of 1800
kg (4000 lb). A three stage mast with carriage and
forks will weigh more than 1800 kg (4000 lb).

1. Two Stage Mast



Do not work under a raised carriage. Lower the car-
2. Three Stage Mast riage before servicing the lift truck.

REPAIRS

FORKS assembly (6), then sliding the fork over the fork removal
(See FIGURE 1) notch (3) located in the center of the carriage.
Refer to the section, PERIODIC MAINTENANCE,
The identification of a fork is determined by its connec- 8000 SRM 900 for the identification, removal, inspec-
tion to the carriage. tion and installation of the forks.

Hook type forks are connected to the carriage by hooks 


and locking pins. These pins fit through the top fork Never repair damaged forks by heating or welding.
hooks and into slots on the top carriage bar. The forks can Forks are made of special steel using special proce-
be removed from the carriage by unlatching the lock pin dures. Replace damaged forks.

1. LOAD ROLLERS
2. CHAIN ANCHORS
1
3. FORK REMOVAL NOTCH
4. FORK
1 5. HOOK
6. LOCKING PIN ASSEMBLY

1
6

1
5
2 4

FIGURE 1 – HOOK AND PIN FORKS

1
CARRIAGE


When working on or near the mast or carriage, see
SAFETY PROCEDURES WHEN WORKING
NEAR THE MAST. See section, PERIODIC MAIN-
TENANCE, 8000 SRM 900.
Removal
1. Lower the mast and carriage. Disconnect the battery
and separate the connector, remove the forks and load
backrest extension and disconnect any hydraulic attach-
ments to the carriage.
2. On the three stage mast, remove the two carriage
stop bolts located near the top of the inner mast. See
FIGURE 2.
WARNING
Make sure the lifting device has adequate capacity to
handle the weight of the carriage.
3. Connect a lifting device to the carriage.
4. Remove the inner chains from the carriage. Refer to
INNER CHAINS–REMOVAL in this section.
5. Carefully lift the carriage out of the mast.
6. Inspect the load roller bearings for wear or damage
and replace as necessary.
INNER MAST (FRONT)
2
1
1. INNER MAST
2. CARRIAGE STOP BOLTS
FIGURE 2 – CARRIAGE STOP BOLTS
Installation
WARNING
Make sure the lifting device has adequate capacity to
handle the weight of the carriage.
1. Connect a lifting device to the carriage. Be certain
that the lifting device has adequate capacity to lift the
carriage. Raise the carriage directly above the mast
assembly.
2. Align the load rollers on the carriage with the inner
mast of the mast and carefully lower the carriage into the
inner mast.
3. Adjust the carriage as described below.
4. Install the inner chains. Refer to INSTALLATION–
INNER CHAINS in this section.
5. For the three stage mast, install the carriage stop
bolts near the top of the inner mast. See FIGURE 2.
6. If the carriage has a hydraulic attachment, connect
the hydraulic lines and install the mounting hardware.
7. Connect the battery.
MAST ASSEMBLY
Removal
NOTE: The mast assembly can be removed with the
carriage installed on the mast. However, if the mast is
being removed for disassembly and service, remove the
carriage before removing the mast. Refer to CAR-
RIAGE–REMOVAL in this section.
1. Lower the mast and tilt it so that it is vertical. Re-
move the forks and load backrest extension.
WARNING
To prevent electrical shock and injury, disconnect
the battery, separate the connector and discharge
the capacitor bank before inspecting or repairing
any component. DO NOT short the capacitor bank
to the frame or ground.
2. Check that the key switch is in the off “O” position.
3. Disconnect the battery and separate the battery
connector.
4. Turn the key switch to the “I” position. The operator
display will illuminate and go off. After the operator
display is completely dark, the capacitor bank is fully
discharged.
2
5. Turn the key switch to the off “O” position.
WARNING
Before disconnecting any hydraulic lines, relieve the
pressure in the lines. To relieve pressure in the lift
lines and cylinders, pull up on the manual lowering
valve on the manifold. To relieve pressure in any lift
or auxiliary lines, let the truck sit for approximately
five minutes.
6. Clean the area around all hydraulic connections. Put
a drain pan under the truck. Tag, disconnect and cap all
hydraulic lines to the mast. Tag and disconnect any elec-
trical wires from the frame to the mast.
damage the hoses, sheaves, or other parts of the mast as-
sembly. Operate the lifting device until it gives support
to the weight of the mast.
8. Remove the four socket head capscrews and re-
move the mast pivot bearings. See FIGURE 3.
WARNING

DO NOT use fingers to remove the tilt cylinder
pins.

Support the weight of the tilt cylinder when
removing the pin so that it does not drop and
damage the truck or the tilt cylinder.

9. Disconnect the tilt cylinders at the mast. The ends of

WARNING

When lifting the mast, use a chain with ends that
close securely. Either snap hooks or screw links
should be used.

Make sure the lifting device has adequate capacity
to handle the weight of the mast assembly.
7. Connect a lifting device and chain to the top of the
mast. Position the lifting device so that the mast will be
lifted vertically. All the mast rails must be fastened to-
gether with the chain. Position the chain so it will not
each tilt cylinder pin have a 3/8-16 threaded hole. Re-
move the four hair pin clips and use a slide hammer to
remove the tilt cylinder pins.
10. Check to make certain all electrical wires and hoses
have been disconnected.
11. Use the lifting device to carefully lift the mast as-
sembly and move the mast away from the truck.
12. Lay the mast assembly horizontally on blocks with
the back of the mast facing toward the floor.

1
2

4 8
1
7

5
1
6
1. HAIR PIN CLIPS
2. PIN 2
3. TILT CYLINDER
4. SETSCREW
5. CAPSCREW
1
6. MAST PIVOT BEARING
7. JAM NUT
8. ROD END

FIGURE 3 – MAST REMOVAL

3
Installation
WARNING

When lifting the mast, use a chain with ends that
close securely. Either snap hooks or screw links
should be used.

Make sure the lifting device has adequate capacity
to handle the weight of the mast assembly.
1. Connect a lifting device and chain to the top of the
mast. All the masts must be fastened together with the
chain. Position the chain so it will not damage the hoses,
sheaves or other parts of the mast assembly.
WARNING
Ensure that all personnel are clear of the mast when
raising it from the horizontal position. Raise the
mast slowly to maintain control.
2. Raise the mast to the vertical position and position
the lifting device so that the mast assembly will be low-
ered vertically onto the truck.
3. Check to see that all wires and hoses are clear of be-
ing pinched or cut. Carefully lower the mast assembly
onto the frame of the truck.
4. Ensure the mast pivot bearings are properly posi-
tioned, install the mast mount plates and attach them
with four socket head cap screws. See FIGURE 3.
5. Connect the tilt cylinders to the mast with two tilt
cylinder pins and four hair pin clips.
6. Connect all hydraulic lines and electrical wires.
7. Connect the battery.
NOTE: If the carriage was removed, install the
carriage. Refer to CARRIAGE–INSTALLATION in
this section.
LIFT CHAIN REMOVAL AND
INSTALLATION
(SEE FIGURE 4)
Removal–Inner Chains
1. Lower the carriage on two 4x4 wooden blocks. Lay
the wooden blocks flat under each side of the carriage.
2. Let the free lift cylinder completely collapse to re-
lease the tension on the inner lift chains.
3. Disconnect the battery and separate the connector.
4. Loosen the chain anchor nuts on the inner mast.
CAUTION
When removing a lift chain, maintain control of the
ends. If the chain is not controlled, it may run
through the sheave, fall from the mast, and possibly
cause injury to personnel or damage to equipment.
5. Disconnect the lift chain from the chain anchor on
the carriage. Move the lift chain out of the way of the
carriage.
6. For complete disassemby of the mast, remove the
chain anchor bolts and chains. The chain anchor bolts
are attached with two locknuts and one cotter pin per
chain anchor bolt. Each chain is attached with one con-
nector pin and two cotter pins.
Installation–Inner Chains
1. Install the chain anchor bolts (if they were pre-
viously removed) and attach the inner chains. The chain
anchor bolts are attached with two locknuts and one cot-
ter pin per chain anchor bolt. Each chain is attached with
one connector pin and two cotter pins.
2. Route the chains over the chain sheaves on the free
lift cylinder. Connect the lift chains to the chain anchors
on the carriage.
3. Tighten the locknuts on the chain anchor bolts. For
adjustment of the chains. Refer to CHAIN ADJUST-
MENT in this section.
4. Connect the battery.
5. Raise the carriage and remove the two 4x4 wooden
blocks from under the carriage.
4
 OVER INTERMEDIATE
7 MAST SHEAVE TO INNER
6 MAST
OUTER MAST (REAR)
5

INTERMEDIATE
5 MAST
4 3

INNER MAST
8
(FRONT)
OVER FREE LIFT
CYLINDER SHEAVE
8
TO CARRIAGE
8 2 6
3
5
1. FREE LIFT CYLINDER
2. INNER LIFT CHAIN (1 OF 2) 5
3. CHAIN ANCHOR BOLT
4. LOCKNUT
5. COTTER PIN
6. CONNECTOR PIN 4 1
7. OUTER LIFT CHAIN (1 OF 2)
8. INTERMEDIATE MAST SHEAVES
OUTER CHAIN ATTACHES
HERE WITH ITEMS 5 & 6

FIGURE 4 – THREE STAGE MAST LIFT CHAIN ASSEMBLY

Removal–Outer Lift Chains (Three Stage)

1. Completely lower the mast and carriage, disconnect
the battery and separate the connector.
WARNING
Before disconnecting any hydraulic lines, relieve the
pressure in the lines. To relieve pressure in the lift
lines and cylinders, pull up on the manual lowering
valve on the manifold.
CAUTION
When removing a lift chain, maintain control of the
ends. If the chain is not controlled, it may run
through the sheave, fall from the mast, and possibly
cause injury to personnel or damage to equipment.
5. Remove the chain anchor bolts at the top of the in-
termediate mast. The chain anchor bolts are attached
with two locknuts and one cotter pin per chain anchor
bolt.

2. Tag and disconnect the two hydraulic lines from the
free lift cylinder manifold block at the bottom of the in-
ner mast.
3. Loosen the chain anchor nuts at the top of the inter-
mediate mast.
6. Pull the chains through the intermediate mast
sheaves and remove them from the mast.
Installation–Outer Lift Chains (Three Stage)
1. Route the chains through the intermediate mast
chain sheaves.

4. Disconnect the outer chains from the chain anchors 2. Connect the chains to the chain anchors at the bot-
at the bottom of the inner mast. tom of the inner mast.
5
3. Connect the two hydraulic lines at the free lift cylin-
der manifold block at the bottom of the inner mast.
4. Install the chain anchor bolts at the top of the outer
mast. The chain anchor bolts are attached with two lock-
nuts and one cotter pin per chain anchor bolt.
5. Adjust the outer chains. Refer to LIFT CHAIN AD-
JUSTMENT in this section.
6. Connect the battery.
LIFT CYLINDER REMOVAL AND
INSTALLATION
(SEE FIGURE 5)
Removal–Free Lift Cylinder
1. Completely lower the mast and carriage and remove
the forks.
2. Disconnect the battery and separate the connector.
3. Connect a lifting device to the carriage. Be certain
that the lifting device has adequate capacity to lift the
carriage.
4. Remove the inner chains from the carriage. Refer to
REMOVAL–INNER CHAINS in this section.
NOTE: If the mast is equipped with auxiliary hose
take-up, disconnect the hoses from the carriage and free
them from the free lift cylinder hose sheave.
5. Raise the carriage approximately 150 mm (6 in)
above the free lift cylinder.
6. Disconnect the hydraulic line from the bottom of
the free lift cylinder.

OVER INTERMEDIATE MAST

OUTER MAST (REAR) SHEAVE TO INNER MAST

INTERMEDIATE
MAST
12 4
11 5
7
8

INNER MAST
(FRONT)

2 OVER FREE LIFT

CYLINDER SHEAVE
TO CARRIAGE

10

1. FREE LIFT CYLINDER 1

2. INNER LIFT CHAIN (1 OF 2) 6
3. SNAP RING 8. SPACER SLEEVE 5
4. CAPSCREW 9. MAIN LIFT CYLINDER
5. LOCKWASHER 10. ROLL PIN 3
6. CYLINDER STRAP 11. CUSHION RING 4
7. FLAT WASHER 12. SHIM

FIGURE 5 – THREE STAGE MAST LIFT CYLINDER ASSEMBLY

6



Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
7. Remove the heavy duty snap ring (use snap ring pli-
ers) at the bottom of the free lift cylinder.
8. Remove two capscrews, lockwashers and the cylin-
der strap.
9. Lift the free lift cylinder up and out of the inner
mast.
Installation–Free Lift Cylinder
1. Lower the free lift cylinder into position in the inner
mast.
2. Align the cylinder strap and secure it with the two
capscrews and lockwashers.


Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
3. Replace the heavy duty snap ring (use snap ring pli-
ers) at the bottom of the free lift cylinder.
4. Connect the hydraulic line to the bottom of the free
lift cylinder.
5. Lower the carriage approximately 300 mm (1 ft) be-
low the chain sheave pin.
6. Replace the inner chains. Refer to INSTALLA-
TION–INNER CHAINS in this section.
NOTE: If the mast is equipped with auxiliary hose
take-up, route the twin-line hose through the free lift
cylinder hose sheave and connect to the carriage.
WARNING
Keep hands and fingers from being pinched between
the chain and sheave while lowering the carriage.
7. Lower the carriage and remove the lifting device.
Replace the forks.
7
8. Connect the battery and operate the mast. Look for
leaks or loose fittings. Bleed any air from the cylinder.
Refer to BLEEDING AIR FROM THE LIFT CYL-
INDERS in this section.
Removal–Main Lift Cylinders (Three Stage)
NOTE: Remove the carriage from the mast before
performing this procedure. Refer to CARRIAGE–RE-
MOVAL in this section.
1. Remove the mast. Refer to MAST ASSEMBLY–
REMOVAL in this section.
2. Place the mast on a flat surface with the front down.
3. Remove the capscrew, split lockwasher, flat washer
and spacer sleeve securing the outer lift cylinder to the
intermediate mast upper cross bar (see FIGURE 5).
4. Remove the roll pin at the bottom of the outer
cylinder.
5. Disconnect the hydraulic line from the bottom of
the outer cylinder.
6. Extend the intermediate mast to full length.
7. Remove the cushion ring and shims from the top of
the cylinder.
8. Maneuver the outer lift cylinder out of the top of the
mast.
Installation–Main Lift Cylinders (Three Stage)
1. Maneuver the outer lift cylinder though the top of
the mast to the bottom of the cylinder mount bracket.
2. Reconnect the hydraulic line to the outer lift
cylinder.
3. Install the roll pin at the bottom of the outer lift
cylinder.
4. Install the cushion ring and shims on the top of the
cylinder.
5. Slide the mast rails together.
6. Install the spacer sleeve, flat washer, lockwasher
and capscrew securing the lift cylinder to the top of the
intermediate mast.
7. Install the mast on the truck. Refer to MAST AS-
SEMBLY–INSTALLATION in this section.
8. Install the carriage. Refer to CARRIAGE–
INSTALLATION in this section.
9. Connect the battery and operate the mast while
checking for leaks or loose fittings. Bleed any air from
the cylinders. Refer to BLEEDING AIR FROM THE
LIFT CYLINDERS in this section.
LIFT CYLINDER SHEAVES
(SEE FIGURE 6)
Removal–Free Lift Cylinder Sheaves
1. Completely lower the mast and carriage.
2. Lower the carriage on two 4x4 blocks.
3. Disconnect the battery and separate the connector.
4. Remove the two retaining rings and the chain/hose
safety guide from the free lift cylinder.


Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
5. Remove the two snap rings from the free lift cylin-
der sheave pin and loosen the setscrews.
6. Remove the chain sheaves and machine bushings.
Take note how many machine bushings are on each side
of the free lift cylinder sheave pin.
NOTE: If the truck is equipped with hose take-up,
there is a twin-line hose sheave in the middle of the
sheave pin.
7. Remove the sheave pin from the free lift cylinder.
8. Check for cracks in the sheave pin and on the
sheaves. Replace any damaged components.
Installation–Free Lift Cylinder Sheaves
NOTE: If the truck is equipped with hose take-up,
place the twin-line hose sheave on the sheave pin before
pushing the sheave pin all the way through.
1. Replace the sheave pin on the free lift cylinder and
tighten the setscrews.
2. Place the chain sheaves and machine bushings on
the sheave pin. Make sure the machine bushings are re-
placed exactly as they were removed.


Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
3. Install the snap rings on the sheave pin.
4. Place the lift chains and auxiliary hose (if so
equipped) on the sheaves.
5. Install the chain/hose safety guide on the free lift
cylinder and secure it with two retaining rings.
6. Connect the battery and test the sheaves by raising
and lowering the carriage.
Removal–Intermediate Mast Sheaves
1. Lower the mast completely.
2. Disconnect the battery and separate the connector.
3. Loosen the outer chains. Refer to LIFT CHAIN
ADJUSTMENT in this section.
WARNING
Before disconnecting the hydraulic lines, relieve the
pressure in the lines. To relieve pressure in the lift
lines and cylinders, pull up on the manual lowering
valve on the manifold. To relieve pressure in any aux-
iliary lines, let the truck sit for approximately five
minutes.
4. Disconnect the twin-line hose from the main hy-
draulic manifold block.
8
 INTERMEDIATE MAST

5
11
10

7
8
6
8
7 INNER MAST
(FRONT)
7
12 OVER CENTER
8 CYLINDER SHEAVE
6 TO CARRIAGE
8
7
2
3

2
4
7
8
6
7 5 8
4

1. FREE LIFT CYLINDER 8 9

6
2. RETAINING RING 8
3. CHAIN/HOSE SAFETY GUIDE 1
4. SNAP RING
5. SHEAVE PIN
6. CHAIN SHEAVE
7. BUSHING
8. BEARING
9. SETSCREW
10. CAPSCREW
11. LOCKWASHER
12. HOSE SHEAVE

FIGURE 6 – THREE STAGE MAST CYLINDER SHEAVE ASSEMBLY

5. Remove the capscrew and lockwasher from the Installation–Intermediate Mast Sheaves
sheave pin.
1. Install the sheave pin and sheaves with the chain
and/or hose. Secure the assembly with one capscrew and
NOTE: The left sheave pin has one chain sheave and
lockwasher.
one hose sheave. The right side has only the chain
sheave (unless the mast is equipped with auxiliary hose
2. Attach the twin-line hose to the main hydraulic
take-up).
manifold block.

6. Remove the sheave pin and sheaves, noting the 3. Adjust the outer lift chains. Refer to LIFT CHAIN
location and quantity of machine bushings. ADJUSTMENT in this section.
9
4. Connect the battery and test by raising and lowering 2. Disconnect the battery and separate the connector.
the mast.
WARNING
HYDRAULIC COMPONENTS Before disconnecting any hydraulic lines, relieve the
pressure in the lines. To relieve pressure in the mast
lift lines and cylinders, pull up on the manual lower-
Removal–Main Hydraulic Manifold Block ing valve on the manifold.
(See FIGURE 7)
3. Disconnect the hydraulic lines from the main hy-
1. Lower the mast and carriage completely. draulic manifold block.

OUTER MAST
(INTERMEDIATE MAST NOT SHOWN)

OVER INTERMEDIATE MAST

HOSE SHEAVE TO MANIFOLD
BLOCK
LEFT MAIN CYLINDER

2
4 INNER MAST
(2 PLACES)

FREE LIFT
1 CYLINDER

RIGHT OUTER CYLINDER

SEE CHASSIS HYDRAULIC ASSEMBLY

FOR CONNECTION TO FRAME 5
1. MAIN HYDRAULIC MANIFOLD BLOCK 2
3
2. CAPSCREW
(3 PLACES)
3. LOCKWASHER
4. FLAT WASHER
5. FREE LIFT CYLINDER MANIFOLD BLOCK

FIGURE 7 – THREE STAGE MAST HYDRAULICS ASSEMBLY

10
4. Remove two capscrews, lockwashers and flat wash-
ers and remove the main hydraulic manifold block from
the outer mast.
Installation–Main Hydraulic Manifold Block
1. Attach the main hydraulic manifold block to the
outer mast with two capscrews, lockwashers and flat
washers.
2. Connect the hydraulic lines to the main hydraulic
manifold block.
3. Connect the battery.
4. Test the mast hydraulics for leaks and loose fittings
by raising and lowering the mast.
Removal–Free Lift Cylinder Manifold Block
1. Lower the mast and carriage completely.
2. Disconnect the battery and separate the connector.
WARNING
Before disconnecting any hydraulic lines, relieve the
pressure in the lines. To relieve pressure in the mast
lift lines and cylinders, pull up on the manual lower-
ing valve on the manifold.
3. Disconnect the hydraulic lines from the free lift cyl-
inder manifold block.
4. Remove the manifold block and spacer from
the inner mast by removing three capscrews and
lockwashers.
Installation
1. Attach the manifold block and spacer on the inner
mast with three capscrews and lockwashers.
2. Connect the hydraulic lines to the free lift cylinder
manifold block.
3. Connect the battery.
4. Test the mast hydraulics for leaks and loose fittings
by raising and lowering the mast.
Removal–Optional Auxiliary Hose Take-up
(See FIGURE 8)
1. Lower the carriage on two 4x4 hardwood blocks.
Let the inner cylinder completely collapse.
11
2. Disconnect the battery and separate the connector.
WARNING
Before disconnecting any hydraulic lines, relieve the
pressure in the lines. To relieve pressure in the auxil-
iary lines, let the truck sit for approximately five
minutes.
3. Disconnect the twin-line hose assembly from the
carriage.
4. Remove the hose sheave from the free lift cylinder.
Refer to REMOVAL–FREE LIFT CYLINDER
SHEAVES in this section.
5. Remove the hose sheave from the intermediate mast
left side. Refer to REMOVAL–INTERMEDIATE
MAST SHEAVES in this section.
6. Remove the twin-line hose assembly from the bulk-
head union on the outer mast.
7. Remove three capscrews and lockwashers and re-
move the auxiliary hose guide from the inner mast.
Installation–Optional Auxiliary Hose Take-up
1. Connect the twin-line hose assembly to the bulk-
head union on the outer mast.
2. Install the hose sheave to the intermediate mast left
side. Refer to INSTALLATION–INTERMEDIATE
MAST SHEAVES in this section.
3. Install the auxiliary hose guide on the inner mast
with three capscrews and lockwashers.
NOTE: Make sure the twin-line hose assembly is in
the guide before attaching it.
4. Attach the free lift cylinder hose sheave with twin-
line hose assembly. Refer to INSTALLATION–FREE
LIFT CYLINDER SHEAVES in this section.
5. Connect the twin-line hose to the carriage.
6. Test by operating the sideshift carriage and check-
ing for leaks or loose fittings.
Removal–Standard Hose Assembly
1. Lower the carriage and mast completely.
2. Disconnect the battery and separate the connector.

WARNING
Before disconnecting the hydraulic lines, relieve the
pressure in the lines. To relieve pressure in the mast
lift lines and cylinders, pull up on the manual lower-
ing valve on the manifold.
3. Disconnect the twin-line hose assembly from the
main hydraulic manifold block.
4. Remove the hose sheave from the intermediate mast
right side. Refer to REMOVAL–INTERMEDIATE
MAST SHEAVES in this section.
5. Disconnect the twin-line hose assembly from the
free lift cylinder manifold block and remove the hose.

OUTER MAST INTERMEDIATE MAST

SEE THREE STAGE
MAST–INTERMEDIATE
MAST SHEAVES FOR
PARTS NOT CALLED OUT
TO 4

4
3 3
TO 5

INNER MAST

2 SEE THREE STAGE

MAST–FREE LIFT
CYLINDER SHEAVES
4

FROM 4
5
1
6
SEE AUXILIARY CHASSIS
HYDRAULIC ASSEMBLY FOR 1
7
CONNECTIONS TO FRAME
SEE THREE STAGE LIFT SEE THREE STAGE LIFT
HYDRAULICS FOR ALL RELATED HYDRAULICS FOR ALL
CONNECTIONS RELATED CONNECTIONS

1. CARRIAGE HOSE CONNECTIONS

2. BULKHEAD UNION STANDARD CARRIAGE
3. TWIN-LINE HOSE ASSEMBLY
4. HOSE SHEAVE
5. AUXILIARY HOSE GUIDE INTEGRAL SIDESHIFT CARRIAGE NOT SHOWN
6. LOCKWASHER
7. CAPSCREW

FIGURE 8 – THREE STAGE MAST OPTIONAL AUXILIARY HOSE TAKE-UP

12
Installation–Standard Hose Assembly
1. Connect the twin-line hose assembly to the free lift
cylinder manifold block.
2. Install the hose sheave with twin-line hose assembly
on the intermediate mast right side. Refer to INSTAL-
CHECKS AND ADJUSTMENTS
BLEEDING AIR FROM THE LIFT
CYLINDERS
WARNING
The carriage and forks may drop suddenly during
the bleeding process. DO NOT lift the load higher
than six to eight inches off the floor. Make sure feet
and hands are kept clear of the load and away from
any moving parts. DO NOT place arms or hands be-
tween the masts.
1. Elevate a moderate weight load 150 to 200 mm (6 to
8 in) off the floor.
2. Locate the bleeder plug on each cylinder, located at
the top of the cylinder case.
3. Loosen the bleeder plug 1 to 1-1/2 turns and allow
the trapped air to escape.
4. Tighten the plug when hydraulic oil comes out.
5. Repeat steps 3 and 4 for each cylinder.
6. Test the operation of the mast. If it does not operate
smoothly, repeat the entire bleeding process until all
trapped air is removed.
CARRIAGE ADJUSTMENT
Specification: Maximum clearance is 0.38 mm
(0.015 in) at the tightest point. Keep the shim arrange-
ment on each side of the carriage approximately equal.
1. Remove the carriage as described above. Inspect the
load rollers for damage and wear. Replace as necessary.
2. Lower the carriage into the inner mast. Find the
tightest point between the load rollers and the inner
mast.
13
LATION–INTERMEDIATE MAST SHEAVES in this
section.
3. Connect the twin-line hose assembly to the main hy-
draulic manifold block.
4. Test for leaks or loose fittings by raising and lower-
ing the mast.
3. Remove the carriage from the mast. Adjust the shim
arrangement on each roller for clearance between the
roller and the inner mast to the specification listed.
4. When the adjustment is correct, install the carriage
as described above.
MAST ADJUSTMENT
Load Roller Shims
NOTE: The mast must be removed to perform this
adjustment. Refer to MAST ASSEMBLY–REMOVAL
in this section.
The load rollers control the alignment of the rails. The
alignment conditions are given in the following list,
with the most important condition first.
1. The vertical channels of the mast must be parallel to
each other to decrease wear.
2. The clearance between the load roller and the chan-
nel at the tightest point is 0.18
0.18 mm (0.007

0.007 in).
3. The number of shims behind a load roller must be
about the same as those behind the load roller on the op-
posite channel. The channels should be approximately
centered within each other.
Adjust the mast load rollers as follows:
1. Use a prybar to move the channels from side to side.
With the channel forced to one side, measure the amount
of clearance between the roller and the inner surface of
the mast rail. The clearance must 0.18
0.18 mm
(0.007
0.007 in).
2. For a more reliable measurement, rail-to-roller
clearance should be checked at more than one place for
each roller set. Clearance is checked with:
a. mast fully lowered,
 b. at one-half extension and
c. at full extension for each roller set.
3. Separate the masts to remove or install shims as
needed. Slide the mast all the way to the top and bottom
to find the tightest point.
4. Repeat steps 1 through 3 until the maximum clear-
ance at the tightest point is 0.36 mm (0.014 in).
Brass Setscrew Adjustment
(See FIGURE 9)
NOTE: The brass setscrews can only be adjusted with
the mast installed on the truck.
The brass setscrews reduce the movement between the
masts. See FIGURE 9. The brass setscrews are too tight
if there are scrape marks on the back side of the inner or
OUTER MAST (REAR)
2
1. STEEL SETSCREW
2. BRASS SETSCREW
3. JAM NUT
FIGURE 9 – BRASS SETSCREW LOCATIONS
intermediate mast. The brass setscrews are too loose if
there is excessive front/back play in the channels of the
masts. On the three stage mast, one pair of setscrews is
located at the top of the outer mast. These are secured by
nylon-tipped steel setscrews. Another pair of setscrews
is located at the top of the intermediate mast. These are
secured by hex. jam nuts.
1. Loosen the steel setscrew or jam nut.
2. Tighten the brass setscrew into the rail so it is tight
against the next rail.
3. Back off the brass setscrew 1/4 turn.
4. Tighten the steel setscrew, or jam nut, while holding
the brass setscrew in place.
5. Verify that the adjustment is still correct.
INTERMEDIATE
MAST
2
3
14
LIFT CHAIN ADJUSTMENT same time. If one cylinder stops before the other, adjust-
ment is needed.
Specification: When correctly adjusted:
3. Tilt the mast to the full forward position. Use an
S The tension will be the same on each chain of the pair.
angle protractor to measure the tilt angle. If the tilt angle
Do not over-tighten or under-tighten the chains.
does not match the specifications listed in TABLE 1,
S The length will be the same on each chain. both tilt cylinders need adjustment.
S The chains will travel freely though full extension
and retraction of the rails. ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
All Two Stage Three Stage Four Stage

CAUTION
If, on the three stage mast, the outer chains are out of
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
3_ Forward

ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
5_ Back
3_ Forward
5_ Back
2_ Forward
5_ Back

adjustment, the inner mast may lower too far and
damage the free lift cylinder manifold block.
1. Position the lift truck on a level floor. Completely
lower the mast and carriage.
2. Use an angle protractor to adjust the tilt of the mast
to zero degrees. Disconnect the battery and separate the
connector.
3. Clean the lift chains with solvent and dry
thoroughly.
CAUTION
The cotter pin must be in place at the bottom of each
chain anchor.
4. Loosen the locknuts on the chain anchor bolts and
tighten or loosen the chain as necessary. Tighten the
locknuts after the necessary adjustment has been made.
TILT ANGLE ADJUSTMENT
Test Procedure
TABLE 1 – TILT SPECIFICATIONS
Adjustment
1. Loosen the setscrews in the end of the tilt cylinder
rod.
2. Loosen the jam nut on the rod end.
3. Use the flats on the tilt cylinder rod to adjust the
length of the tilt cylinder rod end. As viewed from the
base of the tilt cylinder, a counterclockwise rotation of
the rod increases the length.
NOTE: Test both forward and backward tilt after
each change in tilt cylinder shaft length to verify proper
adjustment. Continue adjusting as necessary until both
tilt cylinders stop at the same time in both the forward
and backward tilt.
4. Once properly adjusted, rotate the tilt cylinder rod
until the slot in the threaded rod end aligns with the set-
screws in the tilt cylinder rod. Once they are aligned,
tighten the setscrews.

1. Check the adjustment of the tilt cylinders by slowly
tilting the mast to the full forward position. As the mast
is tilted forward, make sure both of the tilt cylinders stop
at the same time. If one cylinder stops before the other,
adjustment is needed.
2. Tilt the mast to the full back position. As the mast is
tilted back, make sure both of the tilt cylinders stop at the
5. Using a wrench on the non-threaded portion of the
tilt cylinder and one on the hex. jam nut, tighten the jam
nut.
6. Test the tilt cylinder adjustment. Refer to the TEST
PROCEDURE in this section. For repairs to the tilt cyl-
inders see the section, TILT CYLINDERS, 2100 SRM
884.

15
 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE

No movement of lifting cylinder(s) Lifting control linkage disconnected.

No oil or not enough oil supplied to cylinder.

Hydraulic leaks, bad pump or pump drive.

Weak or broken spring in relief valve.

Slow action of lifting cylinder(s) Not enough oil supply to cylinder.

Cylinder seal bad.

Check for inside cylinder seal leaks by installing gate valve in

hydraulic line. Raise carriage. Close gate valve. See if carriage
lowers because of internal leak.

Rough movement of the mast assembly Air in system.

Bent rod(s), cylinders with distortion or damage.

Mast assembly damaged or not in alignment.

Carriage raises slowly Lift cylinder leaking oil.

Lift control linkage incorrectly adjusted.

Fluid level low.

Main relief valve set too low.

Mast raises extremely slow, even with no load Return filter clogged or return hose restricted.

Lowering valve damaged.

Mast lowers too fast Lowering valve damaged.

The tilting cylinder movement is slow or is not smooth Not enough oil going to cylinders.

Cylinder seals damaged.

Tilting system hydraulic lines restricted.

Air in hydraulic system.

Tilting cylinders have internal damage.

The tilting cylinders permit mast movement when the lever Tilting system hydraulic lines leaking.
is in the “NEUTRAL” position

Damaged cylinder seals.

Tilting control valve damaged.

16