Maintenance

MAST REPAIR
(S/N A698, A699, B551)
GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]

PART NO. 550013978 4000 YRM 1431

 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.
Mast Repair (S/N A698, A699, B551) Table of Contents

TABLE OF CONTENTS

General ..................................................................................................................................................................... 1
Safety Procedures When Working Near Mast .......................................................................................................... 2
Forks Replacement ...................................................................................................................................................4
Remove ................................................................................................................................................................ 4
Install .................................................................................................................................................................... 5
Checks ..................................................................................................................................................................5
Adjustment ............................................................................................................................................................6
Carriage Repair ........................................................................................................................................................ 6
Standard Carriage ................................................................................................................................................ 6
Remove ............................................................................................................................................................6
Clean and Inspect ............................................................................................................................................ 8
Install ................................................................................................................................................................9
Integral Sideshift Carriage .................................................................................................................................... 9
Remove ............................................................................................................................................................9
Clean and Inspect .......................................................................................................................................... 10
Install ..............................................................................................................................................................13
Disconnecting Attachment Hydraulic Quick Disconnect Hoses ..........................................................................14
Connecting Attachment Hydraulic Quick Disconnect Hoses .............................................................................. 14
Two-Stage Mast With Limited Free-Lift Repair .......................................................................................................14
Mast ....................................................................................................................................................................14
Remove ..........................................................................................................................................................14
Disassemble ...................................................................................................................................................15
Clean and Inspect .......................................................................................................................................... 20
Assemble ....................................................................................................................................................... 20
Install ..............................................................................................................................................................22
Header Hoses, Installation and Adjustment ....................................................................................................... 23
Install ..............................................................................................................................................................23
Adjustment ..................................................................................................................................................... 30
Three-Stage Mast With Full Free-Lift Repair .......................................................................................................... 30
Remove .............................................................................................................................................................. 30
Disassemble ....................................................................................................................................................... 32
Clean and Inspect ...............................................................................................................................................40
Assemble ............................................................................................................................................................40
Install .................................................................................................................................................................. 42
Header Hose Installation and Adjustment .......................................................................................................... 43
Standard .........................................................................................................................................................43
Install ..........................................................................................................................................................43
Adjust .........................................................................................................................................................51
Optional Equipment, Lift Truck GLP/GDP050LX (A974) manufactured after May, 2012 ...............................51
Install ..........................................................................................................................................................51
Adjust .........................................................................................................................................................57
Main Lift Cylinder Repair ........................................................................................................................................ 57
Lift and Tilt System Leak Check ............................................................................................................................. 57
Tilt Cylinders Adjustment ........................................................................................................................................ 57
Lift Chain Adjustment ..............................................................................................................................................58
Mast Adjustments ................................................................................................................................................... 59
Load Roller Adjustment ...................................................................................................................................... 59
Mast Side Kicking Adjustment ............................................................................................................................ 61
Carriage Adjustment ............................................................................................................................................... 62

©2014 Yale Materials Handling Corp. i

Table of Contents Mast Repair (S/N A698, A699, B551)

This section is for the following models:

(GLC050LX) [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]

ii
4000 YRM 1431 General

General
This section has the repair procedures for the Two-
WARNING Stage, Limited Free-Lift (LFL) and Three-Stage, Full
Before working on or near the mast, see the Free-Lift (FFL). Procedures for adjusting the carriage,
section Safety Procedures When Working Near lift chains, and mast are located at the end of this
Mast in this YRM. manual.

NOTE: Hoses have a service life that is determined

by application and time. Install a new hose if the hose
is worn, damaged, soft or hard, and no longer flexible.
If necessary, compare old hose to a new hose that is
the correct replacement for the hose you are
inspecting.

1
Safety Procedures When Working Near Mast 4000 YRM 1431

Safety Procedures When Working Near Mast

The following procedures MUST be used when in- OR
specting or working near the mast. Additional precau-
tions and procedures can be required when repairing • If parts of the mast must be in a raised posi-
or removing the mast. tion, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
WARNING these procedures:
Mast parts are heavy and can shift. Distances be-
1. Put mast in vertical position.
tween parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast 2. Raise mast to align bottom crossmember of mast
or the carriage. upright that moves in outer mast with crossmem-
• Never put any part of the body into or under ber on outer mast. On the two-stage mast, the
the mast or carriage unless all parts are moving part is the inner mast. On the three-stage
completely lowered or a safety chain is in- mast, it is the intermediate mast. See Figure 1.
stalled. Also make sure that the power is
OFF and the key is removed. Put a DO NOT 3. Use a 3/8-inch minimum safety chain with a hook
OPERATE tag in the operator's compart- to fasten the crossmembers together so the mov-
ment. Disconnect the battery and put a tag able member cannot lower. Put hook on back side
or lock on the battery connector. of mast. Make sure hook is completely engaged
with a link in the chain. Make sure safety chain
• Be careful of the forks. When the mast is does not touch lift chains or chain sheaves, tubes,
raised, the forks can be at a height to cause hoses, fittings, or other parts on the mast.
an injury.
• DO NOT climb on the mast or lift truck at 4. Lower mast until there is tension in safety chain
any time. Use a ladder or personnel lift to and free-lift cylinder (full free-lift models) is com-
work on the mast. pletely retracted.
• Mast repairs require disassembly and re- NOTE: Apply the parking brake. After lowering or re-
moval of parts and can require removal of straining the mast, shut off the power, and remove
the mast or carriage. Follow the repair pro- key. Put a DO NOT OPERATE tag in the operator's
cedures in this section. compartment. Disconnect battery and put a tag or
lock on battery connector.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely: 5. Install another safety chain (9.5 mm (3/8 in.) mini-
Turn the key switch to the ON position and mum) between the top or bottom bar of the car-
push the lift/lower control lever forward un- riage (6) and a crossmember on the outer mast
til there is no movement in the mast. Make as a secondary safety device. Install a DO NOT
sure that all parts of the mast that move are REMOVE tag on the safety chain(s).
fully lowered.

2
4000 YRM 1431 Safety Procedures When Working Near Mast

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

1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK

Figure 1. Safety Chaining the Mast

3
Forks Replacement 4000 YRM 1431

Forks Replacement
The forks are held on the carriage by hooks. The NOTE: Forks must be removed or installed by trained
forks are kept in position by lock pins that fit through personnel only.
the top fork hooks and into slots in the top bar car-
riage. If lock pin does not remain engaged in carriage NOTE: Forks are to be replaced only in sets, not indi-
slot, replace with new lock pin. Always check that the vidually.
lock pins for the forks keep the forks in position on the
carriage. Replace damaged fork lock pin parts. The A fork can be removed from the carriage for replace-
forks can be removed from the carriage by aligning ment of the fork or other maintenance. Slide the fork
the forks with the fork removal notch. The fork re- to the fork removal notch in the bottom bar of the car-
moval notch is in the bottom bar of the carriage. See riage. See Figure 2. Lower the fork onto blocks so the
Figure 2. bottom hook of the fork moves through the fork re-
moval notch. See Figure 3. Lower the carriage further
REMOVE so the top hook of the fork is disengaged from the top
carriage bar. Move the carriage away from the fork or
use a lifting device to move the fork away from the
WARNING carriage.
DO NOT try to remove a fork without a lifting de-
vice. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).

1. LOAD BACKREST 6. WEDGE

2. CARRIAGE 7. WASHER
3. FORKS 8. SPRING
4. FORK 9. LOCK PIN
5. KNOB 10. FORK REMOVAL NOTCH

Figure 2. Carriage and Forks

4
4000 YRM 1431 Forks Replacement

CHECKS

WARNING
Never repair damaged forks by heating or weld-
ing. Forks are made of tempered steel using spe-
cial procedures. Always replace damaged forks as
a pair.

Inspect the forks for cracks and wear. Check the

alignment of the fork tips. The difference in height of
the fork tips must be less than three percent of the
length of the forks. See Table 1 and Figure 4.

Table 1. Fork Tip Alignment

Fork Tip Alignment Specifications

Standard Fork Lengths Maximum Fork Tip Dif-
ference1
1. CARRIAGE BARS
2. HOOK FORK mm (in.) mm (in.)
3. BLOCKS
914 (36) 27 (1.08)
Figure 3. Hook Fork Removal
1067 (42) 32 (1.26)
1219 (48) 37 (1.44)
INSTALL 1372 (54) 41 (1.62)
NOTE: Forks must be removed or installed by trained 1524 (60) 46 (1.80)
personnel only. 1829 (72) 55 (2.16)
NOTE: Forks are to be replaced only in sets, not indi- 1Differenceof alignment between fork tips must be
vidually. no more than 3% of the total fork length.

Move the fork and carriage so the top hook on the Some applications may require closer alignment. If
fork can engage the upper carriage bar. Raise the the forks do not meet specification, they both must be
carriage to move the lower hook through the fork re- replaced. Check that the bottom of each fork is not
moval notch. Slide the fork on the carriage so both excessively worn. Check for smooth and proper oper-
upper and lower hooks engage the carriage bars. En- ation of the fork lock pins. Repair or replace any dam-
gage the lock pin with a notch in the upper carriage aged or broken fork lock pins or components and lu-
bar. bricate, as necessary. See Figure 2.

5
Carriage Repair 4000 YRM 1431

ADJUSTMENT
NOTE: Forks must be removed or installed by trained
personnel only.

NOTE: Forks are to be replaced only in sets, not indi-

vidually.

NOTE: During adjustment of the forks, the heel of the

forks should not be touching the ground.

The forks are connected to the carriage by hooks and

lock pins. See Figure 2. The lock pins are installed
through the top fork hooks and fit into slots in the top
carriage bar. If lock pin does not remain engaged in
carriage slot, replace with new lock pin.

Adjust forks as far apart as possible for maximum

support of the load. Hook forks will slide along the
A. HEEL OF FORK (MUST BE 90% OF DIMEN- carriage bars to adjust for the load to be lifted. Raise
SION B)
B. ORIGINAL FORK THICKNESS (DIMENSION B) the lock pin in each fork to slide the fork on the car-
riage bar. Make sure the lock pin is engaged in the
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF carriage bar to lock the fork in position after the width
FORK LENGTH) adjustment is made.
2. CRACKS
3. MAXIMUM ANGLE 93°
4. FORK REMOVAL NOTCH
5. CARRIAGE
Figure 4. Fork Check

Carriage Repair
STANDARD CARRIAGE
WARNING
Remove When disconnecting the lift chains, keep control
of the ends. Use wire to temporarily connect the
1. Put a one-quarter capacity load on the forks. The ends of the lift chains to the mast. This procedure
load must provide carriage with stability and not will prevent the lift chains from falling from the
allow carriage to fall when it is disconnected from sheaves and causing an injury or damage.
mast.
4. Remove the cotter pin and chain pin from each
2. Lower the carriage and forks onto blocks to chain anchor at the carriage. See Figure 6. Dis-
loosen lift chains. See Figure 3. connect the lift chains from the carriage. Use wire
to connect the ends of the lift chains to a part of
3. Remove the four capscrews, washers, and nuts
the mast. Make sure the chains can move freely
securing the load backrest to the carriage. Re-
when the inner mast is raised.
move the load backrest. See Figure 5.

6
4000 YRM 1431 Carriage Repair

WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast is above
the load rollers of the carriage.

5. Use the lift cylinders to raise the inner or inter-

mediate mast. If the hydraulic system cannot be
used, disconnect the lift cylinders from the inner
mast. For procedures, see the section Cylinder
Repair (Mast S/N A551, A555, A559, A661,
A662, A663, A66, B507, B508, B509, B551,
B555, B559, B562, B563, B564, B661, B662,
B663, C515, C551, C555, C559, D507, D508,
D509, D515, D562, D563, D564, E509, and
E564) 2100YRM1139. Connect a crane [the ca-
pacity of the crane must be at least
681 kg (1501 lb)] to the top of the inner mast.
Carefully raise the inner mast until it is above the
load rollers of the carriage. Install safety chains to
secure the mast in its extended position and dis-
connect the crane. See Safety Procedures When
Working Near Mast.

6. Move the lift truck away from the carriage. Com-

pletely lower the inner mast so it cannot move.

7. Connect a lifting device to carriage. Remove load

from forks with another lift truck. Remove forks
from carriage. See Forks Replacement for proce- 1. CAPSCREW
2. WASHER
dures. Remove blocks and lower carriage to floor 3. NUT
so the load rollers are facing up. 4. LOAD BACKREST

Figure 5. Load Backrest Removal

7
Carriage Repair 4000 YRM 1431

1. SNAP RING 6. LOAD ROLLER

2. CHAIN ANCHOR PIN 7. SHIM
3. COTTER PIN 8. STUBSHAFT
4. CARRIAGE 9. CHAIN PIN
5. SPACER 10. CHAIN ANCHOR

Figure 6. Standard Carriage

Clean and Inspect

CAUTION
NOTE: Shims are installed on the bottom and middle DO NOT use cleaning solvent, compressed air, or
rollers only. steam to clean lift chain sheaves or load rollers.
1. If any of the load rollers must be replaced, make a The bearings in the lift chain sheaves and load
note of the location and number of the shims. In- rollers are sealed and lubricated. Cleaning sol-
stall the shims, load rollers, and snap rings. For vent, compressed air, and steam can damage the
the top rollers, install spacers. See Carriage Ad- load roller bearings.
justment for correct adjustment of the load rollers. 2. Clean any oil, grease, dirt, and other debris from
the carriage frame. Use a cleaning solvent and
WARNING compressed air to dry.
Compressed air can move particles so that they
cause injury to the user or to other personnel. WARNING
Make sure that the path of the compressed air is Improper welding procedures can damage the
away from all personnel. Wear protective goggles structure of the mast or cause mast to function in-
or a face shield to prevent injury to the eyes. correctly. Consult your Yale lift truck dealer for
more information before welding on the mast.
WARNING 3. If the carriage bars have any protruding welds or
Cleaning solvents can be flammable and toxic, damaged notches, repair by grinding, filing, or
and can cause skin irritation. When using clean- welding.
ing solvents, always follow the recommendations
of the manufacturer.

8
4000 YRM 1431 Carriage Repair

4. Clean and inspect the chain anchors, chain an-

chor pins, and chain pins. See Figure 6. Check
chain anchors, chain anchor pins, and chain pins
for wear and serviceability. Discard worn or un-
serviceable chain anchors, chain anchor pins, and
chain pins. Discard cotter pins.

Install
1. Use the hydraulic system of the lift truck (if it has
not been disconnected) to raise the inner mast. If
hydraulic system cannot be used, connect a
crane [the capacity of the crane must be at least
681 kg (1501 lb)] to the top of the inner mast. 1. COTTER PIN
Carefully raise the inner mast until it is above the 2. CHAIN PIN
load rollers of the carriage. Install safety chains to 3. CHAIN ANCHOR
secure the mast in its extended position and dis- 4. CHAIN ANCHOR PIN
connect the crane. See Safety Procedures When 5. SNAP RING
Working Near Mast. Figure 7. Cotter Pin Installation
2. Move the lift truck toward the carriage until the in-
ner mast is aligned with the carriage rollers. If the
5. Install four capscrews, washers, and nuts secur-
inner mast has been raised and secured using a
ing the load backrest to the carriage. See Fig-
crane and safety chains, connect the crane, raise
ure 5. Tighten nuts to 53 N•m (39 lbf ft).
the inner mast, and remove the safety chains.
Carefully lower the inner mast until it engages all 6. Install the forks. See Forks Replacement.
of the load rollers. Disconnect the crane, if at-
tached, and reconnect the lift cylinders. See the INTEGRAL SIDESHIFT CARRIAGE
section Cylinder Repair (Mast S/N A551, A555,
A559, A661, A662, A663, A66, B507, B508, Remove
B509, B551, B555, B559, B562, B563, B564,
B661, B662, B663, C515, C551, C555, C559, 1. Lower the carriage completely. Remove the forks.
D507, D508, D509, D515, D562, D563, D564, See Forks Replacement for removal procedures.
E509, and E564) 2100YRM1139.
2. Remove the four capscrews securing the load
3. Check the clearance of the load rollers. See Car- backrest to the carriage. See Figure 5. Remove
riage Adjustment in this manual. the load backrest.

NOTE: Use new cotter pins each time the chain pins
are removed. WARNING
Before disconnecting the hydraulic hoses, relieve
4. Connect the lift chains to the chain anchors at the the pressure in the hydraulic system. Serious in-
carriage. Install the cotter pins in the chain pins. jury can occur if pressure is not relieved from hy-
Be sure cotter pins are installed on the outside of draulic system prior to disconnecting hydraulic
chain anchor. See Figure 7. Bend both legs of hoses.
cotter pin against chain anchor pin. Adjust the lift
chains as described in Lift Chain Adjustment in 3. Relieve hydraulic pressure to the sideshift cylin-
this manual. der by moving sideshift lever in both directions
several times.

9
Carriage Repair 4000 YRM 1431

WARNING WARNING
Always wear the proper protective equipment in- Improper welding procedures can damage the
cluding eye protection and petroleum-resistant structure of the mast or cause incorrect function
gloves when handling hydraulic oil. Thoroughly of the mast. Consult your Yale lift truck dealer for
wash oil from exposed areas of skin as soon as more information before welding on the mast.
possible.
2. Clean and inspect the carriage bars for damage
The hydraulic oil is hot at normal operating tem- and smoothness. Ensure the bars are parallel and
peratures. Be careful when draining the oil. the ends are flush. If carriage bars have any pro-
truding welds or damaged notches, repair by
Never check for leaks by putting hands on hy- grinding, filing, or welding.
draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the 3. Clean the bearing areas. Inspect the sideshift
skin. bearings for wear as follows:

a. Remove the upper bearings from the upper

CAUTION carriage bar. If either upper bearing is worn to
Protect the hydraulic system from dirt and con- less than 2.5 mm (0.1 in.) thickness, replace
taminants when servicing the hydraulic system. both upper bearings by driving the upper bear-
ings from the upper carriage bar. See Figure 8.
NOTE: Tag hydraulic lines and fittings prior to dis-
connecting to aid in connecting during installation. b. Remove the lower bearings from the lower car-
riage bar. If either lower bearing is worn to less
NOTE: If lift truck is equipped with hydraulic quick than 2.5 mm (0.1 in.) thickness, replace both
disconnect hoses, see section Disconnecting Attach- lower bearings by prying the lower bearings
ment Hydraulic Quick Disconnect Hoses. from the lower carriage bar. See Figure 8.
4. Disconnect hydraulic lines from sideshift cylinder. 4. Inspect the sideshift cylinder. Replace the entire
Put caps and plugs on open lines and cylinder cylinder assembly if a cylinder rod is bent or
ports. scored or if there is damage on the outside of the
cylinder shell that could impair performance or
5. Remove the lower mounting hooks by removing cause leaks under pressure. See Figure 11. See
the four capscrews securing the hooks. See Fig- also Cylinder Repair (Mast S/N A551, A555,
ure 8. A559, A661, A662, A663, A66, B507, B508,
6. Remove two cotter pins, two pins, and sideshift B509, B551, B555, B559, B562, B563, B564,
cylinder from carriage. See Figure 8. B661, B662, B663, C515, C551, C555, C559,
D507, D508, D509, D515, D562, D563, D564,
7. Use a crane with a capacity of at least E509, and E564) 2100YRM1139 for more infor-
450 kg (992 lb) to lift outer frame away from the mation on inspecting and repairing the sideshift
inner frame (see Figure 9). Lay the outer frame cylinder.
flat on a pallet or workbench.
5. Clean load rollers and inspect for wear and dam-
Clean and Inspect age. If any load rollers must be replaced, make a
note of the location and number of the shims. In-
1. Inspect the lower mounting hooks for wear. Re- stall shims, load rollers, and snap rings. For top
place the hooks if they are worn beyond the wear rollers, install spacers. See Carriage Adjustment.
limit. The wear limit clearance range is
0.76 mm (0.03 in.) minimum and
1.52 mm (0.06 in.) maximum. See A in Figure 10.

10
4000 YRM 1431 Carriage Repair

1. INNER FRAME 11. LUBE FITTING

2. OUTER FRAME 12. PIN
3. SIDESHIFT CYLINDER 13. CHAIN ANCHOR
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. COTTER PIN
6. LOWER HOOK 16. LOAD ROLLER
7. CAPSCREW 17. SHIMS
8. WASHER 18. SPACER
9. CLEVIS PIN 19. FORK REMOVAL NOTCH
10. PIN

Figure 8. Integral Sideshift Carriage

11
Carriage Repair 4000 YRM 1431

1. OUTER FRAME
2. LIFTING HOOK
3. LIFTING DEVICE
Figure 9. Remove Outer Frame 1. CYLINDER SHELL AND ROD
2. SEAL
3. O-RING
4. RETAINER
5. WIPER

Figure 11. Integral Sideshift Cylinder

A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND

1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
Figure 10. Lower Mounting Hooks Wear Limit and
Clearance Adjustment

12
4000 YRM 1431 Carriage Repair

Install 3. Use a crane with a capacity of at least

450 kg (992 lb) to install the outer frame on the in-
1. If necessary, install new upper and lower sideshift ner frame.
bearings as follows:
4. Install the lower mounting hooks using four cap-
a. To install new upper bearings, align pin on the screws. Tighten to 165 ±15 N•m (120 ±12 lbf ft).
bottom side of bearing to notches on top car- For proper sideshift operation, make sure there is
riage bar and slide into place on top carriage. 0.76 to 1.52 mm (0.03 to 0.06 in.) clearance be-
See Figure 12. tween the bottom of the hooks and the outer
frame. See B in Figure 10.
b. To install new lower bearings, align the circular
pins on backside of lower bearing to holes on NOTE: If lift truck is equipped with hydraulic quick
lower carriage bar and tap bearing into place disconnect hoses, see section Connecting Attach-
on lower carriage bar using a rubber or brass ment Hydraulic Quick Disconnect Hoses.
hammer. See Figure 12.
5. Connect the hydraulic lines, as noted during re-
NOTE: The pin, located on the left top of the cylinder moval, to the sideshift cylinder.
looking from the front of the carriage, is for alignment
purposes and to prevent the cylinder from rolling to 6. Install load backrest on the sideshift carriage.
the front or to the back. Tighten nuts to 53 N•m (39 lbf ft). See Figure 5.

2. Install sideshift cylinder onto the carriage with the 7. Install the forks. See the section Forks Replace-
pin in the up position. Install two pins and two cot- ment in this service manual for procedures.
ter pins. See Figure 8.

A. MINIMUM THICKNESS 2.5 mm (0.1 in.)

1. LOWER BEARINGS 3. UPPER BEARINGS
2. CARRIAGE BARS

*BOLD ARROWS INDICATE WHICH SIDE TO APPLY GREASE.

Figure 12. Replacing Upper and Lower Bearings

13
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

DISCONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT
HOSES
1. Turn the key switch or keyless switch to the OFF
position.

2. Disconnect the negative terminal of the battery.

3. Move the manual hydraulic levers forward and

backward to relieve the system hydraulic pres-
sure.

4. Disconnect the Quick-Disconnect hose connec-

tions. See Figure 13.

CONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT
HOSES
1. Connect the Quick-Disconnect hose connections.
See Figure 13.
1. QUICK-DISCONNECT FITTINGS
2. Connect the negative terminal of the battery. 2. HYDRAULIC TUBES

Figure 13. Quick Disconnect Hoses

3. Turn the key switch or keyless switch to the ON
position and start the engine.

4. Move the manual hydraulic levers forward and

backwards, and check the hydraulic system for
leaks.

Two-Stage Mast With Limited Free-Lift Repair

MAST NOTE: If mast needs to be disassembled, remove
the forks and carriage. See the sections Forks Re-
Remove placement and Carriage Repair for removal proce-
dures. If only the main lift cylinders or tilt cylinders
need to be repaired or replaced, the mast does not
WARNING need to be removed from lift truck. See service man-
The mast is heavy. The mast can weigh approxi- ual Cylinder Repair (Mast S/N A551, A555, A559,
mately 380 kg (838 lb). Make sure all lifting devi- A661, A662, A663, A66, B507, B508, B509, B551,
ces (hoists, cables, chains, slings, etc.) are suita- B555, B559, B562, B563, B564, B661, B662, B663,
ble and of adequate capacity to lift the mast. Seri- C515, C551, C555, C559, D507, D508, D509, D515,
ous injury can occur if the mast falls. D562, D563, D564, E509, and E564) 2100YRM1139
for cylinder removal procedures.
CAUTION NOTE: The length of lift chains must be checked be-
Make sure all mast weldments are fastened to- fore removing the mast. See Lift Chain Adjustment.
gether. Make sure safety chains will not damage
the sheaves, tubing, or other parts of the mast. 1. Fully lower inner mast.

2. Connect a lifting device to all top crossmembers

of the mast weldments. See Safety Procedures
When Working Near Mast. Raise lifting device so
the mast has stability.

14
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

3. Disconnect header hoses. Disassemble

4. Remove self-aligning nuts and base rings from 1. Slide inner mast from the bottom of outer mast
chain anchors. Remove lift chains from chain approximately 30 mm (12 in.).
sheaves.
NOTE: Note shim placement to aid in assembly.
See Figure 16 for lift truck models
2. Remove strip bearings, shims, and O-rings. Dis-
• Manufactured before January, 2012 card O-rings. See Figure 15.
See Figure 17 for lift truck models 3. Remove snap rings, shims, and load rollers from
• Manufactured after January, 2012 stub shafts at the bottom of inner mast. Remove
snap rings, shims and load rollers from stub
5. Remove lift and tilt cylinders following procedures shafts top of outer mast. Make a note of each
found in Cylinder Repair (Mast S/N A551, A555, shim arrangement and load roller location. The
A559, A661, A662, A663, A66, B507, B508, shim arrangements will be approximately the
B509, B551, B555, B559, B562, B563, B564, same during assembly.
B661, B662, B663, C515, C551, C555, C559,
D507, D508, D509, D515, D562, D563, D564, See Figure 16 for lift truck models
E509, and E564) 2100YRM1139. • Manufactured before January, 2012
6. Remove four capscrews, washers, and two trunn- See Figure 17 for lift truck models
ion caps from mast mounts. See Figure 14.
• Manufactured after January, 2012
7. Remove mast from lift truck. Put mast in a posi-
tion so the crossmembers are on the floor.

1. STRIP BEARING
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. 2. SHIMS
3. TOP OF OUTER MAST
1. CAPSCREW 4. O-RING
2. WASHER
3. TRUNNION CAP Figure 15. Strip Bearings
4. MAST MOUNT
Figure 14. Mast Mounts

15
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

Figure 16. Two-Stage Mast With Limited Free-Lift - Lift Trucks GLP/GDP20-25LX (A974) Manufactured
Before January, 2012

16
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 16

NOTE: MAIN LIFT CYLINDERS AND ATTACHING PARTS SHOWN FOR REFERENCE ONLY.

1. OUTER MAST 15. CHAIN ANCHOR

2. SNAP RING 16. PIN
3. LOAD ROLLER 17. COTTER PIN
4. SHIM 18. LIFT CHAIN
5. STUB SHAFT 19. LOWERING CONTROL VALVE WASHER
6. O-RING 20. SPRING
7. BEARING STRIP 21. SPECIAL FITTING
8. WASHER 22. HOSE ASSEMBLY
9. CAPSCREW 23. FITTING
10. THIN WALL SPACER 24. VALVE
11. NUT 25. LOWERING CONTROL VALVE HOUSING
12. MAIN LIFT CYLINDER 26. CHAIN SHEAVE
13. SELF-ALIGNING NUT 27. INNER MAST
14. BASE RING

17
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

Figure 17. Two-Stage Mast With Limited Free-Lift - Lift Trucks GLP050LX (A967) and GLP/GDP20-25LX
(A974) Manufactured After January, 2012

18
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 17

NOTE: MAIN LIFT CYLINDERS AND ATTACHING PARTS SHOWN FOR REFERENCE ONLY.

NOTE: THREE-FUNCTION MAST SHOWN. LIFT TRUCK MODELS GLP050LX (A967) AND GLP/GDP20-25LX
(A974) MANUFACTURED AFTER MAY, 2012 AND EQUIPPED WITH FOUR-FUNCTION HEADER HOSES ARE
SIMILAR.

1. OUTER MAST 15. CHAIN ANCHOR

2. SNAP RING 16. PIN
3. LOAD ROLLER 17. COTTER PIN
4. SHIM 18. LIFT CHAIN
5. STUB SHAFT 19. LOWERING CONTROL VALVE WASHER
6. O-RING 20. SPRING
7. BEARING STRIP 21. SPECIAL FITTING
8. WASHER 22. HOSE ASSEMBLY
9. CAPSCREW 23. FITTING
10. THIN WALL SPACER 24. VALVE
11. NUT 25. LOWERING CONTROL VALVE HOUSING
12. MAIN LIFT CYLINDER 26. CHAIN SHEAVE
13. SELF-ALIGNING NUT 27. INNER MAST
14. BASE RING

4. Slide inner mast halfway out of the top of outer

mast. Connect a crane to the center of inner
mast. See Figure 18.

5. Slide inner mast out of outer mast until stub shafts

are in the notches of the outer mast. Remove in-
ner mast from outer mast.

6. Using a brass drift pin, remove tilt rod bushing

from outer mast. Discard tilt rod bushing. See Fig-
ure 19.

1. TILT ROD BUSHING

Figure 19. Mast Bushing Location

7. Remove two capscrews, two nuts, and lowering

control valve housing from outer mast.

See Figure 16 for lift truck models

• Manufactured before January, 2012

See Figure 17 for lift truck models

1. INNER MAST • Manufactured after January, 2012
2. OUTER MAST
8. Disconnect hose assemblies from fitting (item 23,
Figure 18. Inner Mast Figure 16 and Figure 17).

19
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

9. Remove lowering control valve washer, spring,

and special fitting from hose assemblies. WARNING
Commercial cleaning solvents may be flammable
See Figure 16 for lift truck models and toxic and can cause severe skin irritation.
• Manufactured before January, 2012 When using commercial cleaning solvents, al-
ways comply with solvent manufacturer's recom-
See Figure 17 for lift truck models mended safety precautions.
• Manufactured after January, 2012

10. Remove three fittings and valve from lowering WARNING

control valve housing. Never replace just the worn section of a chain. Re-
place the complete chain. Never replace just one
See Figure 16 for lift truck models chain of a chain pair. Replace both chains.
• Manufactured before January, 2012
3. Clean lift chains with solvent. Inspect lift chains
See Figure 17 for lift truck models for wear or damage. See Figure 20. A lift chain
becomes longer when it is worn. If a section of
• Manufactured after January, 2012
chain is 3% longer than a similar section of new
11. Remove snap rings and chain sheaves from stub chains, the chain is worn and must be replaced.
shafts at the top of inner mast. Disassemble chain
a. If a chain scale is available, check lift chains as
sheaves as necessary for cleaning and repair.
shown in Figure 20. If a chain scale is not
See Figure 16 for lift truck models available measure 20 links of chain. Measure
from the center of a pin to the center of another
• Manufactured before January, 2012 pin 20 pitches away. Compare length with the
See Figure 17 for lift truck models chart in Figure 20.

• Manufactured after January, 2012 b. Replace chain if the length of 20 links of the
worn section is more than the maximum wear
Clean and Inspect limit. Lubricate chains with SAE 30W engine
oil. The best procedure is to remove lift chains
from lift truck and soak them in SAE 30W en-
CAUTION gine oil.
DO NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam and Assemble
high-pressure water can remove the lubrication
from the bearings in the load rollers. Water in the
bearings of the sheaves and the link pins of WARNING
chains can also shorten the service lift of these The mast is heavy. The mast can weigh approxi-
parts. mately 380 kg (838 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
1. Inspect sheaves and load rollers for wear or dam- ble and of adequate capacity to lift the mast. Seri-
age. DO NOT use steam to clean lift chains, ous injury can occur if the mast falls.
sheaves, or load rollers. The bearings in the
sheaves and load rollers are sealed and lubrica- NOTE: The shims for the load rollers keep the weld-
ted. ments parallel and provide correct clearance. During
assembly, the shim arrangement will be approxi-
2. Inspect chain anchors, pins, and cotter pins for mately the same as before disassembly. Check the
damage. Replace if damaged. clearance and adjust the shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims. See Carriage Adjust-
ment in this section for the adjustment procedures.

20
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

3. Install new O-rings, shims as noted during disas-

sembly, and strip bearings. See Figure 21. Apply
grease to bearing surface.

NOTE: THE INSTRUCTIONS FOR MEASURING

CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE (YALE P/N 580034684).

1. CHAIN WEAR SCALE 1. STRIP BEARINGS

2. SHIMS
Pitch Wear Limit The 3. TOP OF OUTER MAST
Total length of 4. O-RING
maximum
20 links (pitch)
length of 20 Figure 21. Strip Bearings
of new chain
links

12.7 mm 254.0 mm 261.6 mm 4. Install shims, load rollers, and snap rings to top of
(0.5 in.) (10.0 in.) (10.3 in.) outer mast and bottom of inner mast. Check
15.9 mm 317.5 mm 327.0 mm clearance of load rollers as described in Mast Ad-
(0.6 in.) (12.5 in.) (12.9 in.) justments.
19.1 mm 381.0 mm 392.4 mm
(0.8 in.) (15.0 in.) (15.5 in.) See Figure 16 for lift truck models
25.4 mm (10 in.) 508.0 mm 523.3 mm
• Manufactured before January, 2012
(20.0 in.) (20.6 in.)
See Figure 17 for lift truck models
Figure 20. Lift Chains Check
• Manufactured after January, 2012

NOTE: When the mast has header hoses, see sec- 5. Install new tilt rod bushing in outer mast. See Fig-
tion Header Hoses, Installation and Adjustment. ure 22.

1. Connect lifting device to center of inner mast. See

Figure 18.

2. If removed, put stub shafts through notches in

outer mast. Using lifting device, slide inner mast
into outer mast so stub shafts are seen at top and
bottom of outer mast.

21
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

B555, B559, B562, B563, B564, B661, B662,

B663, C515, C551, C555, C559, D507, D508,
D509, D515, D562, D563, D564, E509, and
E564) 2100YRM1139 for procedures. Check
clearance at top of lift cylinder mounts. Add or re-
move shims at the top of main lift cylinder rods
until they are even. Install washer and snap ring
at the top of main lift cylinders.

2. Install special fitting, spring, and lowering control

valve washer on hose assemblies. Connect hose
assemblies to main lift cylinders.

See Figure 16 for lift truck models

• Manufactured before January, 2012
1. TILT ROD BUSHING
See Figure 17 for lift truck models
Figure 22. Mast Bushing Location • Manufactured after January, 2012

NOTE: Both legs of cotter pin must be bent against

6. Install valve and three fittings on lowering control chain anchor pin. Make sure cotter pin is positioned
housing. as noted during removal.
See Figure 16 for lift truck models 3. If removed, install pin and cotter pin on lift chain
• Manufactured before January, 2012 and chain anchor. Repeat for opposite lift chain.

See Figure 17 for lift truck models See Figure 16 for lift truck models
• Manufactured after January, 2012 • Manufactured before January, 2012

7. Connect hose assemblies to fitting (item 23, Fig- See Figure 17 for lift truck models
ure 16 and Figure 17). • Manufactured after January, 2012
8. Install lowering control valve housing, two cap- 4. Place lift chains over sheaves and connect them
screws, and two nuts on outer mast. to chain anchors at bottom of inner mast.
See Figure 16 for lift truck models 5. Install chain anchor through lift cylinder mount. In-
• Manufactured before January, 2012 stall base ring and self-aligning nut on chain an-
chor. Tighten self-aligning nut to
See Figure 17 for lift truck models 40 N•m (30 lbf ft). Repeat for opposite lift chain.
• Manufactured after January, 2012
See Figure 16 for lift truck models
9. Install chain sheaves and snap rings on stub • Manufactured before January, 2012
shafts at the top of inner mast.
See Figure 17 for lift truck models
See Figure 16 for lift truck models
• Manufactured after January, 2012
• Manufactured before January, 2012
6. Connect a lifting device to the top of the mast as-
See Figure 17 for lift truck models sembly. Make sure inner and outer mast are fas-
• Manufactured after January, 2012 tened together. Make sure the chains DO NOT
damage any of the hydraulic lines or other parts.
Install
7. Raise mast assembly to a vertical position. Move
1. Install lift cylinders. See service manual Cylinder mast assembly into correct position.
Repair (Mast S/N A551, A555, A559, A661,
A662, A663, A66, B507, B508, B509, B551,

22
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

8. Install tilt cylinders. See service manual Cylinder HEADER HOSES, INSTALLATION AND
Repair (Mast S/N A551, A555, A559, A661, ADJUSTMENT
A662, A663, A66, B507, B508, B509, B551,
B555, B559, B562, B563, B564, B661, B662, Install
B663, C515, C551, C555, C559, D507, D508,
D509, D515, D562, D563, D564, E509, and
E564) 2100YRM1139 for procedures. WARNING
Always wear the proper protective equipment in-
9. Install trunnion cap, two washer, and two cap- cluding eye protection and petroleum-resistant
screws on mast mount. Tighten capscrews to gloves when handling hydraulic oil. Thoroughly
115 N•m (85 lbf ft). See Figure 23. Repeat for op- wash oil from exposed areas of skin as soon as
posite mast mount. possible.

10. Install header hoses. See Header Hoses, Installa-

tion and Adjustment. WARNING
Never check for leaks by putting hands on hy-
draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the
skin.

WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this sec-
tion.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

NOTE: Before installing header hoses, make sure

you know the lift height of the mast. The tension on
header hoses is adjusted according to lift height. Lift
height is on the Nameplate of lift truck and right-hand
side of outer mast.
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.

1. CAPSCREW Some lift trucks are equipped with auxiliary hydraulic

2. WASHER functions that are fastened to the carriage. Examples
3. TRUNNION CAP of these auxiliary functions are sideshift carriages or
4. MAST MOUNT roll clamps. These auxiliary function require header
hoses for their operation.
Figure 23. Mast Mounts

23
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

1. For header hose placement, see

Figure 24 for lift truck models

• Manufactured before January, 2012

Figure 25 for lift truck models

• Manufactured after January, 2012

Figure 26 for lift truck models

• Manufactured after May, 2012

NOTE: THREE-FUNCTION MAST SHOWN.

A. HEADER HOSE A (THREE-FUNCTION)

B. HEADER HOSE B (THREE-FUNCTION)
1. CLAMP
2. ALIGN MARK E FOR HOSES A AND B AT BOT-
TOM OF CLAMP
3. CONNECTION TO COWL HOSES
Figure 24. Two-Stage LFL Header Hose
Arrangement - Lift Trucks Manufactured Before
January, 2012

24
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

NOTE: FOUR-FUNCTION MAST SHOWN.

A. HEADER HOSE A (THREE-FUNCTION)

B. HEADER HOSE B (THREE-FUNCTION)
C. HEADER HOSE C (FOUR-FUNCTION)
D. HEADER HOSE D (FOUR-FUNCTION)
1. CLAMP
2. ALIGN MARK E FOR HOSES A AND B AT BOT-
TOM OF CLAMP
3. ALIGN MARK E FOR HOSES C AND D AT BOT-
TOM OF CLAMP
NOTE: THREE-FUNCTION MAST SHOWN. Figure 26. Two-Stage LFL Header Hose
Arrangement - Lift Trucks Manufactured After
A. HEADER HOSE A (THREE-FUNCTION)
B. HEADER HOSE B (THREE-FUNCTION) May, 2012

1. CLAMP
2. ALIGN MARK E FOR HOSES A AND B AT BOT-
TOM OF CLAMP
3. CONNECTION TO COWL HOSES

Figure 25. Two-Stage LFL Header Hose

Arrangement - Lift Trucks Manufactured After
January, 2012

25
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

NOTE: This procedure is for the four-function option. See Figure 24 for lift truck models
The three-function option will have hoses A and B • Manufactured before January, 2012
only.
See Figure 25 for lift truck models
NOTE: The lift chains and carriage height must be
correctly adjusted before the header hoses can be ad- • Manufactured after January, 2012
justed. See section Lift Chain Adjustment for proce- See Figure 26 for lift truck models
dures.
• Manufactured after May, 2012
2. Mark each hose with a single letter: A, B, C, and
D. 9. The sheave(s) and stubshafts must be assem-
bled, and the hose(s) must be routed onto the
See Figure 24 for lift truck models sheave(s) before hose(s) are attached to the
• Manufactured before January, 2012 mast. Tighten the hose clamp hardware to
8 N•m (71 lbf in) and the sheave assembly cap-
See Figure 25 for lift truck models screws to 66 N•m (49 lbf ft). See Figure 28. Install
clamps to main lift cylinders. Tighten capscrews
• Manufactured after January, 2012
and nuts to 25 N•m (221 lbf in).
See Figure 26 for lift truck models
10. Put the clamps over the hoses and attach the
• Manufactured after May, 2012 clamps to upper brackets. DO NOT tighten the
hardware.
3. Clamp end of the hose (the smaller fitting) that at-
taches to the carriage in a vise (DO NOT clamp NOTE: To make alignment of dimension E easier,
on the threads), and pull on the other end until the use a crane with a capacity of at least
hose is straight. DO NOT apply enough force to 907.2 kg (2000 lb) to raise carriage high enough to in-
stretch the hose. See Figure 27. stall a safety chain. See .
NOTE: Dimension E is determined by the height of 11. Align dimension mark E, which is determined us-
outer mast channel from the ground and the length of ing Figure 27, at bottom of clamps. Tighten hard-
outer mast channel. See dimensions Y and Z in Fig- ware to 8 N•m (71 lbf in).
ure 27. To determine E use Table 2 or Table 3 to de-
termine pre-calculated tension mark locations. See Figure 24 for lift truck models
• Manufactured before January, 2012
4. Place a mark on all the hoses at dimension E.
See Figure 25 for lift truck models
5. Lift carriage off the ground approximately
76 mm (3 in.). Place blocks under carriage for • Manufactured after January, 2012
support.
See Figure 26 for lift truck models
6. Install carriage brackets to carriage. Tighten cap- • Manufactured after May, 2012
screws to 18 N•m (159 lbf in). See Figure 28.
12. Connect header hoses to the truck hoses.
7. Install hoses to carriage brackets with the clamps
and tighten capscrews to 18 N•m (159 lbf in). See 13. Use rubber clamps and hose clamps to attach ho-
Figure 28. ses to main lift cylinders and just below the middle
crossmember on the outer mast. Make sure ho-
8. Apply a thin coat of multipurpose grease with mo- ses DO NOT stretch or fold while tilting mast fully
lybdenum disulfide to hose sheave stubshafts be- forward and backward.
fore installing hose sheaves. Place the hose at
the location of the hose sheave. 14. With no load on forks, check head hose adjust-
ment by operating mast through full lift cycle two
times.

26
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE

Figure 27. Header Hose Measurement

27
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1431

Table 2. Standard Mast Height; Header Hose Tension Mark Location Lift Truck Models GLP/GDP20-25LX
(A974)

Tension Marker from Carriage End

Lift Height Channel Length (Reference)
Dimension "E"
mm in. mm in. mm in.
3292 129.6 2090 82.3 2353 92.6
3792 149.3 2340 92.1 2598 102.3

Table 3. Standard Mast Height; Header Hose Tension Mark Location Lift Truck Models GLP050LX (A967)

Tension Marker from Carriage End

Lift Height Channel Length (Reference)
Dimension "E"
mm in. mm in. mm in.
2032 80.0 1440 56.7 1705 67.1
3292 129.6 2090 82.3 2308 90.1
3792 149.3 2340 92.1 2554 100.

28
4000 YRM 1431 Two-Stage Mast With Limited Free-Lift Repair

Figure 28. Header Hoses for Two-Stage Limited Free-Lift Mast

29
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Legend for Figure 28

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP

1. SPECIAL WASHER 9. NUT
2. SPACER 10. HOSE BRACKET
3. HOSE SHEAVE 11. CLAMP
4. STUBSHAFT 12. HOSES
5. LOCKWASHER 13. CARRIAGE
6. CAPSCREW 14. CARRIAGE BRACKET
7. BAR 15. CARRIAGE BRACKET MOUNTING CAPSCREW
8. SOCKET HEAD CAPSCREWS

Adjustment 6. Secure hose assemblies to main lift cylinders with

hose clamp and screw clamp.
When properly adjusted, the hoses will not be so tight
that they compress when they pass over the sheaves, 7. If the tension of the hoses is incorrect, loosen the
nor will they be so loose that they touch the load clamps and pull the hoses down (if too loose) or
backrest or any crossmember that is next to a push the hoses up (if too tight), half the width of
sheave. the clamp 15.0 mm (0.6 in.). Retighten the hard-
ware to 8 N•m (71 lbf in).
1. Cap off hoses when attachments have been re-
8. With no load on the forks, check the header hose
moved.
adjustment by operating the mast through the full
2. Check that hoses and cables are routed properly. lift cycle two times. When properly adjusted, the
hoses will not be so tight that they compress
3. Slowly raise the main cylinders to take up slack in when they pass over the sheaves nor will they be
the lift chains. so loose that they touch the load backrest or any
crossmember that is next to a sheave. If neces-
4. Tighten strap clamps at the bracket weldment. sary, repeat until the hoses are properly adjusted.
5. Cycle the mast a few times to ensure proper
tracking of hoses.

Three-Stage Mast With Full Free-Lift Repair

REMOVE NOTE: If mast needs to be disassembled, remove
the forks and carriage. See the sections Forks Re-
placement and Carriage Repair for removal proce-
WARNING dures. If only the main lift cylinders, tilt cylinders, or
The mast is heavy. The mast can weigh approxi- free-lift cylinder needs to be removed, the mast does
mately 907 kg (2000 lb). Make sure all lifting devi- not need to be removed from lift truck. See service
ces (hoists, cables, chains, slings, etc.) are suita- manual Cylinder Repair (Mast S/N A551, A555,
ble and of adequate capacity to lift the mast. Seri- A559, A661, A662, A663, A66, B507, B508, B509,
ous injury can occur if the mast falls. B551, B555, B559, B562, B563, B564, B661, B662,
B663, C515, C551, C555, C559, D507, D508, D509,
D515, D562, D563, D564, E509, and E564)
CAUTION
2100YRM1139 for removal procedures.
Make sure all mast weldments are fastened to-
gether. Make sure safety chains will not damage NOTE: The length of lift chains must be checked be-
the sheaves, tubing, or other parts of the mast. fore removing the mast. See Lift Chain Adjustment.

30
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

1. Fully lower all of the mast weldments. Tilt the NOTE: Allow the mast to tilt forward enough to gain
mast fully forward. Connect a crane with a ca- access to the mast mount capscrews.
pacity of at least 907 kg (2000 lb) to the top of the
mast using chains to support the mast in an up- 4. Remove capscrews and washers that hold re-
right position when the tilt cylinders are discon- tainer caps and bushings to mast mounts. See
nected. See the section Safety Procedures When Figure 29.
Working Near Mast in this manual.
WARNING
WARNING The mast is heavy. The mast can weigh approxi-
Always wear the proper protective equipment in- mately 907 kg (2000 lb). Make sure all lifting devi-
cluding eye protection and petroleum-resistant ces (hoists, cables, chains, slings, etc.) are suita-
gloves when handling hydraulic oil. Thoroughly ble and of adequate capacity to lift the mast. Seri-
wash oil from exposed areas of skin as soon as ous injury can occur if the mast falls.
possible.
5. Use the crane to lift the mast assembly from the
Completely lower forks to relieve hydraulic pres- lift truck. Position the mast across wooden beams
sure before disassembling any part of the lift on the floor with the carriage side up.
pump or disconnecting any hoses.

The hydraulic oil is hot at normal operating tem-

peratures. Be careful when draining the oil.

CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.

2. Position a drip pan under the area of the hydraulic

fittings. Disconnect the hydraulic line at the lower-
ing control valve on the outer mast.

See Figure 31 for lift truck models

• Manufactured before January, 2012

See Figure 32 for lift truck models

• Manufactured after January, 2012
1. CAPSCREW
See Figure 33 for lift truck models below, equipped 2. WASHER
with optional mast 3. RETAINER CAP
4. BUSHING
• GLP/GDP050LX (A974) manufactured after 5. LUBE FITTING
May, 2012
Figure 29. Mast Mounts, Outer Mast
3. Remove tilt cylinder rod end from outer mast. See
manual Cylinder Repair (Mast S/N A551, A555,
A559, A661, A662, A663, A66, B507, B508,
B509, B551, B555, B559, B562, B563, B564,
B661, B662, B663, C515, C551, C555, C559,
D507, D508, D509, D515, D562, D563, D564,
E509, and E564) 2100YRM1139 for procedures.

31
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

DISASSEMBLE
WARNING
Be careful when removing or installing snap
WARNING rings. These snap rings can come loose during re-
The mast is heavy. The mast can weigh approxi- moval and installation with enough force to cause
mately 907 kg (2000 lb). Make sure all lifting devi- an injury. Always use the correct snap ring pliers,
ces (hoists, cables, chains, slings, etc.) are suita- and wear eye and face protection during removal
ble and of adequate capacity to lift the mast. Seri- or installation
ous injury can occur if the mast falls.
4. Disconnect main lift chains from chain anchors
NOTE: If only the main lift cylinders, tilt cylinders, or near top of main lift cylinders. Disconnect other
free-lift cylinder need to be repaired, the mast does end of main lift chains at bottom of inner mast.
not need to be removed from lift truck. See section Push inner mast towards the bottom of mast as-
Cylinder Repair (Mast S/N A551, A555, A559, sembly until the bottom load rollers can be seen.
A661, A662, A663, A66, B507, B508, B509, B551,
B555, B559, B562, B563, B564, B661, B662, B663, See Figure 31 for lift truck models
C515, C551, C555, C559, D507, D508, D509, D515, • Manufactured before January, 2012
D562, D563, D564, E509, and E564) 2100YRM1139
for procedures. For header hose installation and ad- See Figure 32 for lift truck models
justment procedures, see section Header Hose Instal- • Manufactured after January, 2012
lation and Adjustment.
See Figure 33 for lift truck models below, equipped
1. Clean area around hydraulic fittings for main lift with optional mast
cylinders. Disconnect fittings at main lift cylinders
and put caps on open lines. Disconnect free-lift • GLP/GDP050LX (A974) manufactured after
chains from chain anchors. May, 2012

See Figure 31 for lift truck models 5. Remove lowering control valve housing from
outer mast.
• Manufactured before January, 2012
See Figure 31 for lift truck models
See Figure 32 for lift truck models
• Manufactured before January, 2012
• Manufactured after January, 2012
See Figure 32 for lift truck models
See Figure 33 for lift truck models below, equipped
with optional mast • Manufactured after January, 2012
• GLP/GDP050LX (A974) manufactured after See Figure 33 for lift truck models below, equipped
May, 2012 with optional mast
2. Disconnect header hoses. • GLP/GDP050LX (A974) manufactured after
May, 2012
3. Remove free-lift cylinder. Remove hose and chain
sheaves from free-lift cylinder and disassemble 6. Remove strip bearings from top of intermediate
them as necessary for cleaning, inspection and mast. See Figure 30.
repair. See Cylinder Repair (Mast S/N A551,
A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563,
B564, B661, B662, B663, C515, C551, C555,
C559, D507, D508, D509, D515, D562, D563,
D564, E509, and E564) 2100YRM1139 for proce-
dures.

32
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

WARNING
The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.

7. Remove the load rollers, shims, and snap rings at

the bottom of inner mast. Remove the load rollers,
shims, and snap rings at the top of the intermedi-
ate mast weldment. Make a note of each shim ar-
rangement and load roller location. The shim ar-
rangements will be approximately the same dur-
ing assembly.

See Figure 31 for lift truck models

• Manufactured before January, 2012

See Figure 32 for lift truck models

• Manufactured after January, 2012

1. STRIP BEARING See Figure 33 for lift truck models below, equipped
2. SHIMS with optional mast
3. TOP OF OUTER MAST
4. O-RING • GLP/GDP050LX (A974) manufactured after
May, 2012
Figure 30. Strip Bearings

33
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Figure 31. Three-Stage Full Free-Lift (FFL) Mast - Lift Trucks Manufactured Before January, 2012

34
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 31

1. NUT 17. MAIN LIFT CHAIN

2. WASHER 18. HOSE SHEAVE
3. FREE-LIFT CYLINDER BRACKET 19. BUSHING
4. FREE-LIFT CHAINS 20. BALL BEARING
5. FREE-LIFT CYLINDER 21. CHAIN SHEAVE
6. CAPSCREW 22. CHAIN ANCHOR
7. INNER MAST 23. CHAIN ANCHOR PIN
8. STRIP BEARING 24. COTTER PIN
9. SHIM(S) 25. LEFT MAIN LIFT CYLINDER
10. O-RING 26. LOWERING CONTROL VALVE HOUSING
11. SNAP RING 27. LOWERING CONTROL VALVE
12. LOAD ROLLER 28. CLAMP
13. INTERMEDIATE MAST 29. OUTER MAST
14. STUBSHAFT 30. SPACER
15. BAR 31. RIGHT MAIN LIFT CYLINDER
16. HOSE

35
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Figure 32. Three-Stage Full Free-Lift (FFL) Mast - Lift Trucks Manufactured After January, 2012

36
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 32

NOTE: THREE-FUNCTION MAST SHOWN. LIFT TRUCKS MANUFACTURED AFTER MAY, 2012 (DOES NOT
INCLUDE OPTIONAL MAST SHOWN IN FIGURE 33, WHICH IS THREE-FUNCTION ONLY) AND EQUIPPED
WITH FOUR-FUNCTION HEADER HOSES ARE SIMILAR.

1. NUT 17. MAIN LIFT CHAIN

2. WASHER 18. HOSE SHEAVE
3. FREE-LIFT CYLINDER BRACKET 19. BUSHING
4. FREE-LIFT CHAINS 20. BALL BEARING
5. FREE-LIFT CYLINDER 21. CHAIN SHEAVE
6. CAPSCREW 22. CHAIN ANCHOR
7. INNER MAST 23. CHAIN ANCHOR PIN
8. STRIP BEARING 24. COTTER PIN
9. SHIM(S) 25. LEFT MAIN LIFT CYLINDER
10. O-RING 26. LOWERING CONTROL VALVE HOUSING
11. SNAP RING 27. LOWERING CONTROL VALVE
12. LOAD ROLLER 28. CLAMP
13. INTERMEDIATE MAST 29. OUTER MAST
14. STUBSHAFT 30. SPACER
15. BAR 31. RIGHT MAIN LIFT CYLINDER
16. HOSE 32. CHAIN ANCHOR CAP

37
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Figure 33. Three-Stage Full Free-Lift (FFL) Optional Mast for Lift Trucks GLP/GDP050LX (A974)
Manufactured After May, 2012

38
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 33

1. OUTER MAST 19. HOSE

2. LOAD ROLLER 20. LOWERING CONTROL VALVE
3. SHIM 21. CAPSCREW
4. SNAP RING 22. CLAMP
5. STUBSHAFT 23. TUBE
6. O-RING 24. SPACER
7. SHIM STRIP 25. LOCK NUT
8. BEARING STRIP 26. INTERMEDIATE MAST
9. CHAIN 27. SHEAVE STUBSHAFT
10. COTTER PIN 28. CHAIN SHEAVE ASSEMBLY
11. PIN 29. SHEAVE
12. CHAIN ANCHOR 30. INNER MAST
13. WASHER 31. CHAIN GUARD
14. NUT 32. CROSSHEAD
15. FREE-LIFT CYLINDER 33. BRACKET
16. MAIN LIFT CYLINDER 34. VALVE ASSEMBLY (FLOW LIMITING)
17. BUSHING 35. HOUSING
18. FITTING

9. Remove main lift cylinders. See Cylinder Repair

WARNING (Mast S/N A551, A555, A559, A661, A662,
The mast is heavy. The mast can weigh approxi- A663, A66, B507, B508, B509, B551, B555,
mately 907 kg (2000 lb). Make sure all lifting devi- B559, B562, B563, B564, B661, B662, B663,
ces (hoists, cables, chains, slings, etc.) are suita- C515, C551, C555, C559, D507, D508, D509,
ble and of adequate capacity to lift the mast. Seri- D515, D562, D563, D564, E509, and E564)
ous injury can occur if the mast falls. 2100YRM1139 for procedures.

8. Slide the inner mast weldment halfway out of the 10. Slide the intermediate mast from the bottom of the
top of the intermediate mast weldment. Connect a outer mast approximately 30 cm (12 in.). Remove
crane with a capacity of at least 907 kg (2000 lb) the strip bearings at the top of the outer mast
to the center of the inner mast. See Figure 34. weldment. See Figure 30. Remove the snap rings
Slide the inner mast weldment out of the inter- and load rollers from both weldments. Make a
mediate mast weldment until the stub shafts are note of each shim arrangement and load roller lo-
in the notches of the intermediate mast weldment. cation. The shim arrangements will be approxi-
Remove the inner mast weldment from the inter- mately the same during assembly.
mediate mast weldment.
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast. Seri-
ous injury can occur if the mast falls.

NOTE: If outer mast is being replaced, copy the part

number and date code information from the old chan-
nel and stamp that information on the channel of the
new outer mast with the letter R at the end to indicate
that it has been replaced.

Figure 34. Mast Disassembly

39
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

11. Slide the intermediate mast halfway out of the top

of the outer mast. Connect a crane with a ca- WARNING
pacity of at least 907 kg (2000 lb) to the center of Be careful when cleaning with steam. Steam can
the intermediate mast. See Figure 34. Slide the cause serious burns. Wear protective clothing,
intermediate mast out of the outer mast until the gloves, and eye protection. Never expose your
stub shafts are in the notches of the outer mast. skin to steam.
Remove the intermediate mast from the outer
mast. Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When using
12. Disassemble the chain sheaves as necessary for cleaning solvents, always follow the solvent man-
repair and cleaning. Remove the hydraulic lines ufacturer's recommended safety precautions.
and fittings from the weldments as necessary.
6. Clean the mast weldments with steam or solvent.
CLEAN AND INSPECT
1. Inspect the chain sheaves and load rollers for WARNING
wear or damage. DO NOT use steam to clean the Incorrect welding procedures can damage the
lift chains, sheaves, or load rollers. The bearings structure of the mast or cause the mast to operate
in the sheaves and load rollers are sealed and lu- incorrectly. Obtain information from your Yale lift
bricated. truck dealer before welding on the mast.

7. Inspect the sliding surfaces for wear or damage.

WARNING Inspect the load roller contact surfaces for wear or
Cleaning solvents may be flammable and toxic damage. Inspect all welds for cracks.
and can cause severe skin irritation. When using
cleaning solvents, always follow the solvent man- ASSEMBLE
ufacturer's recommended safety precautions.

2. Clean the lift chains with solvent. Remove all dirt WARNING
and grease. Inspect the lift chains for wear or The mast is heavy. The mast can weigh approxi-
damage. The lift chains must be installed in the mately 907 kg (2000 lb). Make sure all lifting devi-
mast and the mast must be installed on the lift ces (hoists, cables, chains, slings, etc.) are suita-
truck before they can be checked for correct ble and of adequate capacity to lift the mast. Seri-
length. ous injury can occur if the mast falls.

NOTE: The shims for the load rollers keep the weld-
WARNING ments parallel and provide correct clearance. During
Never replace only the worn section of a chain. assembly, the shim arrangement will be approxi-
Replace the complete chain. Never replace only mately the same as before disassembly. Check the
one chain of a chain pair. Replace both chains. clearance and adjust the shims for wear or for
changes caused by repairs. The strip bearings are
3. A lift chain becomes longer when it is worn. If a also adjusted by using shims. See Carriage Adjust-
chain is 3% longer than a new lift chain, the lift ment in this section for the adjustment procedures.
chain must be replaced. If a chain scale is availa-
ble, check the lift chain as shown in Figure 35. If a NOTE: When the mast has header hoses, see sec-
chain scale is not available, measure 20 links of tion Header Hose Installation and Adjustment.
the lift chain. Compare the measurement with the
1. Apply multipurpose grease with 2 to 4% molybde-
lengths given in Figure 35. Lubricate the chains
num disulfide to hose sheave stub shaft and in-
with SAE 30W engine oil. The best procedure is
stall hose sheave to intermediate mast. Install
to soak them in engine oil.
chain sheave to intermediate mast.
4. Inspect chain anchors, pins, and cotter pins for
damage. Replace if damaged.

5. Inspect chain anchor caps (if equipped) on chain

anchors for free lift cylinder. Replace if damaged.

40
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

2. Put outer mast on floor with carriage side up. 3. Apply multipurpose grease with 2 to 4% molybde-
Connect a crane with a capacity of at least num disulfide to bearing surfaces and install strip
907 kg (2000 lb) to the center of the intermediate bearing and shim on channels of outer mast. See
mast weldment. Fit the lower stub shafts of the in- Figure 30. Check the clearance of the strip bear-
termediate mast weldment into the notches in the ings as described in Carriage Adjustment.
top of the outer mast weldment. Slide the inter-
mediate mast weldment into the outer mast weld- 4. Install the load rollers and the shims on the outer
ment so the stub shafts are seen at the top and mast weldment and at the bottom of the inter-
bottom of both weldments. mediate mast weldment. Before doing the next
step, adjust the intermediate mast weldment and
NOTE: The load rollers must be in place before strip check the clearance of the load rollers as descri-
bearing can be shimmed. bed in Carriage Adjustment.

WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval and installation with enough force to cause
an injury. Always use the correct snap ring pliers,
and wear eye and face protection during removal
or installation

NOTE: The clearance check and adjustment in

Step 5 is only an initial setup. The final check and ad-
justment is done after the mast is installed on the lift
truck.

5. Install the main lift cylinders. See Cylinder Re-

pair (Mast S/N A551, A555, A559, A661, A662,
A663, A66, B507, B508, B509, B551, B555,
B559, B562, B563, B564, B661, B662, B663,
C515, C551, C555, C559, D507, D508, D509,
D515, D562, D563, D564, E509, and E564)
2100YRM1139 for procedures. Push the inter-
Pitch mediate mast weldment to engage the lift cylin-
Wear Limit The
Total length of ders. Check the clearance at the top of the lift cyl-
maximum
20 links (pitch) inder mounts. Add or remove shims at the top of
length of 20
of new chain the main lift cylinder rods until they are even. In-
links
stall the snap ring and washer at the top of the lift
12.7 mm 254.0 mm 261.6 mm cylinders.
(0.5 in.) (10.0 in.) (10.3 in.)
6. Install lowering control valve housing and lower-
15.9 mm 317.5 mm 327.0 mm
ing control valve to outer mast weldment. Tighten
(0.6 in.) (12.5 in.) (12.9 in.)
the nuts to 18 N•m (159 lbf in). Connect the hy-
19.1 mm 381.0 mm 392.4 mm
draulic lines and fittings between the lowering
(0.8 in.) (15.0 in.) (15.4 in.)
control valve housing and main lift cylinders.
25.4 mm 508.0 mm 523.3 mm
(1.0 in.) (20.0 in.) (20.6 in.) See Figure 31 for lift truck models

NOTE: THE INSTRUCTIONS FOR MEASURING • Manufactured before January, 2012

CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR See Figure 32 for lift truck models
SCALE (YALE P/N 580037684)
• Manufactured after January, 2012
1. CHAIN WEAR SCALE
Figure 35. Lift Chains Check

41
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

See Figure 33 for lift truck models below, equipped

with optional mast WARNING
• GLP/GDP050LX (A974) manufactured after The mast is heavy. The mast can weigh approxi-
May, 2012 mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
7. Connect a crane with a capacity of at least ble and of adequate capacity to lift the mast. Seri-
907 kg (2000 lb) to the center of the inner mast ous injury can occur if the mast falls.
weldment. See Figure 34. Slide the inner mast
weldment into the intermediate mast weldment so
the stub shafts are seen at the top and bottom of CAUTION
both weldments. Make sure the chains will not damage the
sheaves, tubing, or other parts of the mast.
NOTE: The load rollers must be in place before strip
bearings can be shimmed. 2. Connect a crane with a capacity of at least
907 kg (2000 lb) to top of mast using chains.
8. Install the strip bearings and the shims on the Make sure all mast weldments are fastened to-
channels of the intermediate mast weldment. See gether. Make sure chains will not damage the
Figure 30. Apply chassis lube to the bearing sur- sheaves, tubing, or other parts of the mast.
faces.
3. Install mast on drive axle. Install capscrews and
9. Install the load rollers and the shims on the inter- washers that hold retainer caps and mast assem-
mediate and inner mast weldments. Before doing bly to drive axle. Tighten capscrews to
Step 10, adjust the inner mast weldment as de- 115 N•m (85 lbf ft).
scribed in Mast Adjustments.
4. Install tilt cylinder rod end to outer mast. See Cyl-
10. Connect main lift chains to chain anchors at the inder Repair (Mast S/N A551, A555, A559,
main lift cylinder mounts. Put lift chains over chain A661, A662, A663, A66, B507, B508, B509,
sheaves and connect them to the chain anchors B551, B555, B559, B562, B563, B564, B661,
at the bottom of the inner mast weldment. B662, B663, C515, C551, C555, C559, D507,
D508, D509, D515, D562, D563, D564, E509,
11. Install the free-lift cylinder in the mounts on the in- and E564) 2100YRM1139 for procedures.
ner mast. See section Cylinder Repair (Mast S/N
A551, A555, A559, A661, A662, A663, A66, 5. Connect hydraulic line to lowering control valve.
B507, B508, B509, B551, B555, B559, B562,
B563, B564, B661, B662, B663, C515, C551, See Figure 31 for lift truck models
C555, C559, D507, D508, D509, D515, D562, • Manufactured before January, 2012
D563, D564, E509, and E564) 2100YRM1139 for
procedures. See Figure 32 for lift truck models
• Manufactured after January, 2012
12. Install the hose sheave for the free-lift cylinder.
Tighten the capscrew for the hose sheave to See Figure 33 for lift truck models below, equipped
66 N•m (49 lbf ft). Install the hydraulic hose and with optional mast
tubing for the free-lift cylinder.
• GLP/GDP050LX (A974) manufactured after
13. Connect the free-lift chains to the chain anchors May, 2012
at the crossmember. Attach a wire between the
6. Install the carriage and forks. See sections Car-
end of the lift chain and the bottom of the mast to
riage Repair and Forks Replacement.
control the lift chain during mast installation.

INSTALL
1. Lubricate bushings with chassis lube and install
them into the mounts at bottom of outer mast.
See Figure 29.

42
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

7. Check tilt cylinder adjustment. Operate mast and HEADER HOSE INSTALLATION AND
check tilt cylinders for leaks. See section Cylin- ADJUSTMENT
der Repair (Mast S/N A551, A555, A559, A661,
A662, A663, A66, B507, B508, B509, B551, Standard
B555, B559, B562, B563, B564, B661, B662,
B663, C515, C551, C555, C559, D507, D508, Install
D509, D515, D562, D563, D564, E509, and
E564) 2100YRM1139 for procedures. Check lift
chains as described in Lift Chain Adjustment. WARNING
Before working on or near the mast, see Safety
NOTE: The load rollers and sheaves have sealed Procedures When Working Near Mast in this sec-
bearings and do not need additional lubrication. tion.

8. Lubricate sliding surfaces and load roller surfaces NOTE: The carriage height must be correct before
along the full length of the channels as shown in header hoses can be adjusted. See Lift Chain Adjust-
Figure 36. Apply chassis lube only to surfaces in- ment for carriage adjustment procedures.
dicated in Figure 36.
NOTE: This procedure is for the four-function option.
The three-function option will only have hoses A and
B.

1. Mark each hose with a single letter: A, B, C, and

D.

See Figure 37 for lift truck models

• Manufactured before January, 2012

See Figure 38 for lift truck models

• Manufactured after January, 2012

See Figure 39 for lift truck models

• Manufactured after May, 2012
A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
WITH CHASSIS LUBE
2. LUBRICATE LOAD ROLLER SURFACES WITH
CHASSIS LUBE
3. LOAD ROLLER

Figure 36. Mast Lubrication

43
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Legend for Figure 37

NOTE: PARTS OF MAST OMITTED FOR CLARITY.
THREE-FUNCTION MAST SHOWN.
A. HEADER HOSE A
B. HEADER HOSE B
1. ALIGN MARK G FOR HOSE A AND B AT BOT-
TOM OF CLAMP
2. CLAMP
3. ALIGN MARK E FOR HOSES A AND B AT BOT-
TOM OF CLAMP
4. CONNECTION TO COWL HOSES

Figure 37. Three-Stage FFL Header Hose

Arrangement - Lift Trucks Manufactured Before
January, 2012

44
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 38

NOTE: PARTS OF MAST OMITTED FOR CLARITY.
THREE-FUNCTION MAST SHOWN.
A. HEADER HOSE A
B. HEADER HOSE B
1. ALIGN MARK G FOR HOSE A AND B AT BOT-
TOM OF CLAMP
2. CLAMP
3. ALIGN MARK E FOR HOSES A AND B AT BOT-
TOM OF CLAMP
4. CONNECTION TO COWL HOSES

Figure 38. Three-Stage FFL Header Hose

Arrangement - Lift Trucks Manufactured After
January, 2012

45
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Legend for Figure 39

NOTE: PARTS OF MAST OMITTED FOR CLARITY.
FOUR-FUNCTION MAST SHOWN.
A. HEADER HOSE A
B. HEADER HOSE B
C. HEADER HOSE C
D. HEADER HOSE D
1. CLAMP
2. ALIGN MARK G FOR HOSE A AND B AT BOT-
TOM OF CLAMP
3. ALIGN MARK E FOR HOSES A AND B AT BOT-
TOM OF CLAMP
4. ALIGN MARK G FOR HOSE C AND D AT BOT-
TOM OF CLAMP
5. ALIGN MARK E FOR HOSES C AND D AT BOT-
TOM OF CLAMP
6. CONNECTION TO COWL HOSES
7. ALIGN MARK H FOR HOSES C AND D AT TOP
OF CLAMP

2. Determine dimensions E, G, and H. See Fig-

ure 40 and Table 4, Table 5, and Table 6.

3. Clamp the end of hose (the smaller fitting) that at-

taches to the carriage in a vise (DO NOT clamp
on threads). Pull on the other end until hose is
straight. DO NOT apply enough force to stretch
the hose. See Figure 40.

Figure 39. Three-Stage FFL Mast Header Hose

Arrangement, Lift Trucks Manufactured After May,
2012

46
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

1. DIMENSION G 5. TOP OUTER CHANNEL

2. DIMENSION E 6. BOTTOM OUTER CHANNEL
3. VISE 7. GROUND LEVEL
4. HOSE

Figure 40. Header Hose Measurement

47
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Table 4. Dimensions E and G (Three-Function Option, Hoses A and B)

Lift Height Channel Dim. E Dim. G Dim. E Dim. G

Length
MM Inch. MM (In.) Pneu. MM Pneu. MM Cushion MM Cushion MM
(In.) (In.) (In.) (In.)
4285 168.7 1915 mm 1610 mm 3855 mm 1595 mm 3840 mm
(75.4 in.) (63.4 in.) (151.8 in.) (62.8 in.) (151.1 in.)
4735 186.4 2065 mm 1760 mm 4150 mm 1740 mm 4130 mm
(81.3 in.) (69.4 in.) (164.4 in.) (68.5 in.) (162.6 in.)
5035 198.2 2165 mm 1860 mm 4345 mm 1840 mm 4330 mm
(85.2 in.) (73.2 in.) (171.1 in.) (72.4 in.) (170.5 in.)

Table 5. Dimensions E, G, and H (Four-Function Option, Hose C)

Lift Height Channel Dim. E Dim. G Dim. H Dim. E Dim. G Dim. H

Length
MM Inch. MM (In.) Pneu. MM Pneu. MM Pneu. MM Cushion Cushion Cushion
(In.) (In.) (In.) MM (In.) MM (In.) MM (In.)
4285 168.7 1915 mm 1610 mm 4100 mm 2240 mm 1595 mm 4085 mm 2225 mm
(75.4 in.) (63.4 in.) (161.4 in.) (88.2 in.) (62.8 in.) (160.8 in.) (87.6 in.)
4735 186.4 2065 mm 1760 mm 4405 mm 2395 mm 1740 mm 4385 mm 2375 mm
(81.3 in.) (69.4 in.) (173.4 in.) (94.3 in.) (68.5 in.) (172.6 in.) (93.5 in.)
5035 198.2 2165 mm 1860 mm 4610 mm 2600 mm 1840 mm 4595 mm 2585 mm
(85.2 in.) (73.2 in.) (181.5 in.) (102.4 in.) (72.4 in.) (181.0 in.) (102 in.)

Table 6. Dimensions E, G, and H (Four-Function Option, Hose D)

Lift Height Channel Dim. E Dim. G Dim. H Dim. E Dim. G Dim. H

Length
MM Inch. MM (In.) Pneu. MM Pneu. MM Pneu. MM Cushion Cushion Cushion
(In.) (In.) (In.) MM (In.) MM (In.) MM (In.)
4285 168.7 1915 mm 1610 mm 4045 mm 2185 mm 1595 mm 4030 mm 2170 mm
(75.4 in.) (63.4 in.) (159.3 in.) (86.0 in.) (62.8 in.) (159.0 in.) (85.4 in.)
4735 186.4 2065 mm 1760 mm 4350 mm 2395 mm 1740 mm 4330 mm 2320 mm
(81.3 in.) (69.4 in.) (171.3 in.) (94.3 in.) (68.5 in.) (170.5 in.) (91.3 in.)
5035 198.2 2165 mm 1860 mm 4555 mm 2545 mm 1840 mm 4540 mm 2530 mm
(85.2 in.) (73.2 in.) (179.3 in.) (100.2 in.) (72.4 in.) (178.7 in.) (99.6 in.)

48
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

4. Mark all hoses with dimensions E, G, and H. All 10. Align mark G on hose A at the bottom edge of
measurements are made from carriage end of clamp to create the proper tension. Align mark G
hose (the smaller fitting). on hose B at the top edge of clamp to create the
proper tension. Tighten hardware to
5. Attach hose to carriage bracket with clamp. 8 N•m (71 lbf in).
Tighten hardware for clamps to
18 N•m (159 lbf in). Apply grease to surface of See Figure 37 for lift truck models
hose guide that contacts hoses. See Figure 41. • Manufactured before January, 2012
6. Place hoses over the top of free-lift chains and See Figure 38 for lift truck models
under the hose guides. See Figure 41. Attach the
hose guides to the lower crossmember and • Manufactured after January, 2012
tighten mounting hardware to 33 N•m (24 lbf ft). See Figure 39 for lift truck models
Make sure bracket is between crossmember and
hose guide. Put clamps over hoses and attach the • Manufactured after May, 2012
clamps to free-lift bracket (DO NOT tighten the
11. Install the clamps.
hardware). Align marks for H with top of clamp.
12. Connect header hoses to cowl hoses.
NOTE: To make the alignment of dimension E eas-
ier, use a crane with a capacity of at least See Figure 37 for lift truck models
907 kg (2000 lb) to raise carriage high enough to at-
• Manufactured before January, 2012
tach a safety chain. See Safety Procedures When
Working Near Mast. See Figure 38 for lift truck models
7. Align the mark for dimension E at the bottom of • Manufactured after January, 2012
the clamp to create the proper hose tension.
Tighten hardware to 8 N•m (71 lbf in). Install hose See Figure 39 for lift truck models
guards. Tighten capscrews that mount the guards • Manufactured after May, 2012
to 66 N•m (49 lbf ft).
13. Use rubber clamps and strap clamps to attach
8. Position hoses at hose sheaves. See Figure 41. header hoses to main lift cylinders. Make sure
The hose sheaves and stubshaft must be instal- header hoses do not stretch or fold while tilting
led on the hose before they are attached to the the mast fully forward or backward.
mast. Tighten hardware to 53 N•m (39 lbf ft)
14. With no load on the forks, check the header hose
9. Put clamps over hoses and attached clamps to adjustment by operating the mast through the full
upper brackets (DO NOT tighten the hardware). lift cycle two times.

NOTE: To make the alignment of dimension G eas- 15. When properly adjusted, the header hoses will not
ier, use a crane to raise the inner channel high be so tight that they compress when they pass
enough to install a safety chain. See Safety Proce- over the sheaves nor will they be so loose that
dures When Working Near Mast. they touch the load backrest or any crossmember
that is next to a sheave. If the header hoses re-
quire additional adjustment, see Adjust.

49
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Figure 41. Header Hoses, Three-Stage FFL Mast

50
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 41

NOTE: THREE-FUNCTION MAST SHOWN. FOUR-FUNCTION MAST SIMILAR.

1. CAPSCREW 13. LOWER HOSE GUIDE

2. HOSE GUARD 14. NUT
3. SNAP RING 15. BOTTOM CLAMP
4. HOSE GUIDE 16. HEADER HOSES
5. FREE-LIFT CYLINDER CROSSHEAD 17. FREE-LIFT CHAIN
6. WASHER 18. CLAMP
7. SPACER 19. COWL HOSES
8. HOSE SHEAVE 20. UPPER BRACKET
9. HOSE GUARD 21. CARRIAGE BRACKET
10. CLAMP 22. CLAMP
11. LOWER BRACKET 23. STUBSHAFT
12. HOSE RESTRAINT

Adjust header hoses will not be so tight that they com-

press when they pass over the sheaves nor will
1. If the tension of the header hoses is correct be- they be so loose that they touch the load backrest
tween the carriage and the clamp at the free-lift or any crossmember that is next to a sheave. If
bracket, go to Step 2. If the tension of the header necessary, repeat Step 1 and Step 2 until the
hoses is wrong, loosen the clamps and pull (if ho- header hoses are properly adjusted.
ses are loose) or push (if hoses are tight) on the
hoses so they move 15 mm (0.6 in.). Tighten the Optional Equipment, Lift Truck GLP/
hardware to 8 N•m (71 lbf in). GDP050LX (A974) manufactured after May,
2012
See Figure 37 for lift truck models
• Manufactured before January, 2012 Install
See Figure 38 for lift truck models
• Manufactured after January, 2012 WARNING
Before working on or near the mast, see Safety
See Figure 39 for lift truck models Procedures When Working Near Mast in this sec-
• Manufactured after May, 2012 tion.

See Figure 41. NOTE: This procedure is for the three-function option
and will have hoses A and B only.
2. If the tension of the header hoses is correct be-
tween the clamp at the upper bracket and the NOTE: The lift chains and carriage height must be
clamp at the free-lift bracket, go to Step 3. If the correctly adjusted before the header hoses can be ad-
tension of the header hoses is wrong, loosen the justed. See the section Lift Chain Adjustment for ad-
clamps and pull (if hoses are too loose) or push (if justment procedures.
hoses are too tight) on header hoses so they
1. Mark each hose (1) with a single letter: A or B at
move 15 mm (0.6 in.), plus the amount the header
dimension D. See Figure 42.
hoses were moved in Step 1. Tighten the hard-
ware to 8 N•m (71 lbf in). 2. Determine dimensions E and G See Figure 43
and Table 7.
3. With no load on the forks, check the header hose
adjustment by operating the mast through the full
lift cycle two times. When properly adjusted, the

51
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Figure 42. Header Hose Arrangement for Three-Stage Full Free-Lift Mast (Sheet 1 of 3)

52
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

Figure 42. Header Hose Arrangement for Three-Stage Full Free-Lift Mast (Sheet 2 of 3)

53
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Figure 42. Header Hose Arrangement for Three-Stage Full Free-Lift Mast (Sheet 3 of 3)

54
4000 YRM 1431 Three-Stage Mast With Full Free-Lift Repair

1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE

Figure 43. Header Hose Measurement for Three-Stage Full Free-Lift Mast

55
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1431

Table 7. Standard Three-Stage Hose Dimensions

Channel
Lift Height Length Dimension "D" Dimension "E" Dimension "G"
(Reference)
mm in. mm mm in. mm in. mm in.
5035 198.2 2149 340 13.4 150 5.9 2645 104.1

3. Clamp the end of the hose (the smaller fitting) that 9. Preassemble hoses onto upper sheave and stub-
attaches to the carriage in a vise (DO NOT clamp shaft weldment with spacer, washer and cap-
on the threads), and pull on the other end until the screw. Position hose so female end of hoses are
hose is straight. DO NOT apply enough force to toward back of the mast.
stretch the hose.
10. Using a nut, install sheave assembly onto mast in
NOTE: These marks will be used to pretension the upper corner. Tighten to 53 N•m (39 lbf ft). See
header hose during installation. Figure 42.

4. Place a mark on hoses (2) at dimensions E and G 11. Route male end of hoses (2) through hose guide
(all measurements are made from the carriage and up the back of the free-lift cylinder.
end of the hose [the smaller fitting]). See Fig-
ure 42 and Table 7. 12. Align mark E with bottom of clamp located on
mounting plate on the inside of the mast. Using
5. Attach the hoses to the carriage bracket with two capscrews, install clamp to plate. Tighten
clamps. Apply spray lubricant to the surface of the capscrews to 8 N•m (71 lbf in).
hose guide that contacts the hoses.
13. Connect hoses (1) and (2) at back of free-lift cylin-
6. Place the hoses over the top of the free-lift chains der.
and under the hose guard bracket. Attach the
hose guard to left and right hose guard brackets, 14. Install strap clamp 75 mm (3.0 in.) above fittings
tighten the capscrews to 18 N•m (13 lbf ft). on back side of free-lift cylinder.

Make sure the right and left hose guard brackets 15. Route hoses (2) over bracket in upper corner of
are secured properly to the free lift cylinder. If nec- mast. Secure hoses using clamp and two cap-
essary tighten capscrews to 66 N•m (49 lbf ft). Also screws. Align mark G at bottom of clamp. Tighten
ensure the hoses are routed to the outside of the capscrews to 8 N•m (71 lbf in).
roller located on the inside (mast side) of the free
16. Install upper and lower clamps to main lift cylin-
lift cylinder assembly. See Figure 42.
der.
NOTE: The header hose configuration on this model
17. Connect header hoses to cowl hoses.
lift truck is composed of two hoses, the free lift header
hose and the main lift header hose. 18. Use the rubber clamps and strap clamps to attach
the hoses to the main lift cylinders. Make sure the
7. Hang hoses over hose sheave on free-lift cylinder
hoses do not stretch or fold while tilting the mast
crosshead with dimension D in front. Align mark D
fully forward and backward.
with bottom of clamp and using two capscrews at-
tach to carriage bracket. Tighten capscrews to
8 N•m (71 lbf in). See Figure 42.

8. Connect hoses to sideshift cylinder bracket. Using

two capscrews, attach carriage bracket to car-
riage assembly. tighten capscrews to
18 N•m (13 lbf ft). See Figure 42.

56
4000 YRM 1431 Main Lift Cylinder Repair

Adjust hoses are too tight) on header hoses so they

move 15 mm (0.6 in.), plus the amount the header
1. If the tension of the header hoses is correct be- hoses were moved in Step 1. Tighten the hard-
tween the carriage and the clamp at the free-lift ware to 8 N•m (71 lbf in).
bracket, go to Step 2. If the tension of the header
hoses is wrong, loosen the clamps and pull (if ho- 3. With no load on the forks, check the header hose
ses are loose) or push (if hoses are tight) on the adjustment by operating the mast through the full
hoses so they move 15 mm (0.6 in.). Tighten the lift cycle two times. When properly adjusted, the
hardware to 8 N•m (71 lbf in). See Figure 42. header hoses will not be so tight that they com-
press when they pass over the sheaves nor will
2. If the tension of the header hoses is correct be- they be so loose that they touch the load backrest
tween the clamp at the upper bracket and the or any crossmember that is next to a sheave. If
clamp at the free-lift bracket, go to Step 3. If the necessary, repeat Step 1 and Step 2 until the
tension of the header hoses is wrong, loosen the header hoses are properly adjusted.
clamps and pull (if hoses are too loose) or push (if

Main Lift Cylinder Repair

To repair the main lift cylinders, see the service man- C515, C551, C555, C559, D507, D508, D509, D515,
ual Cylinder Repair (Mast S/N A551, A555, A559, D562, D563, D564, E509, and E564) 2100YRM1139
A661, A662, A663, A66, B507, B508, B509, B551, for procedures.
B555, B559, B562, B563, B564, B661, B662, B663,

Lift and Tilt System Leak Check

See service manual section Cylinder Repair (Mast D507, D508, D509, D515, D562, D563, D564, E509,
S/N A551, A555, A559, A661, A662, A663, A66, and E564) 2100YRM1139 for procedures to check
B507, B508, B509, B551, B555, B559, B562, B563, the main lift cylinders and tilt cylinders for leaks.
B564, B661, B662, B663, C515, C551, C555, C559,

Tilt Cylinders Adjustment

For procedures to adjust the tilt cylinders, see service B663, C515, C551, C555, C559, D507, D508, D509,
manual Cylinder Repair (Mast S/N A551, A555, D515, D562, D563, D564, E509, and E564)
A559, A661, A662, A663, A66, B507, B508, B509, 2100YRM1139.
B551, B555, B559, B562, B563, B564, B661, B662,

57
Lift Chain Adjustment 4000 YRM 1431

Lift Chain Adjustment

2. Install new cotter pins and chain anchor pins.
WARNING Both legs of cotter pin must be bent against chain
When working on or near the mast, see Safety anchor pin.
Procedures When Working Near Mast in this sec-
tion. NOTE: Prior to performing adjustment procedures,
make sure the forklift truck is parked on a level sur-
During test procedures for the hydraulic system, face and the mast is in the vertical position.
fasten the load to the carriage with chains to pre-
vent it from falling. Keep all personnel away from 3. Adjust the chain anchors that support the car-
the lift truck during the tests. riage, until the bottom of the fork heel is 12.0
+3.0/−12.0 mm (0.47 +0.12/−0.47 in.) above the
Never allow anyone under a raised carriage. DO floor level. See Figure 44.
NOT put any part of your body in or through the
lift mechanism unless all parts of the mast are 4. Adjust the chain anchors that support the car-
completely lowered and the engine is STOPPED. riage, until the bottom of the lower carriage bar is
88.5 +3.0/−6.0 mm (3.50 +0.12/−0.24 in.) above
Never check for leaks by putting hands on hy- the floor level. See Figure 45.
draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the
skin. Table 8. Hook-Type Carriage Chain Adjustment

Class II and III 88.5 +3.0/−6.0 mm (3.50

When the lift chains are correctly adjusted: +0.12/−0.24 in.)
• The tension will be the same on each chain of
the chain set. Check tension by pushing on
both chains at the same time.
• The chain length will be correct.
• The chains must travel freely through the com-
plete cycle.

NOTE: When the lift chain adjustments are complete,

make sure the threads on the nuts of the chain an-
chors are completely engaged. Inspect the torque of
the prevailing torque nut (locknut) used to adjust the
chain anchor with every lift chain adjustment. After
carriage and or mast section(s) are adjusted for
proper ground clearance, prevent the carriage and or
mast section(s) from fully lowering (see Safety Proce-
dures When Working Near Mast). With slack chain(s),
check locknut torque. If 2.5 N•m (22.1 lbf in) for
1/2-20, 4.5 N•m (39.8 lbf in) for 5/8-18 nuts,
6.0 N•m (53.1 lbf in) for 3/4-16 of torque cannot be 1. MAST
reached; replace locknut. The chain anchors, after ad- 2. CARRIAGE
justment, must be able to move on their mountings. 3. FORK
4. HEEL OF FORK IS 12.0 +3.0/−6.0 mm (0.47
+0.12/−0.24 in.) ABOVE FLOOR LEVEL
1. When adjusting the lift chains, go to Step 3. If the
forklift truck is normally equipped with a hook-type Figure 44. Lift Chain Adjustment, Forks
carriage and has an attachment without forks, go
to Step 4.

58
4000 YRM 1431 Mast Adjustments

Legend for Figure 45

1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER CAR-
RIAGE BAR

Figure 45. Lift Chain Adjustment, Hook-Type

Carriage

Mast Adjustments
LOAD ROLLER ADJUSTMENT 2. Perform the following steps to adjust the mast
load rollers:
NOTE: Shims are installed on both sides of the load
rollers. Do not add or remove shims from the stub a. Use a crowbar to move mast uprights from side
shafts. To change the position of the roller on the stub to side to measure movement. Measure move-
shaft, move the shims from one side of the load roller ment in a minimum of three different positions
to the other. of each mast upright.

During assembly, the shim arrangement will be ap- b. Separate mast uprights and change shim ar-
proximately the same as before disassembly. Check rangements as required. Assemble uprights.
the clearance and adjust shims after repairs have Slide upright all the way to the top and bottom
been completed. to find the tightest fit.

c. Repeat Step a and Step b until there is zero

1. The load rollers control the alignment of the mast
clearance at the point of the tightest fit.
uprights. See Figure 46. The alignment conditions
are given on a list below with the most important d. Measure distance between channels of mast
condition first. uprights on top and bottom. Change shims to
keep distance equal between top and bottom
a. The mast uprights must be parallel to each
so mast uprights are parallel. Also make sure
other.
the mast uprights are parallel within
b. Use shims to adjust load rollers so there is 1.5 mm (0.060 in.).
zero clearance between load roller and chan-
3. Adjust strip bearings. See Figure 47. Insert shims
nel at point of tightest fit.
under strip bearing. Adjust clearance until there is
c. The number of shims under a load roller must less than 0.8 mm (0.030 in.) at the tightest fit. See
be approximately the same as the stub shaft in Figure 46.
the opposite side of the upright. This ensures
the uprights will be approximately in the center.

59
Mast Adjustments 4000 YRM 1431

NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO GIVE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO GIVE ZERO CLEARANCE
AT POINT OF TIGHTEST FIT.
A. TOP VIEW C. CARRIAGE FRONT VIEW
B. MAST FRONT VIEW
1. CHANNEL 8. EQUAL SPACE ±1.5 mm (0.060 in.)
2. LOAD ROLLER 9. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
3. STUB SHAFT 10. PUT SPACER ON OUTSIDE OF TOP LOAD
4. SNAP RING ROLLER, UNDER SNAP RING
5. SHIMS 11. SHIM FOR ZERO CLEARANCE AT POINT OF
6. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.) TIGHTEST FIT
7. ZERO CLEARANCE AT POINT OF TIGHTEST
FIT
Figure 46. Mast Adjustments

60
4000 YRM 1431 Mast Adjustments

1. STRIP BEARING 4. SHIMS

2. LOAD ROLLER 5. O-RING
3. MAST UPRIGHT

Figure 47. Strip Bearings Arrangement

MAST SIDE KICKING ADJUSTMENT shims will need to either be added or removed
from the top of the left main lift cylinder. See Fig-
To adjust the mast for side kicking, do the following: ure 31 for shim location on the main lift cylinders.
Also see Cylinder Repair (Mast S/N A551,
1. Place the lift truck on a level surface and apply A555, A559, A661, A662, A663, A66, B507,
the parking brake. B508, B509, B551, B555, B559, B562, B563,
B564, B661, B662, B663, C515, C551, C555,
2. Raise the mast and visually inspect it as it rea- C559, D507, D508, D509, D515, D562, D563,
ches its full height. D564, E509, and E564) 2100YRM1139 for shim
location on the main lift cylinders.
3. If the mast is moving to the left, shims will need to
either be added or removed from the top of the 5. If shims are to be added, use the smallest shim
right main lift cylinder. If mast moves to the right, size available on the cylinder being adjusted. See
shims will need to either be added or removed the Parts Manual for shim sizes and part num-
from the top of the left main lift cylinder. For main bers.
lift cylinder shim locations
6. Raise the mast again and visually inspect it to en-
4. If the mast is moving to the left, shims will need to sure that it is no longer side kicking. If side kicking
either be added or removed from the top of the is still present, repeat Step 4 and Step 5.
right main lift cylinder. If mast moves to the right,

61
Carriage Adjustment 4000 YRM 1431

Carriage Adjustment
1. Install the load rollers on the carriage. Install the 3. Remove the carriage from the mast. Adjust the
shims for the rollers in the same sequence on the shim arrangement for each load roller for clear-
stub shaft as before disassembly. ance between the load roller and the inner mast
weldment. Repeat Step 1 and Step 2 until there is
zero clearance at the point of tightest fit.
WARNING
The mast is heavy. The mast can weigh approxi- 4. Keep the shim arrangement between the middle
mately 907 kg (2000 lb). Make sure all lifting devi- and bottom load rollers on the same side of the
ces (hoists, cables, chains, slings, etc.) are suita- carriage approximately equal. Also keep the shim
ble and of adequate capacity to lift the motor. arrangement on each side of the carriage approxi-
mately equal. The carriage must be parallel with
2. Use a crane to raise the carriage up the inner the inner mast weldment within
mast weldment. Find the tightest fit between the ±1.50 mm (±0.06 in.).
load rollers and the inner mast weldment.

62
4000 YRM 1431 2/14 (11/13)(8/13)(3/12)(12/11)(7/11)