1

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

WARNING

Mast parts are heavy and can move. Distances between parts are small.

Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

•

Never put any part of the body into or under the mast or carriage unless all parts are com

pletely lowered or a safety chain is installed. Also make sure that the power is off and the key
is removed.
Put a “DO NOT OPERATE” tag in the operator’s compartment. Disconnect the battery on electric
lift trucks and put a tag or lock on the battery connector.

•

Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

•

DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on

the mast.

•

DO NOT use blocks to support the mast weldments nor to restrain their movement.

•

Mast repairs require disassembly and removal of parts and can require removal of the mast

or carriage. Follow the repair procedures in the correct Service Manual for the mast.

WHEN WORKING NEAR THE MAST ALWAYS:

•

Lower the mast and carriage completely. Push the

lift/lower control lever forward and make sure there is
no movement in the mast. Make sure that all parts of
the mast that move are fully lowered.

OR

•

If parts of the mast must be in a raised position, in-

stall a safety chain to restrain the moving parts of the
mast. Connect moving parts to a part that does not
move. Follow these procedures:

a. Put the mast in a vertical position.

b. Raise the mast to align the bottom crossmember of
the weldment that moves in the outer weldment with a
crossmember on the outer weldment (1). On the two–
stage and free–lift mast, the moving part is the inner
weldment (2). On the three–stage mast it is the inter-
mediate weldment (3).

c. Use a 3/8 inch minimum safety chain with a hook (5) to
fasten the crossmembers together so that the movable
member can not lower. Put the hook on the back side of
the mast. Make sure the hook is completely engaged
with a link in the chain. Make sure the safety chain does
not touch lift chains or chain sheaves, tubes, hoses, fit-
tings, or other parts on the mast.

d. Lower the mast until there is tension in the safety
chain and the free–lift cylinder (6) (free–lift, three–stage
and four–stage masts only) is completely retracted. If
running, stop the engine. Apply the parking brake. Install
a “DO NOT REMOVE” tag on the safety chain(s).

e. Install another safety chain (3/8 inch minimum) be-
tween the top or bottom crossmember of the carriage (7)
and a crossmember on the outer weldment (8).

•

Apply the parking brake. After lowering or restrain-

ing the mast, shut off the power and remove the key.
Put a “DO NOT OPERATE” tag in the operator’s com-
partment. Disconnect the battery on electric lift
trucks and put a tag or lock on the battery connector.

1

2

5

8

The following procedures must be used when inspecting or working near the mast. Additional
precautions and procedures can be required when repairing or removing the mast.

TWO–

STAGE

MAST

FREE–

LIFT

MAST

7

8

5

1

2

7

6

2

SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)

3

7

6

THREE–STAGE

MAST

1

5

INTRODUCTION

GENERAL

WARNING

Do not make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be done by trained service people.

Do not operate a lift truck that needs repairs. Report
the need for repairs immediately. If repair is
necessary, put a “DO NOT OPERATE” tag in the
operator’s area. Remove the key from the key
switch. Disconnect the battery connector.

This section has the repair procedures for the VISTA
two–stage, free–lift, and three–stage masts. Repair
procedures are also included for the lift cylinders, the tilt
cylinder, the side–shift cylinder and the side–shift
carriage. Checks and Adjustments and Troubleshooting
are at the end of this section. See the section, VISTA
MASTS, DESCRIPTION AND OPERATION, 4000

SRM 222 for the description and operation of mast
assemblies.

FORKS (See FIGURE 1.)

The forks are connected to the carriage by hooks and
latches. The latches fit through the top fork hooks and
into slots in the top crossmember of the carriage. The
forks can be removed from the carriage by aligning the
forks with the fork removal notch in the bottom
crossmember of the carriage. Always check that the
latches for the forks keep the forks in position on the
carriage. Replace damaged latch parts. Additional
information for maintenance of the forks is found in the
section, PERIODIC MAINTENANCE, 8000 SRM
370.

WARNING

The forks are heavy. Do not try to move the forks
without using a lifting device.

3

10221

12000

1. LOAD ROLLERS
2. CHAIN ANCHOR (2)
3. NOTCH FOR REMOVAL OF FORKS

FIGURE 1. CARRIAGE AND FORKS

4. FORK
5. HOOK
6. LOCKING PIN ASSEMBLY

1

2

3

4

5

6

5

6

CARRIAGE (See FIGURE 1.)

Removal

1. Lower the carriage and forks on blocks to loosen the
lift chains.

WARNING

If the lift chains are disconnected, use a wire and
temporarily connect the ends of the lift chains to the
mast. This procedure will prevent the ends of the lift
chains from running through the sheaves, falling
from the top of the mast, and causing an injury or
damage.

2. Remove the pin from each chain anchor on the
carriage. Disconnect the lift chains from the carriage.

3. Put a load of 1/4 capacity on the forks to give the
carriage stability. The load will keep the carriage from
falling when the carriage is disconnected from the mast.

WARNING

Make sure that the carriage has stability when the
inner weldment raises above the load rollers of the
carriage.

4. Use the lift cylinders to raise the inner weldment.
Carefully raise the inner weldment until it is above the

load rollers of the carriage. Connect a crane to the top of
the inner weldment if the hydraulic system cannot be
used. Carefully raise the inner weldment until it is above
the load rollers of the carriage.

5. Move the lift truck away from the carriage.

6. If the forks are removed from the carriage before the
carriage is removed from the mast, use a crane to hold
the carriage while the inner channel is raised above the
load rollers. Use the crane to move the carriage away
from the lift truck. Put the carriage on the floor so that
the load rollers are up.

7. If any of the load rollers must be replaced, make a note
of the shim arrangement. The replacement roller will
normally have a similar shim arrangement.

Installation

1. Use the hydraulic system of the lift truck or a crane to
raise the inner weldment. Raise the inner weldment until
it is above the load rollers of the carriage. Carefully
lower the inner weldment until it engages all of the load
rollers.

2. Check the clearance of the load rollers. See Checks
and Adjustments in this section.

3. Install the lift chains. Use new cotter pins in the chain
anchors. See Checks and Adjustments in this section.

4

MAST

REMOVAL FROM THE LIFT TRUCK
(See FIGURE 2.)

WARNING

Before working on or near the mast, read SAFETY
PROCEDURES WHEN WORKING NEAR THE
MAST.

Mast parts are heavy and can move. Distances
between parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast or
the carriage. A lifting device should be used to
support or lift the mast components.

1. Fully lower all of the mast weldments. Move the mast
to a vertical position with the tilt control.

NOTE: If the mast must be disassembled, remove the
forks and carriage.

2. Raise the front of the lift truck for access to the tilt
cylinder. Put blocks under the frame behind the load
wheels.

3. Connect a crane to the top of the mast using chains.
Make sure that all the weldments are fastened together.
Make sure that the chains will not damage the sheaves,
tubing or other parts of the mast. The crane must have a
minimum capacity of at least 1,000 kg (2,200 lb).

WARNING

Use a driver, not your fingers, to push the anchor
pins from the clevises on the tilt cylinders. The
cylinder or mast can move and cause serious injury.

4. Disconnect the clevis on the rod of the cylinder from
the tilt plate on the mast. Remove one of the snap rings

from the pin. Remove the pin from the clevis and the tilt
plate with a driver.

5. Disconnect the hydraulic line at the bottom of the
mast and drain the hydraulic oil into a container. Install
caps on the open hydraulic fittings.

6. Disconnect the brake line at the bottom of the cowl.
Install caps on the open hydraulic fittings.

7. Disconnect the cables for the parking brake at the
bottom of the lever assembly on the cowl.

8. Remove the nuts, washers and capscrews from both
of the bearings of the mast mounts on the cowl of the lift
truck. Rotate the bearing housings away from the
threaded holes in the mast mounts. Install two M12
capscrews into the threaded holes of the bearing
housings until the capscrews touch the mast mount.
Tighten the two capscrews evenly and pull the bearing
assembly from the mast mount and the stub shaft.

NOTE: Disassemble each bearing separately and use
the crane to hold the weight of the mast weldments. Do
not damage the stub shafts on the mast mounts during
disassembly.

9. When both bearings are removed, move the mast fully
to one side against one of the mast mounts on the lift
truck. One of the stub shafts on the mast will be removed
from the mast mount. Move the mast so that the exposed
stub shaft moves away from the mast mount.

10. Use the crane to lift the mast assembly away from the
lift truck. Put the free–lift or three–stage mast assembly
on blocks so that the back of the mast is toward the floor.
Put the two–stage mast on the floor so that the front of
the mast is toward the floor.

5

12013

1. BEARING HOUSING
2. SPHERICAL BEARING
3. SHIM
4. ROD END
5. SPHERICAL BEARING
6. SNAP RING, INTERNAL
7. PIN
8. SNAP RING, INTERNAL
9. TILT PLATE

10. MAST MOUNT

11. TILT CYLINDER

FIGURE 2. MAST MOUNTS

1

2

3

4

5

6

7

9

10

11

10

1

9

4

8

DISASSEMBLY

        

        

              

          

     

Two–Stage And Free–Lift Masts
(See FIGURE 3., FIGURE 4., and FIGURE 5.)

1. Clean the area around the hydraulic fittings for the lift
cylinders. Disconnect the fittings at the lift cylinders
and put caps on the open lines.

2. On the free–lift mast, remove the capscrews, washers
and cylinder clamp from the free–lift cylinder. Remove
the free–lift cylinder. Put the free–lift mast on the floor
so that the front of the mast is toward the floor.

3. Remove the snap rings and washers from the top of
each lift cylinder. Remove the cylinder clamps near the
top of each lift cylinder. Each cylinder clamp is fastened
to the top crossmember of the outer mast by two
capscrews and washers. Disconnect the hydraulic tube
from the left main cylinder on the free–lift mast.

4. Slide the inner weldment from the outer weldment
approximately 30 cm (12 in) to disengage the lift
cylinders from the inner weldment. Remove the lift
cylinders from the mount plates at the bottom of the
outer weldment.

5. Slide the inner weldment from the bottom of the outer
weldment as far as possible. Remove the load rollers.
Make a note of the shim arrangement. The shim
arrangement will be used during the procedure for
assembly.

6

12001

1. LIFT CYLINDER (2)
2. LIFT CHAIN (2)
3. OUTER WELDMENT
4. CHAIN SHEAVE (2)
5. INNER WELDMENT
6. LOWERING CONTROL

VALVE, EXTERNAL

FIGURE 3. TWO–STAGE MAST

1

2

3

4

5

6

1

FIGURE 4. INNER WELDMENT

6. Slide the inner weldment half–way out of the top of
the outer weldment. Connect a crane to the center of the
inner weldment. See Figure 4. Slide the inner weldment
out of the outer weldment until the stub shafts are in the
notches of the outer weldment. Remove the inner
weldment from the outer weldment.

7. Remove and disassemble the sheaves and strip
bearings as necessary for repair and cleaning. Make a
note of the shim arrangement under the strip bearings.
The shim arrangement will be used during the procedure
for assembly.

Three–Stage Mast (See FIGURE 6.)

1. Disconnect and remove the hydraulic lines from the
free–lift cylinder. Disconnect and remove the lift chain.
Remove the capscrews, washers and cylinder clamp that
holds the lift cylinder to the inner weldment. Remove
the free–lift cylinder.

2. Remove the chain anchors from the bottom of the
inner weldment. Push the inner weldment toward the
bottom of the mast assembly until the top load rollers
and the bottom load rollers are visible.

3. Remove the load rollers. Make a note of the shim
arrangement.

4. Disconnect the main lift chains from the chain
anchors at the top of the outer weldment. Remove the lift
chains.

7

12002

1. OUTER WELDMENT
2. INNER WELDMENT
3. MAIN LIFT CYLINDERS
4. FREE–LIFT CYLINDERS
5. CLAMP, FREE–LIFT CYLINDER
6. LIFT CHAIN
7. CLAMP, MAIN CYLINDERS (2)
8. LOWERING CONTROL VALVE, EXTERNAL

FIGURE 5. FREE–LIFT MAST

1

2

3

4

5

6

7

8

3

12003

FIGURE 6. THREE–STAGE MAST

1. OUTER WELDMENT
2. INTERMEDIATE WELDMENT
3. INNER WELDMENT
4. FREE–LIFT CYLINDER
5. MAIN LIFT CYLINDER (2)
6. LOWERING CONTROL VALVE, EXTERNAL
7. MAIN LIFT CHAINS (2)
8. FREE–LIFT CHAIN
9. CLAMP, MAIN LIFT CYLINDER (2)

10. CLAMP, FREE–LIFT CYLINDER

11. SHEAVE, MAIN LIFT CHAIN (2)

12. SHEAVE, FREE–LIFT CHAIN (2)

1

2

3

4

5

6

7

8

9

10

11

12

5

8

5. Slide the inner weldment half–way out of the outer

weldment. Connect a crane to the center of the inner

weldment. See Figure 4. Slide the inner weldment out of

the outer weldment until the stub shafts are in the

notches of the intermediate weldment. Remove the

inner weldment from the intermediate weldment.

6. Remove the snap rings and washers from the top of

each lift cylinder. Remove the cylinder clamps near the

top of each lift cylinder. Each cylinder clamp is fastened

to the top crossmember of the inner mast by two

capscrews and washers.

7. Push the intermediate weldment to disengage the lift

cylinders. Remove the lift cylinders.

8. Slide the intermediate weldment from the bottom of

the outer weldment as far as possible. Remove the load

rollers. Make a note of the shim arrangement. The shim

arrangement will be similar during the assembly

procedure.

9. Slide the intermediate weldment half–way out of the

top of the outer weldment. Connect a crane to the center

of the intermediate weldment. See FIGURE 4. Slide the

intermediate weldment out of the outer weldment until

the stub shafts are in the notches of the outer weldment.

Remove the intermediate weldment from the outer

weldment.

10. Remove and disassemble the sheaves and strip

bearings as necessary for repair and cleaning. Make a

note of the shim arrangement under the strip bearings.

This shim arrangement will be used during assembly.

Remove the hydraulic lines and fittings from the

weldments as necessary.

CLEANING AND INSPECTION

1. Inspect the sheaves and load rollers for wear or

damage. DO NOT use steam to clean the lift chains,

sheaves or load rollers. The bearings in the sheaves and

load rollers are sealed and lubricated.

FIGURE 7. CHECKING THE LIFT CHAINS

1. WORN PIN
2. CRACKS
3. EDGE WEAR
4. HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. RUST
8. WEAR SCALE FOR CHAIN

6705

1

5

6

7

Total length of
20 links(pitch)

of new chain

WEAR LIMIT

The maximum

length of 20

links

(inch)

mm

(inch)

mm

(inch)

mm

12.7
15.9
19.1
25.4
31.8

(0.50)

(0.625)

(0.75)
(1.00)
(1.25)

254.0
317.5
381.0
508.0
635.0

(10.0)
(12.5)
(15.0)
(20.0)
(25.0)

261.6
327.0
392.4

523.25

654.1

(10.3)

(12.88)
(15.45)

(20.6)

(25.75)

2

3

4

8

pitch

9

WARNING

Commercial cleaning solvents may be flammable
and toxic, and can cause severe skin irritation. When
using commercial cleaning solvents, always comply
with the solvent manufacturer’s recommended
safety precautions.

2. Clean the lift chains with solvent. Inspect the lift
chains for wear or damage. See FIGURE 7. A lift chain
becomes longer as it wears. If a chain is 3% longer than a
new lift chain, the lift chain must be replaced. If a chain
scale is available, check the lift chain as shown in
FIGURE 7. If a chain scale is not available, measure 20
links of the lift chain. Compare the measurements with
the lengths given in FIGURE 7.. Lubricate the chains
with SAE 30 motor oil.

WARNING

Never replace the worn section of a chain. Replace
the complete chain. Never replace one chain of a
chain pair. Replace both chains.

3. Inspect the chain anchors and pins. Replace any parts
that are worn or damaged.

WARNING

Be careful when cleaning with steam. Steam can
cause serious burns. Wear protective clothing and
gloves. Never expose your skin to steam.

4. Clean the mast weldments with steam or solvent.

5. Inspect the sliding and rolling surfaces for damage.
Inspect all welds for cracks.

WARNING

DO NOT weld mast assemblies. Get information
from your Hyster dealer before welding on any mast
assembly.

ASSEMBLY

Two–Stage And Free–Lift Mast
(See FIGURE 3. and FIGURE 5.)

NOTE: The shims for the load rollers keep the
weldments parallel and give correct clearance during
their movement. The arrangement of the shims during
assembly will be similar to the arrangement before
disassembly. Check the clearance and adjust the shims.
The strip bearings are also adjusted by using shims. The
strip bearings must be adjusted before the weldments
are assembled. Access to the strip bearings for
adjustments are not possible after the weldments are
assembled. See Checks and Adjustments in this section
for the instructions to make the necessary adjustments.

1. Connect a crane to the center of the inner weldment.
Fit the stub shafts through the notches in the outer
weldment. Slide the inner weldment into the outer
weldment so that the stub shafts are seen at the top and
bottom of the weldments.

2. Install the strip bearings and the shims on the outer
weldment. Apply grease to the surfaces of the strip
bearings. See FIGURE 21.

3. Install the load rollers and shims on both weldments.
Check the clearance of the load rollers and strip bearings
as described in Checks and Adjustments.

4. Install the main lift cylinders to the mounts at the base
of the outer channel of the mast. The base of the main lift
cylinders have a tab in the casting which fits into a notch
in the mount. Push the inner weldment to engage the
rods of the lift cylinders at the top crossmember. Install
the washers and snap rings at the top of the lift cylinders.
Install the cylinder clamps near the top of each cylinder.
Fasten the clamps to the top crossmember of the outer
weldment with the capscrews and washers.

10

Two–Stage Mast (See FIGURE 3. )

1. Install the lowering control valve on the outer
weldment. Connect the hydraulic lines and fittings
between the lowering control valve and the lift
cylinders.

2. Install the chain sheaves and brackets. Connect the lift
chains to the chain anchors on the inner weldment.
Attach wires between the ends of the lift chains and the
crossmember so that the lift chains can be controlled
during the installation procedure.

Free–Lift Mast (See FIGURE 5.)

1. Install the free–lift cylinder in the inner weldment.
Install the spacers, washers, nuts and bolts at the lift
cylinder mounts. Install the chain sheave and brackets to
the lift cylinder rod.

2. Install the tubes and fittings at the top and bottom of
the main lift cylinders. Install the lowering control
valve. Install the hydraulic fitting in the end of the rod of
the left main cylinder. Install the tube between the top of
the main lift cylinders and the base of the free–lift
cylinder.

3. Install the lift chain to the free–lift cylinder. Attach a
wire between the end of the lift chain and the bottom of
the mast so that the lift chain can be controlled during
the installation procedure.

Three–Stage Mast (See FIGURE 6.)

1. Put the outer weldment on the floor with the back of
the mast toward the floor. Install the strip bearings and
the shims on the channels of the outer weldment. See
FIGURE 21. Apply grease to the surfaces of the strip
bearings.

2. Connect a crane to the center of the intermediate
weldment. Fit the lower stub shafts of the intermediate
weldment into the notches in the top of the outer
weldment. Slide the intermediate weldment into the
outer weldment so that the stub shafts are seen at the top
and bottom of both weldments.

3. Install the load rollers and the shims on the outer and
intermediate weldments. Install the chain sheaves.

Before the next step, adjust the intermediate weldment
as described in Checks and Adjustments.

4. Install the main lift cylinders to the mounts at the base
of the outer mast weldment. The base of the main lift
cylinders have a tab in the casting which fits into a notch
in the mount. Push the intermediate weldment to engage
the rods of the lift cylinders at the top crossmember.
Install the washers and snap rings at the top of the lift
cylinders. Install the cylinder clamps near the top of
each cylinder. Fasten the clamps to the top crossmember
of the outer mast with the capscrews and washers.

5. Install the strip bearings and the shims on the channels
of the intermediate weldment. Apply grease to the
surfaces of the strip bearings. Connect a crane to the
center of the inner weldment. Slide the inner weldment
into the intermediate weldment so that the stub shafts
are seen at the top and bottom of both weldments.

6. Install the load rollers and the shims on the
intermediate and inner weldments. Before the next step,
adjust the inner weldment according to the steps
described in Checks and Adjustments.

7. Install the lift chains. Use new cotter pins when
installing the chain anchors.

8. Install the free–lift cylinder in the inner weldment.
Install the spacers, washers, nuts and bolts at the lift
cylinder mounts. Install the chain sheave and brackets to
the lift cylinder rod. Install the sheave for the hydraulic
hose to the free–lift cylinder.

9. Install the lowering control valve to the outer
weldment. Install the tube between the lowering control
valve and the top of the outer weldment. Install the tubes
to the main lift cylinders and the lowering control valve.
Install the tube at the base of the free–lift cylinder.
Install the hydraulic hose from the free–lift cylinder to
the top of the outer weldment. Check that the hose is on
the hose sheave.

10. Install the lift chain to the free–lift cylinder. Attach a
wire between the end of the chain and the bottom of the
mast to control the lift chain during installation.

11

INSTALLATION (See FIGURE 2.)

1. Connect a crane to the top of the mast assembly.
Fasten all of the weldments of the mast together. Check
that the chains do not damage any of the hydraulic lines
or other parts.

2. Raise the mast assembly to a vertical position. Move
the mast assembly into position on the lift truck.

3. Move the mast at an angle toward the mast mounts on
the lift truck. Carefully slide one of the stub shafts on the
mast into the hole for the bearing in one of the mast
mounts. Rotate the mast toward the lift truck so that the
opposite stub shaft enters the opposite mast mount.

4. Hold the mast in the centered position. Push the
bearings onto the stub shafts of the mast mounts. Install
the capscrews, washers and nuts. Tighten the capscrews
so that the bearings are pulled into the mast mounts.
Tighten the capscrews to 51 N.m (38 lbf ft).

5. Connect the hydraulic line to the mast assembly.
Connect the brake line at the bottom of the cowl.

6. Install the parking brake cables and connect them to
the lever assembly on the cowl. If the parking brake
needs adjustment, see PERIODIC MAINTENANCE,
8000 SRM 370 for the adjustment procedure.

WARNING

Do not use your fingers to align the tilt cylinder
bearing. Unexpected movement of the mast or tilt
cylinder may cause injury. Use a drift.

7. Install the rod end of the tilt cylinder to the mount on
the base of the mast. Use a short drift with a chamfer to
align the bearing. Install the pin through the rod end and
bearing. Install the snap rings at each end of the pin to
fasten the pin to the rod end.

WARNING

Never allow anyone under a raised carriage. Do not
put any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.

8. Adjust the lift chains, carriage and tilt cylinder as
described in Checks and Adjustments.

12

LIFT CYLINDERS

DESCRIPTION (See FIGURE 8.)

All lift cylinders are single–action hydraulic cylinders.
The hydraulic force is applied only in one direction.
When hydraulic oil enters one end of the cylinder, the
hydraulic force extends the rod. When the force is
removed, the weight of the carriage and inner mast
channels cause the rod to retract.

The most common maintenance problem is the repair of
oil leaks. If the bore of the shell of the lift cylinder is
damaged and cannot be repaired completely, the lift
cylinder must be replaced.

VISTA



two–stage masts have two main lift cylinders.

(See FIGURE 8.) The free–lift mast has two main lift
cylinders and a shorter free–lift cylinder. (See
FIGURE 9. and FIGURE 10.) The three–stage mast has
two main lift cylinders and a free–lift cylinder. (See
FIGURE 12.)

Spacers are used in some cylinders to limit the stroke of
the rod. Worn spacers must be replaced with the same
size spacer.

The main lift cylinders are displacement cylinders. A
displacement cylinder does not have a piston nor a

piston seal. The rod diameter is almost the same
diameter as the inside diameter of the cylinder shell.
There are wear rings on the rod that are the bearings
between the rod and the cylinder shell. The wiper seal at
the top of the cylinder is also the high pressure seal for
these cylinders. The lift cylinders use a single lip seal
assembly to prevent hydraulic oil leaks past the piston
and past the retainer, or rod end of the cylinders.

The free–lift cylinder has a single lip seal on the piston
to prevent hydraulic oil leaks past the piston and
retainer. The rod is a smaller diameter than the piston.

During operation, some hydraulic oil will leak past the
piston area to the rod end of the lift cylinder. Small leaks
are permitted if the internal leak rate of the hydraulic
system is not greater than the specification. An internal
check valve is installed in the piston of the free–lift
cylinders. When the rod extends, the pressure increases
more quickly on any oil in the rod end of the cylinder.
The hydraulic oil transfers through the check valve to
the piston end of the free–lift cylinder. This action
prevents hydraulic damage to the single lip seal and the
wiper ring. See FIGURE 11.

12018

FIGURE 8. MAIN LIFT CYLINDER

1. CYLINDER BASE
2. WIRE RETAINER
3. BACK–UP RING
4. O–RING
5. GUIDE RING
6. SNAP RING
7. ROD

8. SHELL
9. WEAR RING

10. CAPSCREW

11. WASHER

12. SINGLE LIP SEAL
13. BACK–UP RING
14. WIPER RING

1

2

3 4

5

6

7

8

9

10

11

12 13

14

13

12019

FIGURE 9. MAIN LIFT CYLINDERS, FREE–LIFT MAST

1. CYLINDER BASE
2. WIRE RETAINER
3. O–RING
4. BACK–UP RING
5. BEARING, INNER RING
6.SNAP RING

7. GUIDE RING
8. SNAP RING
9. SHELL

10. ROD

11. WEAR RING

12. CAPSCREW

13. WASHER
14. SINGLE LIP SEAL
15. BACK–UP RING
16. WIPER RING
17. O–RING
18. ROD END

RIGHT–HAND CYLINDER

LEFT–HAND CYLINDER

10

11

1

2

3

4

5 6 7

8

9

10

11

12
13

14 15 16

1

2

3

4

5 6 7

8

9

12
13

14151617

18

12020

FIGURE 10. FREE–LIFT CYLINDER (FREE–LIFT AND THREE–STAGE MASTS)

1. CHECK VALVE
2. WEAR RING
3. SINGLE LIP SEAL
4. BACK–UP RING
5. O–RING
6.SPACER
7.ROD

8. SHELL
9. WEAR RING

10. O–RING

11. RETAINER

12. SINGLE LIP SEAL
13. BACK–UP RING
14. WIPER RING

1

2

3

4

5

6

7

8

9 10 11 12

13

14

14

12021

6029

1. PISTON AND ROD ASSEMBLY
2. CHECK VALVE
3. O–RING
4. INLET AND OUTLET PORT
5. SINGLE LIP SEAL
6. O–RING
7. BACK–UP RING

FIGURE 11. INTERNAL CHECK VALVE AND

SINGLE LIP SEAL

1

2 3

4

5

6

7

5

INSTALLED

NOT INSTALLED

A lowering control valve is installed in the hydraulic
line to the bases of the lift cylinders. The lowering
control valve permits easy entry of hydraulic oil into the
cylinders, but gives a restriction when the rods retract.
This restriction controls the maximum speed at which a
load on the forks can be lowered. The lowering control
valve limits the speed at which the forks lower if a
hydraulic hose breaks.

LOWERING CONTROL VALVE
(See FIGURE 13.)

The lowering control valve includes the following parts:
(1) valve body, (2) spring, (3) washer, (4) cylinder, (5)
orifice sleeve, (6) plunger and (7) main sleeve. The
orifice sleeve position is controlled by oil flow. The
plunger position is controlled by oil pressure and spring
tension. During lifting, oil entering the cylinder goes
through the center of the main sleeve to the large holes.
The oil continues between the plunger and bore to move
the orifice sleeve to the end of the plunger. The flange of
the orifice sleeve is then aligned with the large part of the
bore in the body. This alignment lets the oil flow around
the orifice sleeve to the inlet port of the cylinder

12022

1. CYLINDER BASE
2. WIRE RETAINER
3. O–RING
4. BACK–UP RING
5. BEARING, INNER RACE
6. SNAP RING
7. GUIDE RING
8. SNAP RING

FIGURE 12. MAIN LIFT CYLINDER (THREE–STAGE MAST)

9. SHELL

10. ROD

11. WEAR RING

12. CAPSCREW
13. WASHER
14. SINGLE LIP SEAL
15. BACK–UP RING
16. WIPER RING, LOWERING CONTROL VALVE

1

2

3

4

5 6

7

8

9

10

11

12
13 1415

16

15

FIGURE 13. LOWERING CONTROL VALVE

1. VALVE BODY
2. SPRING
3. WASHER
4. CYLINDER
5. ORIFICE SLEEVE
6. PLUNGER
7. MAIN SLEEVE

LIFTING

LOWERING

1

2 3

4

5

6

7

During the lowering operation, oil from the cylinder
moves the orifice sleeve. The sleeve moves away from
the larger area of the bore in the valve body. This
movement makes a restriction to the oil flow. When the
pressure increases, the plunger begins to move against
the spring. The movement begins to close the openings
of the large holes in the main sleeve. Additional pressure
will push the plunger against the main sleeve to close the
large holes completely. All the oil must go through the
small holes to the center of the main sleeve. This
restriction permits the cylinder rod to lower only at a
maximum controlled speed.

REMOVAL OF THE LIFT CYLINDERS
WITHOUT REMOVING THE MAST

WARNING

Lower the mast and carriage completely. Push the
lift/lower control lever forward to make sure there is
no movement in the mast. Make sure that all parts of
the mast that move are fully lowered. See the
SAFETY PROCEDURES WHEN WORKING
NEAR THE MAST at the front of this section.

Remove the carriage before removing the lift cylinder.
See the procedure described in the MAST section. If the

mast assembly must be removed for repairs, then
remove the lift cylinders when the mast assembly is
disassembled. When only the lift cylinders must be
removed for repairs, then remove the lift cylinders from
the mast as described in the following paragraphs:

1. Clean the area around the hydraulic fittings for the lift
cylinders. Disconnect the fittings at the lift cylinders
and put caps on the open lines.

2. On the free–lift mast, remove the capscrews, washers
and cylinder clamp from the mount for the free–lift
cylinder. Remove the free–lift cylinder.

3. Remove the snap rings and washers from the top of
each main lift cylinder. Remove the cylinder clamps
near the top of each lift cylinder. Each cylinder clamp is
fastened to the top crossmember of the inner mast by
two capscrews and washers.

4. Support the cylinder. Connect a crane to the top of the
inner weldment using chains. Raise the inner weldment
from the outer weldment approximately 30 cm (12 in).
Disengage the rod ends of lift cylinders from the top
crossmember of the inner weldment. Remove the lift
cylinders from the mount plates at the bottom of the
outer weldment.

16

DISASSEMBLY

CAUTION

Carefully disassemble and assemble the lift
cylinders so that the rods and sliding surfaces are not
damaged.

NOTE: Disassembly of the main lift cylinders and the
free–lift cylinder is similar. The free–lift cylinder is
disassembled from the end of the cylinder shell with the
rod, and the main lift cylinders are disassembled from
the base of the shell.

Main Lift Cylinders
(See FIGURE 8., FIGURE 9., and FIGURE 12.)

1. Loosen the cylinder base with a wrench. Disconnect
the cylinder base from the shell.

2. Carefully slide the rod assembly from the shell. Drain
the hydraulic oil into a container.

3. Remove and discard the O–rings, seals, and bearings.

4. Clean all parts. Check the sliding surfaces for
damage. Repair or replace any damaged parts.

Free–Lift Cylinder
(See FIGURE 10.)

1. Loosen the retainer with a spanner. Disconnect the
retainer from the shell.

2. Remove the protective cap from the inlet and slide the
rod assembly from the shell. Drain the hydraulic oil into
a container.

3. Remove the retainer from the rod. Remove and
discard the O–rings, seals, and bearings.

4. Remove the internal check valve from the cylinder
base.

5. Clean all the parts. Check the sliding surfaces for
damage. Repair or replace any damaged parts.

ASSEMBLY

NOTE: Lubricate all internal parts of the cylinder with
hydraulic oil during assembly.

Use new O–rings, seals and bearings. Apply lubricant
(hydraulic oil) during assembly. Packing lubricant (Part
Number 186061) is also available.

Make sure the single lip seal assemblies are installed
with the O–ring towards the base of the cylinder. (See
FIGURE 8.)

CAUTION

A difficult and important step in assembling
cylinders is the correct installation of the seals. Most
cylinder maintenance is caused by seal leaks. Special
tools are available from Hyster Parts and Service.
See Parts–Service Gram L–A–2 (Latest Revision)
for the available tools.

Main Lift Cylinders
(See FIGURE 8., FIGURE 9., and FIGURE 12.)

1. If a guide ring and bearing is used, install them on the
piston.

2. Install the wear ring, single lip seal, back–up ring and
wiper ring onto the piston assembly. Use shim material
and a clamp as a guide to move the single–lip seal over
the threads of the shell.

3. Carefully push the piston and the rod into the shell.
Release the clamp on the seal when the seal travels over
the threads of the shell.

4. Install the seal, O–ring, wear ring and wiper ring in the
retainer. For wiper seals that have a spring, the spring
must be towards the base of the cylinder.

5. Carefully install the retainer on the rod.

6. Engage the threads and tighten the retainer in the shell
until it is tight. Use a correct spanner. Do not hit the
retainer with a hammer and driver.

7. Install the lowering control valve. Make sure the
special washer and the spring are installed correctly. A
wrong installation can cause the load to lower too fast.
See FIGURE 13.

Free–Lift Cylinders
(See FIGURE 10. and FIGURE 11.)

1. Install the internal check valve. Make sure the arrow
on the internal check valve is towards the base of the
piston.

2. Install the wear ring, single lip seal and back–up ring
onto the piston assembly. If a spacer sleeve is used,
install it. Use shim material and a clamp as a guide to
move the single–lip seal over the threads of the shell.

3. Carefully push piston and rod into the shell. Release
the clamp on the seal when the seal travels past the
threads of the shell.

17

4. Install the seal, O–ring, wear ring and wiper ring in the
retainer. For wiper seals that have a spring, the spring
must be towards the base of the cylinder.

5. Carefully install the retainer on the rod.

6. Engage the threads and tighten the retainer in the shell
until it is tight. Use a correct spanner. Do not hit the
retainer with a hammer and driver.

7. Install the lowering control valve. Make sure the
special washer and the spring are installed correctly. A
wrong installation can cause the load to lower too fast.
See FIGURE 13.

INSTALLATION OF THE LIFT CYLINDERS
INTO THE MASTS

NOTE: Connect a crane to the top of the inner
weldment (and intermediate weldment, if it is a 3–stage
mast) using chains. If it is a 3–stage mast, make sure that
both weldments are fastened together. Make sure that
the chains will not damage the sheaves, tubing or other
parts of the mast. The crane must have a capacity of at
least 1,000 kg (2,200 lb).

Main Lift Cylinders

1. Install the main lift cylinders to the mounts at the base
of the outer mast weldment. The base of the main lift
cylinders have a lug in the casting which fits into a notch
in the mount. Use a crane and lower the inner weldment
to engage the rods of the lift cylinders to the holes in the
top crossmember of the inner channel. Install the
washers and snap rings at the top of the lift cylinders.
Install the cylinder clamps near the top of each cylinder.
Fasten the clamps to the top crossmember of the outer
mast with the capscrews and washers.

2. Install the lowering control valve on the outer
weldment. Connect the hydraulic lines and fittings
between the lowering control valve and the lift
cylinders.

3. Install the chain sheaves and brackets. Connect the lift
chains to the chain anchors on the inner weldment.
Fasten wires between the ends of the lift chains so that
they can be controlled during installation of the
carriage.

4. Install the carriage. Connect the lift chains.

Free–Lift Cylinder

1. When the inner channel is lowered, install the
free–lift cylinder in the inner weldment. A pin in the
base of the cylinder will fit into the cylinder mount at the
base of the inner channel. Fasten the upper end of the
cylinder to the center crossmember with the bracket,
washers and capscrews. Install the chain sheave and
brackets to the top of the lift cylinder rod.

2. Install the tubes and fittings at the bottom of the main
lift cylinders. Install the lowering control valve. Install
the hydraulic fitting in the end of the rod at the top of the
left main cylinder. Install the tube between the top of the
main lift cylinder and the base of the free–lift cylinder.

3. Install the carriage. Install the lift chain.

12015

1. TILT ANCHOR PLATE, LIFT TRUCK
2. CYLINDER BASE
3. TILT CYLINDER
4. CLEVIS, ROD END
5. TILT PLATE, MAST

FIGURE 14. TILT CYLINDER INSTALLATION

1

2

3

4

5

(NEW MODEL SHOWN)

TILT CYLINDER

DESCRIPTION

The tilt cylinder moves the mast forward and backward.
When the cylinder rod moves the mast for the tilt
forward function, hydraulic oil enters the tilt cylinder
through the port at the rod end of the piston. The oil
pressure pushes the piston and causes the rod to retract
in the cylinder. Hydraulic oil in the piston end of the
cylinder returns to the hydraulic tank. When the
cylinder rod moves the mast for the tilt backward
function, the hydraulic oil enters the port at the piston

18

end of the tilt cylinder. The oil pressure pushes the
cylinder and causes the rod to extend. The hydraulic oil
in the rod end of the tilt cylinder returns to the hydraulic
tank.

REMOVAL
(See FIGURE 2. and FIGURE 14.)

WARNING

Before disconnecting the tilt cylinder, tilt the mast
forward. Use a chain to hold the mast to the frame,
and prevent the bottom of the mast from rolling
forward.

1. Disconnect the hydraulic lines at the tilt cylinder.
Install caps on the hydraulic lines and ports.

WARNING

Use a driver, not your fingers, to push the anchor
pins from the clevises on the tilt cylinders. The
cylinder or mast can move and cause serious injury.

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

2. Remove the cotter keys (snap rings on older models)
from the anchor pins at the base of the cylinder and at the
clevis on the end of the rod. Push the anchor pins out of
the clevis and the base of the cylinder with a tool.

DISASSEMBLY (See FIGURE 15.)

1. Put the tilt cylinder in a vise with soft jaws. Remove
the rod clevis from the rod.

2. Remove the end cap from the tilt cylinder. Remove
the rod and piston from the cylinder.

3. Disassemble the tilt cylinder as necessary.

CLEANING

WARNING

Commercial cleaning solvents may be flammable
and toxic, and can cause severe skin irritation. When
using commercial cleaning solvents, always comply
with the solvent manufacturer’s recommended
safety precautions.

Clean all parts in solvent and dry with compressed air.

ASSEMBLY (See FIGURE 15.)

NOTE: Always use new seals and O–rings. Make sure
all parts are clean. Lubricate all parts with hydraulic oil
during assembly.

INSTALLATION
(See FIGURE 2. and FIGURE 14.)

1. Attach the base of the tilt cylinder to the tilt amchor
plate on the frame of the lift truck. Carefully install the
pin through the bearing in the tilt plate. This bearing
must be aligned so that the pin will be installed without
damaging the bearing. Install the snap rings on the pin.

WARNING

Do not use your fingers to align the tilt cylinder
bearing. Unexpected movement of the mast or tilt
cylinder may cause injury. Use a drift.

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

2. Install the clevis of the cylinder rod to the tilt plate on
the mast. Carefully install the pin through the clevis and
the bearing in the tilt plate. Install the cotter key through
the pin (snap rings on older models).

3 . Connect the hydraulic lines to the tilt cylinder.

4. Operate the tilt cylinders. Check for correct operation
and possible leaks. See CHECKS AND
ADJUSTMENTS for alignment of the tilt angle, and
cylinder leak checks.

1

19

12023

4. BACK–UP RING
5. O–RING
6. ROD AND PISTON

FIGURE 15. TILT CYLINDER

7. SHELL
8. PISTON SEAL
9. GUIDE RING

1. WIPER
2. END CAP
3. ROD SEAL

1

2 3

4

5

6

7

8

9

1

7

2

3

4 5

6

8

9

SIDE–SHIFT CARRIAGE
(See FIGURE 16.)

NOTE: See the MAIN CONTROL VALVE in the
HYDRAULIC SYSTEM section for information on the
control valve linkage for the side–shift carriage.

Removal (Early Models)

1. Remove the forks.

2. Connect a crane to the top bar of the sliding weldment.

3. Disconnect the hydraulic lines at the side–shift
cylinder. Put caps onto the open lines and fittings.
Remove the anchor pins and cotter pins from the
side–shift cylinder. Remove the side–shift cylinder.

4. Remove the two carriage hooks at the bottom of the
sliding weldment.

5. Lift the sliding weldment from the carriage. Remove
the bearings at the top of the carriage.

Removal (Late Models)

WARNING

Do not disassemble the sliding weldment until the
sliding weldment assembly has been removed from
the standard carriage. Place the sliding weldment
assembly flat on the floor and then remove the
bottom assembly capscrews.

1. Remove the forks.

2. Connect a crane to the lifting eye on the top
weldment.

3. Remove the top two capscrews from the lower
weldment.

4. Loosen the two lower capscrews to allow the lower
weldment to drop below the standard carriage.

5. Lift the side–shift carriage assembly from the
standard carriage. Remove the strip bearings at the top
and bottom of the carriage.

6. Disconnect the hydraulic lines at the side–shift
cylinder. Put caps onto the open lines and fittings.

7. Lift the mounting plate from the standard carriage.

Repairs (Early Models)
See FIGURE 16. and FIGURE 17.)

The only item in the side–shift carriage that normally
needs repairs is the side–shift cylinder.

1. Remove the snap–ring from the retainer. Remove the
retainer ring.

2. Pull the rod and piston assembly from the shell.
Replace any seals, O–rings or back–up rings as
necessary.

3. Lubricate all parts with clean hydraulic oil. Tighten
the nut for the piston to 122 to 135 N.m (90 to 100 lbf ft).
Install the retainer, piston and rod assembly in the shell.

4. Install the retainer ring and snap–ring.

20

Repairs (Late Models)
(See FIGURE 16. and FIGURE 17.)

The only item in the side–shift carriage that normally
needs repairs is the side–shift cylinder.

1. Remove both end caps.

2. Pull the rod assembly from the shell. Replace any
seals, O–rings, or back–up rings as necessary.

3. Lubricate all parts with clean hydraulic oil. Install the
rod assembly into the shell.

4. Apply Loctite 242 to the threads of the end caps and
install the end caps. Tighten the end–caps to 27 N.m (20
lbf ft).

Installation (Early Models)

1. Install the bearings on the carriage. Lubricate the
bearings with muli–purpose grease.

2. Use a crane and install the carriage apron on the
carriage.

3. Install the two carriage hooks at the bottom of the
carriage apron. Check the clearance between the
carriage hook and the carriage. (See FIGURE 16.) If the
clearance is more than 4.0 mm (0.16 in), remove the
hooks and install them to the higher mounting position
in the carriage apron. Tighten the capscrews to 165 N.m
(122 lbf ft).

4. Install the side–shift cylinder in position. Install the
anchor pins and cotter pins. Connect the hydraulic lines
to the cylinder.

5. Install the forks.

Installation (Late Models)

NOTE: See the CHECKS AND ADJUSTMENTS
section for the side–shift cylinder shim procedure.

1. Apply multi–purpose grease to the ends of the
side–shift cylinder rods. Put mounting bracket onto the
standard carriage. Be certain that the locating tab under
the bracket engages the center notch on the standard
carriage.

2. Connect the hydraulic lines to the cylinder.

3. Install the upper strip bearing onto the standard
carriage. Lubricate the outer surface of the bearing with
muli–purpose grease.

4. Loosen the two lower sliding weldment capscrews to
allow the lower weldment to drop below the standard
carriage.

5. Install the lower strip bearing into the lower
weldment. Lubricate the inner surface of the bearing
with muli–purpose grease.

6. Use a crane and install the side–shift carriage
assembly onto the standard carriage.

7. Move the lower carriage weldment into place until the
top assembly capscrews can be installed. Install the top
capscrews

8. Tighten the four assembly capscrews to 435 N.m (320
lbf ft).

9. Install the forks.

21

10

1. CARRIAGE
2. SIDE–SHIFTCARRIAGE-

WELDMENT

3. ANCHOR PIN
4. CARRIAGE HOOK
5. BEARING
6. SIDE–SHIFT CYLINDER
7. ADJUSTMENT HOLES
8. TOP SLIDING WELDMENT

FIGURE 16. SIDE–SHIFT CARRIAGE

1

2

3

4

5

6

7

3

LATE MODELS

EARLY MODELS

6

9. BOTTOM SLIDING WELDMENT

10. TOP STRIP BEARING

11. BOTTOM STRIP BEARING

12. SHIM
13. ASSEMBLY CAPSCREW
14. MOUNTING PLATE
15. LIFTING EYE

8

9

10

11

12

13

14

15

22

12024

1. SHELL
2. NUT
3. ROD SEAL
4. BACK–UP RING
5. PISTON
6. ROD

FIGURE 17. SIDE–SHIFT CYLINDER

7. O–RING
8. BACK–UP RING
9. RETAINER

10. RETAINER

11. SNAP–RING

12. WIPER RING
13. ROD ASSEMBLY
14. SEAL
15. END–CAP

1

2

3 4 5

6

7 8

9

10 11

12

EARLY MODELS

LATE MODELS

1

3

7

8

12

13

14

15

CHECKS AND ADJUSTMENTS

CHECK FOR LEAKS IN THE LIFT AND
TILT SYSTEM

WARNING

Before working on or near the mast, read SAFETY
PROCEDURES WHEN WORKING NEAR THE
MAST.

Never allow anyone under a raised carriage. Do not
put any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the key switch is “OFF.”

Do not try to find hydraulic leaks by putting your
hand on hydraulic components under pressure.

Hydraulic oil can be injected into the body by the
pressure.

During the test procedures for the hydraulic system,
fasten the load to the carriage with chains to prevent
it from falling. Keep all personnel away from the lift
truck during the tests.

Check The Lift Cylinders For Leaks

1. Operate the hydraulic system. Put a capacity load on
the forks and raise and lower the load several times.
Lower the load and tilt the mast forward and backward
several times. Check for leaks.

2. Raise the carriage and the load until all the weldments
are extended. If the carriage lowers slowly with the

23

control valve in a neutral position, there are leaks inside
the hydraulic system. The maximum speed that the
carriage can be lowered when inside leaks are present in
the lift system is 50 mm (2 in) per 10 minutes. This
maximum speed occurs when the hydraulic oil is 30

°

C

(90

°

F). If the oil temperature is 70

°

C (160

°

F), the

maximum speed that the carriage can lower is 150 mm
(6 in) per 10 minutes.

3. Check the lift cylinder for internal leaks. Remove the
load from the forks. Install a gate valve in the supply line
between the main control valve and the lift cylinder. Put
a capacity load on the forks again. Raise the carriage
until all the weldments are extended. Close the gate
valve. If the carriage or mast weldments lower slowly,
the seals in the lift cylinders have leaks.

4. If the mast does not move, slowly open the valve and
check for movement again. If the mast moves down with
the valve open, check for leaks in the hydraulic lines or
fittings. If no leaks are found, the main control valve
could be damaged. Remove the load from the forks.

Check The Tilt Cylinders For Leaks

1. Put a capacity load on the forks. Slowly tilt the mast
forward. If the mast continues to slowly tilt forward
with the control valve in a neutral position, there are
leaks inside the hydraulic system. The maximum speed
that the mast can tilt forward when internal leaks are
present in the lift system is 13 mm (0.50 in) per 10
minutes (measured at the tilt cylinder). [If this speed is
measured between the overhead guard and the top
crossmember of the mast, the maximum speed is 23 mm
(0.90 in) per 10 minutes.] This maximum speed is
measured when the hydraulic oil is 30

°

C (90

°

F). If the

oil temperature is 70

°

C (160

°

F), the maximum speed

will increase to three times the value shown at the lower
temperature.

2. If the leak rate is greater than the specification,
remove the load from the mast. Install a valve between
the port at the rear of the tilt cylinder and the hydraulic
line. Put the load on the forks again. Close the valve. If
the mast tilts slowly forward, the cylinder seals are
leaking.

3. If the mast does not move, open the valve and check
for movement again. If the mast moves forward with the
valve open, check for leaks in the hydraulic lines or

fittings. If no leaks are found, the main control valve
could be damaged. Remove the load from the forks.

ADJUSTMENT OF THE TILT CYLINDER
STROKE AND THE BACKWARD TILT
ANGLE (See FIGURE 18.)

1. Adjust the rod end for the tilt cylinder as shown in
FIGURE 18. Tilt the mast fully backward. Measure the
tilt angle (See Nameplate for tilt angles.) Adjust the tilt
cylinder for the correct tilt angle as follows:

a. Tighten or loosen the rod connector (clevis) on the
end of the cylinder rod as necessary to get the correct
tilt angle. This procedure will shorten or lengthen the
cylinder stroke as required.

b. After the cylinder stroke and the tilt angle are
adjusted, lock the rod end to the rod by tightening the
capscrew and nut.

WARNING

If a tilt limit spacer was installed, make sure it is
installed again during assembly.

DIMENSION “A” = 26.0 – 30.0 mm

(1.01 – 1.17 in)

12013

FIGURE 18. TILT CYLINDER ADJUSTMENTS

1. ROD ANCHOR
2. ANCHOR PIN
3. ROD CONNECTOR
4. ROD END

“A”

1

2

3

4

LIFT CHAIN ADJUSTMENTS
(See FIGURE 19.)

When the lift chains are correctly adjusted, the
following conditions will exist.

•

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 length of the chain will be correct.

24

•

The chains must travel freely through the complete cycle.

1. Put a 80 to 90% capacity load on the forks. Lower the
forks as much as possible. Tilt the mast fully backward.

2. Check that the carriage roller does not extend more
than 1/3 of the diameter of the roller below the inner
channel of the mast. If the rollers extend more than 1/3
of the diameter of the roller, adjust the chain anchors.
Check that each anchor is adjusted an equal amount.

CAUTION

The chain anchor must extend through the lock nut.
Check the chain adjustments periodically to make
sure that they are correct.

3. Remove the load from the forks. Check the clearance
of the carriage when the mast is fully extended. The
carriage stops must not touch the stop on the top
crossmember of the inner weldment. The chains are too
tight if the carriage touches the crossmember. Put the
mast in a vertical position and lower the carriage
completely. If the forks do not touch the surface, the
chains are too tight. If the chains are too tight, adjust the
chain anchors. Adjust each chain anchor the same
amount.

NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain
anchors are completely engaged. Make sure that all of
the adjustment is not removed from the chain anchors.

4. Three–stage mast chain adjustment: Adjust the main
lift chains so that the top of the inner weldment is the
same height as the top of the intermediate weldment.
The tops of both weldments must be within +–1.5 mm
(+–0.060 in). Adjust the free–lift chains as described in
step C.

MAST ADJUSTMENTS
(See FIGURE 20. and FIGURE 21.)

NOTE: Shims are installed on both sides of the load
roller. Do not add or remove shims from the stub shafts.
To change the position of the roller on the stub shaft,

move the shims from one side of the load roller to the
other.

During assembly, the arrangement of the shims will be
approximately the same as the arrangement used before
disassembly. Check the clearance and adjust the shims
as required to maintain the correct clearances.

1. The load rollers control the alignment of the mast
weldments. The alignment conditions are shown on a
following list with the most important condition first.
See FIGURE 20.

a. The mast weldments must be parallel to each other so that
wear will be reduced.

b. The maximum clearance between the load roller and the
channel at the tightest fit is 3.8 mm (0.15 in).

c. The number of shims behind two opposite load rollers
must be approximately the same. The inner weldment will
be approximately centered within the outer weldment.

2. Adjust the load rollers of the mast as follows:

a. Use a prybar to move the weldments from side to side to
measure the amount of movement. Repeat in a minimum of
three different positions of the weldments.

b. Separate the weldments and change the shim
arrangements as needed. Assemble the weldments. Slide the
weldment all the way to the top and bottom to find the
tightest fit.

c. Repeat steps 1 and 2 until there is zero clearance at the
point of tightest fit.

d. Measure the distance between the channels of the
weldments on the top and bottom. Change shims to keep the
distance equal between the top and bottom of the
weldments. Check that the weldments are parallel within 1.5
mm (0.060 in).

3. Check the adjustment of the strip bearings. The mast
must be disassembled to make adjustments to the strip
bearings. The adjustment of the strip bearings is
normally done during assembly of the mast. Insert
shims between the strip bearing and the mast weldment.
Adjust the strip 363445 bearings so that the maximum
clearance at the point of tightest fit is 0.8 mm (0.030 in).
See FIGURE 21.

25

12000

12004

FIGURE 19. LIFT CHAIN ADJUSTMENTS

1. CARRIAGE ROLLER
2. FORK
3. DO NOT PERMIT MORE THAN

1/3 OF CARRIAGE ROLLER TO
EXTEND BELOW THE MAST
CHANNEL

1

2

3

USE SHIMS TO KEEP CARRIAGE AND MAST WELDMENTS PARALLEL, TO GIVE APPROXIMATELY

EQUAL SPACE BETWEEN BOTH SIDES OF THE CARRIAGE AND THE WELDMENTS AND TO GIVE

THE CORRECT CLEARANCE AT THE TIGHTEST FIT.

4690

FIGURE 20. MAST ADJUSTMENTS

1. CHANNEL
2. LOAD ROLLER
3. STUB SHAFT
4. SNAP RING
5. SHIMS
6. PARALLEL

7. SHIM FOR ZERO

CLEARANCE AT TIGHT-
EST POINT OF FIT.
MAXIMUM CLEARANCE
IS 3.8 mm (0.15 in).

8. EQUAL SPACE

±

1.5 mm

(0.060 in)

9. PARALLEL

10. PLACE ALL SHIMS ON

OUTSIDE OF TOP LOAD
ROLLER UNDER SNAP
RING

10

1

2

3

4

5

6

7

8

9

8

2

5

TOP VIEW

MAST

FRONT VIEW

CARRIAGE

FRONT VIEW

7

26

CARRIAGE ADJUSTMENT

1. Install the load rollers on the carriage. Install the
shims for the rollers in the same sequence on the stub
shaft as before disassembly. Do not put any shims under
the top load rollers.

2. Use a crane to lift the carriage within the inner
channel. Find the tightest fit between the load rollers and
the inner channels.

3. Remove the carriage from the mast. Adjust the shim
arrangement for each roller for clearance between the
roller and the inner weldment. Adjust for zero clearance
at the tightest fit. Repeat steps B and C if necessary.

4. Keep the shim arrangement on each side of the
carriage approximately equal. The carriage must be

parallel with the inner mast channel within +–l.5 mm
(+–0.060 in).

5. After adjustment, lubricate the channels with a thin
layer of grease.

CAUTION

Too much grease will cause the rollers to slide and
wear flat areas on the rollers.

SIDE–SHIFT CYLINDER ADJUSTMENT
(LATE MODELS)

1. The clearance between the cylinder and the cylinder
mounting bracket should be 0 mm. to 0.60 mm (0.024
in). Install the shims on each side between the cylinder
mounting bracket and the cylinder. See

FIGURE 16.

12005

1. STRIP BEARING
2. LOAD ROLLER
3. WELDMENTS
4. SHIMS
5. O–RINGS

FIGURE 21. ADJUSTMENT OF THE STRIP BEARINGS

1

2

3

4

1

4

5

1

27

TROUBLESHOOTING

PROBLEM CAUSE

No movement of lift cylinders

Lift control linkage is damaged or disconnected.

No oil or not enough oil to the lift cylinders.

Hydraulic leaks, bad pump or pump drive,
relief valve set too low, bad check valve.

Slow action of lift cylinders

Not enough oil to lift cylinders.

Bad lift cylinder seals.

Lift cylinders have internal or external leaks.

Relief valve is set wrong at main control valve.

Rough movement of the mast assembly

Air in the hydraulic system.

Bent cylinder rod or damaged cylinder shell.

The lowering control valves do not operate correctly.

The tilt cylinder movement is slow

or is not smooth

There is not enough oil going to the tilt cylinder.

The seals in the tilt cylinder is worn or damaged.

There is a restriction in the hydraulic lines
of the tilt system.

There is air in the hydraulic system.

The tilt cylinder has internal damage.

The tilt cylinder permits mast movement

when the control lever is in the NEUTRAL

position.

There is leakage in the hydraulic lines of the tilt system.

The seals in the tilt cylinder is worn or damaged.

The main control valve is worn or damaged.

The tilt cylinder tilts the mast

forward or backward too slowly.

The main control valve is worn or damaged.

There is a leak in the hydraulic system.

The relief pressure at the main control valve
is not correct.

The mast assembly is damaged or not in alignment.