MASTS

REPAIR
 INTRODUCTION
GENERAL

REPAIRS
FORKS
CARRIAGE
Removal

.
.
Disassembly
.

Cleaning And Inspection

Assembly
INSTALLATION .

CHECKS AND ADJUSTMENTS

CONTENTS

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SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
Installation
MASTS
Removal .

CHECKING FOR LEAKS INTHE LIFT SYSTEM

ADJUSTING THE TILT CYLINDER STROKE
AND THE BACKWARD TILT ANGLE
LIFT CHAINADJUSTMENTS
MAST ADJUSTMENTS
Guide Shoe Adjustment
CARRIAGE ADJUSTMENT

TROUBLESHOOTING

This section is for the following models:

A66-80A, J40-60A, E30-60BC, P40-50A,
N30-50BA, E30-60B, P60-80A, S60-100B,
S60-120E, H110-150F, S125-150A, E60-100B,
H60-90C, S30-60ES, S30-50C, S40-50F, H30-60H,
_ H40-50J, H60JS, H60-110E_

©HYSTER COMPANY 1997

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 INTRODUCTION
GENERAL
This section has the instructions for the disassembly
and assembly of the masts for 1500 to 7000 kg (3000 to
15,000 lb) capacity lift trucks. This lift truck can be
equipped with the following types of masts:
a. Standard two stage
b. Two stage with full free-lift
c. Three stage with full free-lift
d. Four stage with full free-lift
REPAIRS
FORKS (SEE FIGURE 1)
The identification of a fork is how the fork is con¬
nected to the carriage. See FIGURE 1.
Hook forks are connected to the carriage by hooks and
locking pins. These pins fit through the top fork hooks
and into slots on the top carriage bar. The forks can be
removed from the carriage by aligning them with the
fork removal notch.
Pin forks are optionally available on some 1500 to
4500 kg (3000 to 10,000 lb) capacity lift trucks. Lift
trucks with 4500 to 7000 kg (10,000 to 15,000 lb) ca¬
pacity usually have pin forks. The forks can be re¬
moved by removing the keeper (5) and pin (3).
A WARNING
Do not try to remove the forks without using a lift¬
ing device.
CARRIAGE
Removal
1. Lower the carriage and forks on to blocks so that the
lift chains become loose.
The checks and adjustments are given at the end of this
section.
A WARNING
The crane, slings, and chains used to lift assemblies
in this section must have a minimum capacity of
2000 kg (4000 lb). An important exception follows
for lift trucks of 5000 to 7000 kg (11,000 to 15,000
lb) capacity. A three stage or four stage mast with
carriage and forks connected will have a weight of
more than 2000 kg (4000 lb). If a complete assembly
must be lifted, the lifting mechanism must have a
minimum capacity of 2500 kg (5000 lb).
A WARNING
When disconnecting the lift chains, keep control of
the ends. If the chains are not controlled, they will
run through the sheaves, fall from the top of the
mast and cause injury and damage.
2. Disconnect the lifting chains from the chain anchors
on the lift cylinder.
3. On lift trucks equipped with sideshift carriages, dis¬
connect the hydraulic lines at the carriage. Put a cap on
each open fitting.
4. Put a weight of more than 100 kg (200 lb) on the
fork tips. The weight must give the carriage stability so
that the carriage can not fall over when disconnected
from the masts.
5. Standard Masts
Use the hydraulic system and lift cylinder to raise the
inner mast. Carefully lift the inner channel until it is
above the load rollers of the carriage. If the hydraulic
system can not be used, do step 6. instead of step 5.
6. Connect the 2000 kg (4000 lb) capacity crane to the
top of the inner mast channel. Make sure the chain or
sling will not damage the sheaves or other parts of the
channel when lifting.
1
_ SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2) _
The following procedures must be used when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast. See the correct Service Manual sec¬
tion for the specific mast being repaired.
A WARNING
Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast or the carriage.
• Never put any part of the body Into or under the mast or carriage unless all parts are completely
lowered or a safety chain isinstalled. Also make sure that the power Is off and the key is removed.
Put a "DO NOT OPERATE" tag in the operator's compartment.
• careful of the forks. When the mast is raised, the forks can be at a height to cause an Injury.
Be
• 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 ran require removal of the mast or
carriage. Follow the repair procedures In the correct SERVICE MANUAL section 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- .TWO-STAGE
MAST
stage and free-lift mast, the moving part is the inner
weldment (2). On the three-stage mast it is the intermedi¬
ate weldment (3). On the four-stage mast it is the first
intermediate weldment (4).
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 foe hook on foe back side of
the mast. Make sure foe hook is completely engaged with
a link in foe chain. Make sure the safety chain does not
touch lift chains or chain sheaves, tubes, hoses, fittings or
other parts on foe mast.
d. Lower foe mast until there is tension in the safety chain
and the free-lift cylinder (6) (free-lift and three-stage
masts only) is completely retracted. If foe engine is run¬
ning, stop the engine. Apply the parking brake. Install a
"DO NOT REMOVE" tag on foe safety chain(s).
e. Install another safety chain (3/8 inch minimum) be¬
tween foe top or bottom crossmember of the carriage (7)
and a crossmember on the outer weldment (8).
• Apply foe parking brake. After lowering or restraining
the mast, shut off the power and remove the key. Put FREE-LIFT
a "DO NOT OPERATE" tag in the operator's com¬ MAST
partment.

2
 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)
THREE-STAGE
MAST
7. Carefully lift the inner channel until it is above the
load rollers of the carriage.
8. Separate the lift truck from the carriage.
A WARNING
Make sure that weights are put on the fork tips so
that the carriage has stability and can not fall over.
9. If any of the carriage load rollers must be replaced,
make a note of the shim arrangement. When the load
rollers are assembled again, the shim arrangement nor¬
mally will be similar.
FOUR-STAGE
MAST
Installation
1. Raise the inner channel with a crane until it is above
the load rollers of the carriage. Align the inner channel
with the load rollers of the carriage. Carefully lower
the inner mast until it engages all the load rollers.
2. Check the load roller clearance. See the CAR¬
RIAGE ADJUSTMENT procedure at the end of this
section.
3. Install the lift chains. Make sure new cotter pins are
installed. See the LIFT CHAIN ADJUSTMENT at the
end of this section.
4. Connect the hydraulic lines if the carriage has a hy¬
draulic attachment.
3
 PIN FORK

1. LOAD ROLLERS
2. CHAIN ANCHORS
3. FORK PIN
4. FORK
5. KEEPER

HOOK FORK

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

FIGURE 1. HOOK AND PIN FORKS

4
MASTS
Removal
NOTE: The mast assembly can be removed with the
carriage in position on the masts. If the mast assembly
is being removed for disassembly and service, remove
the carriage assembly before removing the masts.
3. Connect the 2000 kg (4000 lb) capacity crane to the
top of the masts with chans. Make sure all the channels
are fastened together with a chain. Make sure the
chains will not damage the sheaves or other parts of the
mast assembly. Raise the crane until it will give sup¬
port to the weight of the masts. Put the crane in posi¬
tion so that the masts will be lifted vertically.

1. Fully lower all the mast channels.
2. Clean the area next to the fittings that connect the
hydraulic line to the cylinder. Put a drain pan under the
area where the lines are disconnected. Disconnect the
hydraulic lines and put a cap on each open fitting.
4. Make marks on the pivot fastening caps so that they
will be replaced in the same position. Make sure the
mast assembly will not move suddenly when the pivot
fastening caps are removed. Remove the fastening
caps. See FIGURE 2. for the types of pivots and fas¬
tening caps.

H30-40H
H40-50J, H60JS

1. BUSHING
2. PIN
3. O-RING
4. CAP

H60-110E

1. LUBE FITTINGS
2. MAST HANGER
3. LUBE OPENING
4. CAP
5. LUBE GROOVE
6. BUSHING
7. THIMBLE HOLES 1. DRIVE AXLE HOUSING
8. THIMBLE 2. MAST HANGER 6. PIN
3. MAST HANGER CAP 7. CUP (2)
S30-60E, S60-100E 4. CAPSCREW (2) 8. BEARING
E30-60B, E60-100B, 176 N.m (130 ft lb) 9. LUBE FITTING
S125-150A (SIMILAR) 5. BOLT 104 N.m (77 ft lb)
NOTE: REMOVE MAST HANGER
CAP TO REMOVE MAST.
FIGURE 2. TYPICAL MAST PIVOTS (1 of 2)

5
 CD
1. CAPSCREW

>
2. BUSHING ASSEMBLY
4 PAP
A. STUBSHAFT
5. RETAINING CAP
6. O-RING

P40-50A

1. CAP
2. CAPSCREW

H110-150F
S60-100B
P60-80A
H60-80C

1. PIN
2. BUSHING
3. CAPSCREW
4. KEEPER

1. AXLE HOUSING
2. PIN
3. CAPSCREW
J40-60A A66-80A

FIGURE 2. TYPICAL MAST PIVOTS (2 of 2)

6
A WARNING
DO NOT use fingers to push the connecting pins
from the clevis of the tilting rods. Use a driver.

5. Disconnect the tilt cylinders at the mast. Do cause

damage to some piston rods by letting them fall on the
edge of the cowl.
6. Carefully lift the mast assembly away from the lift
truck. Make sure all cables and hoses are released.
8556
7. Put the mast assembly on the floor with the back of 1. CYLINDER 6. CHAIN
2. TOP CROSSMEMBER 7. INNER MAST
the carriage towards the floor. 8. OUTER MAST
3. SHEAVE
Disassembly 4. PIN 9. LOAD ROLLER
5. SNAP RING 10. CHAIN ANCHOR
In order to disassemble the mast assembly:
FIGURE 3. LIFT CYLINDER CONNECTED TO
a. The carriage and lift chains must be removed. TOP CROSSMEMBER

b. The mast assembly must be removed from the

lift truck.
c. The mast assembly must be put on the floor with
the back of the mast towards the floor.
NOTE: The disassembly, repair, and adjustments of
the masts in this section is similar. The size and
mounting of the lift cylinders is different. Instructions
for the removal from the different mountings is given
separately in the following paragraphs.
1. Lift cylinders connected directly to crossmembers:
See FIGURE 3. Some lift cylinders are connected to
crossmembers with capscrews and some are connected
with snap rings.
a. Disconnect the tube assembly from the bottom
of the lift cylinder.
d. Raise the lift cylinder and move it away from the
mast assembly.
2. Lift cylinders connected to a sliding crosshead as¬
sembly: See FIGURE 4.
a. Connect a sling and crane to the lift cylinder.
b. Disconnect the tube assembly fm the bottom of
the lift cylinder.
c. Remove the capscrews holding the crosshead
assembly to the lift cylinder.
d. Remove the crosshead guide(s) and lift the
crosshead assembly away from the channels.
Disassemble the crosshead assembly as neces¬
sary to make repairs.

b. Connect a sling and crane to the lift cylinder so e. Disconnect the lift cylinder from the bottom
that the cylinder can be raised. crossmember.

c. Remove the capscrews or snap ring that hold the f. Raise the lift cylinder and move it away from the
lift cylinder to the crossmember. mast assembly.

7
 1. CHAIN GUARD
2. SPACER
3. WEAR PAD
4. CROSSHEAD ASSEMBLY
5. CHAIN SHEAVE AND BEARING ASSEMBLY
6. SNAP RING
7. CHAIN ANCHOR (2)
8. SPECIAL WASHER
9. LOCKNUT
10. LIFT CYLINDER
11. SPRING
12. SPECIAL FITTING
13. TUBE
14. CAM FOLLOWER
15. MAST GUIDE BAR
16. RETAINER PLATE
17. CAPSCREW AND LOCKWASHER (4)
18. BOTTOM CROSSMEMBER ASSEMBLY

C7

4146

FIGURE 4. LIFT CYLINDER CONNECTED TO CROSSHEAD ASSEMBLY

3. Mast assemblies with two lift cylinders, a free-lift e. Disconnect the lift cylinder from the bottom
cylinder and a main lift cylinder: See FIGURE 5. crossmember

a. Connect a sling and crane to the free-lift cylin¬ f. Raise the lift cylinder and move it away from the
der. mast assembly.

b. Disconnect the tube assemblies from both cylin¬ g. Connect a sling and crane to the main lift cylin¬
ders. der.

h. Disconnect the lift cylinders from the top cross-

c. Remove the capscrews holding the crosshead
member.
assembly to the free-lift cylinder.
i. Disconnect the lift cylinder from the bottom
d. Remove the crosshead guides and lift the cross- crossmember.
head assembly away from the channels. Disas¬
semble the crosshead assembly as necessary to j. Lift the main cylinder away from the mast chan¬
make repairs. nels.

8
1. FREE-LIFT PILOT LINE
2. FREE-LIFT PRESSURE LINE
3. FREE-LIFT CYLINDER
4. SNAP RING
5. CHAIN SHEAVE
6. BEARING
7. SNAP RING
8. SPACER
9. CHAIN GUARD
10. CROSS HEAD
11. GUIDE SHOE (2)
12. SHIMS
13. RETAINER
14. CHAIN ANCHOR
15. PRESSURE LINE
16. PILOT LINE
17. LOWERING CONTROL

FIGURE 5. MAST WITH A FREE-LIFT CYLINDER (1 of 2)

 1. ROLL PIN
2. CYLINDER
3. CHAIN ANCHOR
4. INLET PRESSURE LINE
5. LOWERING CONTROL VALVE

FIGURE 5. MAST WITH A MAIN LIFT CYLINDER (2 of 2)

4. Remove the main lift chains 5. Slide the inner channel out of the bottom of the next
outer channel until there is access to the load rollers.
10 See FIGURE 6.

8557
FIGURE 6. REMOVING THE LOAD ROLLERS
6. Remove the snap rings and the load rollers on both
the inner channel and the next outer channel. Make a
note of the shim arrangement for each load roller. The
shim arrangement will be approximately the same
when the channels are assembled again.
7. Slide the inner channel more than half way out of the
next outer channel. Connect a crane to the inner mast
channel near its center of gravity. See FIGURE 7.
8. Slide the inner channel to the top of the next outer
channel. When the stub shafts are in the channel
notches, lift the inner channel out of the next outer
channel. If the mast assembly has more than two chan¬
nels, each inner channel is removed from the next outer
channel in the same way.
8558
FIGURE 7. REMOVAL OF INNER WELDMENT
9. Disassemble the sheaves and rollers as necessary for
repair and cleaning.
Cleaning And Inspection
1. DO NOT use steam to clean the lifting chains,
sheaves, or load rollers. The sheaves and roller bear¬
ings are sealed and permanently lubricated. Do not
wash the lubricant from the bearings. Replace rollers
and sheaves that roll rough or are damaged.
2. Wash the lift chains with solvent. Use compressed
air to dry the chains. Inspect the chains for wear and
damage.
3. Inspect the lifting chains for cracks or broken links
and pins. Check for corrosion or worn holes in the
links. When the pins or the holes wear, the chain be¬
comes longer. The chain links that run over the chain
sheaves have the most wear. If a chain is 3% longer
than a new chain, the chain is worn and can not be used
again. If a chain scale is available, check the lifting
chains as shown in FIGURE 8. If a chain scale is not
available, measure 20 links of chain. Compare the
length as shown in TABLE 1. Replace the chains if the
wear is 3% or greater.
A CAUTION
Never replace just the worn section of a chain. Re¬
place the complete chain. Never replace just one
chain of a chain pair. Replace both chains.
4. Inspecting the chain anchors and pins. Replace chain
anchors for cracks or broken fingers, or holes worn out
of round. Replace chain anchor pins that are worn or
have cracks.
5. For lift chains that can be used again, apply Hyster-
Approved chain and cable lubricant or SAE 30 oil.
6. Clean the mast channels with steam or solvent.
7. Inspect the sliding and rolling surfaces. Inspect the
welds around the stub shafts.
A CAUTION
Get information from your Hyster dealer before
welding on masts.
11
 1217*

NEW CHAIN
1. WORN PIN 5. LOOSENESS
2. CRACKS 6. PIN WEAR
3. 5% EDGE WEAR 7. CORROSION NOTE: The instructions for measuring chain
4. HOLE WEAR 8. CHAIN WEAR SCALE wear are shown on the Chain Wear Scale.
FIGURE 8. CHAIN PARTS AND WEAR

TABLE 1. MEASURING THE CHAIN WEAR 1. Use a crane to lift the next inner channel (inner or
intermediate channel). Fit the stub shafts through the
pitch
Total length of WEAR LIMIT notches in the outer channel. Slide the next inner chan¬
20 links(pitch) The maximum
of new chain length of 20 links nel into the outer channel so that stub shafts are seen at
the top and bottom of the channels.
mm (Inch) mm (Inch) mm (Inch)

12.7 (0.50) 254.0 (10.0) 261.6 (10.3) 2. Install the strip bearings and the approximate shim
15.9 (0.63) 317.5 (12.5) 327.0 (12.9) arrangement on the outer channel.
19.1 (0.75) 381.0 (15.0) 392.4 (15.6)
25.4 (1.00) 508.0 (20.0) 523.3 (20.6) 3. Install the load rollers and the approximate shim ar¬
rangement on both channels.
Assembly
4. Check the clearance of the load rollers and strip bea¬
NOTE: On all models, the load rollers have shims to
rings. Make the necessary adjustments as described in
keep the channels parallel and give correct clearance.
the CHECKS AND ADJUSTMENTS in this section.
During assembly, the shim arrangement will be the
same or approximately the same arrangement before 5. If the mast assembly has three or four stages, install
disassembly. Check the clearance to adjust for wear or the next inner channel as described in steps 1 to 4.
changes because of repairs. The strip bearings found
on the top of the outer channls are also adjusted using 6. Install the necessary sheaves on the channels.
shims. See the CHECKS AND ADJUSTMENTS in
this section for the instructions to make the necessary 7. On three or four stage masts, install the main lifting
adjustments. chains.

12
INSTALLATION TABLE 2. TORQUE VALUES FOR PIVOT
.
1 Connect the 2000 kg (4000lb) crane to the top of the CAPSCREWS
mast assembly. Make sure all the channels are fastened UFT TRUCK CAPSCREWS FOR
together with a chain. Make sure the chains will not MODEL MAST PIVOT
damage the sheaves or other parts of the mast assem¬
N.m ftlbf
bly.
A66-80A Not used Not used
2. Raise the mast assembly to a vertical position. Move
J40-60A 108 80
the mast assembly into position on the lift truck.
E30-60BC 244 180
3. Lubricate the pivots and bushings with multi-pur¬ P40-50A 176 130
pose grease. Connect the pivots. See FIGURE 2. for
E30-60BS 244 180
the different designs of pivots and fastening caps.
P60-80A 244 180
NOTE: Most pivots have fastening caps. Make sure H30-60H 88 65
the fastening caps are installed in the same position
H40-60JS 88 65
before they were removed.
S60-100B 122 90
4. Tighten the fastening capscrews to the correct tor¬ S60-120E 244 180
que. See TABLE 2. H60-110E 176 130
5. Move the mast so that the tilting cylinders can be H110-150F 814 600
connected. Installthe pins and retainers. S125-150A 190 140
6. Connect the hydraulic lines. E60-100B 244 180
H60-80C 176 130
7. If the carriage was not installed with the masts,
S30-60ES 244 180
install the carriage. See CARRIAGE - Installation, in
this section. S30-50C 122 90

CHECKS AND ADJUSTMENTS

CHECKING FOR LEAKS INTHE LIFT This maximum is when the hydraulic oil is 32°
SYSTEM C (90° F). If the oil temperature is 71° C (160°
F), the maximum lowering of the carriage is
1. Leakage Outside the Hydraulic Lift System 152.4 mm (6 in) per 10 minutes.

a. Operate the hydraulic system. Put a near capac¬
ity 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. Leakage Inside the Hydraulic Lift System.
b. Check the lift cylinder for inside leakage. Install
a gate valve in the hydraulic line betweenthe lift
cylinder and the control valve. Put an 80 to 90%
capacity load on the forks. Raise the carriage un¬
til all the channels are extended. Close the gate
valve. If the carriage or mast channels slowly
lower, the seals in the lift cylinder have leaks.

a. Put a 80 to 90% capacity load on the forks.
Raise the carriage until all the channels are ex¬
tended. If the carriage slowly lowers with the
control valve in a neutral position, there is leak¬
age inside the hydraulic system. Maximum low¬
ering of the carriage because of inside leakage in
the lift system is 50.8 mm (2 in) per 10 minutes.
c. The method for checking internal leakage in the
tilt system is like steps a. and b. above. Tilt the
masts to a position forward by a small amount
with an 80 to 90% capacity load on the forks.
Return the control valve to neutral position. If
the masts continue to tilt slowly forward, there is
an inside leak in the system. Maximum rod ex-

13
 tension because of inside leakage is 13 mm (0.5
in) per 10 minutes. This maximum is when the
hydraulic oilis 32° C (90° F)). If the oil temper¬
ature is 71° C (160° F), the maximumrod exten¬
sion is 38 mm (1.5 in) per 10 minutes.
d. To check for leakage past the piston seals of the
tilt cylinder, tilt the mast fully forward. Discon¬
nect the hydraulic line from the front of the tilt
cylinder. Leave the cylinder port open. Put a cap
on the open hydraulic line. Operate the hydrau¬
lic system and move the control leva1so that the
mast is tilted against the forward stops. Leakage
from the open cylinder port indicates that the
piston seals leak.
ADJUSTING THE TILT CYLINDER
STROKE AND THE BACKWARD TILT
ANGLE
1. Check the tilt cylinder stroke by slowly tilting the
mast fully forward and backward several times. Each
tilt cylinder must stop its stroke at the same time. There
must be no twist in the mast channels. Tilt the mast ful¬
ly backward. Measure the tilt angle. Adjust the tilt cyl¬
inder stroke and the tilt angle as follows:
a. The cylinder that stops last when tilting back¬
ward has a shorter rod adjustment. Adjust the
rod length by loosening and then turning the rod
connector. Both cylinders must have the same
stroke.
b. The cylinder that stops last when tilting forward
has a longer rod adjustment. Adjust rod end as
described in step a.
14
c. Adjust the tilt angle by turning the rod connec¬
tors as necessary to get the correct tilt angle.
d. After cylinder stroke and the tilt angle are ad¬
justed, tighten the capscrews on the rod connec¬
tor.
A WARNING
If equipped, make sure the tilt limit spacers are
installed.
For additional instructions and specifications see the
sections LIFT CYLINDERS, 4000 SRM 135, and
TILT CYLINDERS, 2100 SRM 103.
LIFT CHAIN ADJUSTMENTS
(See FIGURE 9.)
When correctly adjusted:
a. The tension will be the same on each chain of
the chain set.
b. The chain length will be correct.
c. The chains must travel freely through the com¬
plete cycle.
1. Put a 80 to 90% capacity load on the forks. Lower
the forks as much as possible.
2. Check the amount of the bottom carriage roller ex¬
tending below the inner channel of the mast. No more
than one third of the roller can extend below the mast.
If the rollers are too low, adjust the chain anchors.
Make sure each anchor is adjusted the same amount.

FIGURE 9. LIFTING CHAIN ADJUSTMENTS
A CAUTION
A minimum of two times the thread diameter must
be available below the nut on the chain anchor. Pe¬
riodic checks must be made to correct chain adjust¬
ments because of wear.
3. Remove the load from the forks. Check the clear¬
ance of the carriage when the mast is fully extended.
The carriage must not touch the top of the inner chan¬
nel. The chains are too tight if the carriage touches the
crossmember. Put the mast in the vertical position and
lower the carriage completely. If the forks do not just
touch the surface, the chains are too tight. If the chains
are too tight, adjust the chain anchors. Make sure each
anchor is adjusted the same amount.
4. Three and four stage mast chain adjustment. Adjust
the main lifting chains untilthe top of the intermediate
mast channel is at the same height as the top of the out¬
er mast channel. Adjust the free-lift chains as de¬
scribed in step 3.
MAST ADJUSTMENTS
NOTE: Eachload roller is held in position on the stub
shaft with shims. The 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 roller
to the other. The total shim thickness is always 5 shims.
During assembly, the shim arrangement will be
approximately the same as before disassembly. Make
notes of each shim arrangement during disassembly.
1. TILT MAST FULLY BACKWARD
2. CARRIAGE ROLLER
3. CARRIAGE
4. NO MORE THAN 1/3 OF CARRIAGE
ROLLER MUST EXTEND BELOW
MAST
5. CHAIN LENGTH ADJUSTMENT. A
MINIMUM OF TWO TIMES THE
CHAIN PITCH MUST BE AVAILABLE
Check the clearance to adjust for wear or change be¬
cause of repairs.
1. The load rollers control the alignment of the masts.
The alignment conditions are given on a list below
with the most important condition first. See
FIGURE 10.
a. The vertical channels must be parallel to each
other to decrease wear.
b. The maximum clearance between the load roller
and the channel at the tightest fit is 0.8 mm
(0.030 in).
c. The order of shims on a stub shaft must be
approximately the same as the stub shaft in the
opposite channel. The channels will be approxi¬
mately in the center.
2. Adjust the mast load rollers as follows:
a. Use a crowbar to move the channels from side to
side to measure the movement. Repeat in a mini¬
mum of three different positions of the channels.
b. Separate the masts and change the shim arrange¬
ments as required. Assemble the channels. Slide
the channel all the way to the top and bottom to
find the tightest fit.
c. Repeat steps a. and b. until the clearance is not
more than 0.8 mm (0.030 in) at the tightest fit.
d. Measure the distance on the top and bottom be¬
tween the channels. Change shims to keep the
distance equal between the top and bottom so
that the masts are parallel.
15
3. Adjust the strip bearings. Insert shims between the
strip bearing and the spacer bar. Adjust the clearance
until there is less than 0.8 mm (0.030 in) at the tightest
fit. See FIGURE 11.
Guide Shoe Adjustment (See FIGURE 12.)
4. The masts having full free-lift have guide shoes.
The guide shoes make sure the free-lift cylinder rod is
parallel to the masts during the full travel. Adjust the
guide with shims so that the cylinder is parallel to the
masts when the rod is retracted. Then adjust the clear¬
ance for 0.8 mm (0.030 in) at the tightest fit in the trav¬
el of the guide shoes.
5. Cushion adjustment (standard masts with intermedi¬
ate free-lift). See FIGURE 13. The adjustable cushion
stops the inner channel when the lifting cylinder is ful¬
ly retracted. Add or remove shims to make the top of
the inner channel even with the top of the outer channel
within 1.5 mm (0.060 in).
6. Latch Adjustment (full free-lift masts). See
FIGURE 13. The correct operation of the latches
makes necessary the correct adjustment of the inner
channel load rollers and the cushion. Adjust the inner
channel cushion with shims so that the latches will re¬
lease smoothly and will operate as shown in
FIGURE 13.

TOP VIEW MAST CARRIAGE

FRONT VIEW FRONT VIEW

1. MAST WELDMENT (CHANNEL) 5. STUB SHAFT

2. LOAD ROLLER 6. PARALLEL, EQUAL SPACE WITHIN 1.5 mm (0.060 in)
3. SNAP RING 7. ADJUST LOAD ROLLERS FOR ZERO CLEARANCE
4. SHIMS
USE SHIMS TO KEEP CARRIAGE AND MAST PARALLEL, TO PROVIDE APPROXIMATELY EQUAL SPACE
BETWEEN BOTH SIDES OF CARRIAGE AND MASTS AND TO PROVIDE THE CORRECT CLEARANCE AT
TIGHTEST FIT.
FIGURE 10. MAST AND CARRIAGE ADJUSTMENTS
 10106

FULL FREE LIFT MAST ASSEMBLY

5 4692

1. STRIP BEARING
2. LOAD ROLLER FREE LIFT CYLINDER
3. WELDMENTS (3-STAGE ONLY)
4. SHIMS 1. 54 N.m (40 FT LBS) TORQUE
5. O-RING 2. 1.5 mm (0.06 INCH) TOTAL CLEARANCE
AT TIGHTEST POINT OF TRAVEL 0.8 mm
FIGURE 11. ADJUSTMENT OF THE STRIP (0.03 INCH) EACH SIDE
BEARING 3. CYLINDER
4. SHIMS
5. PARALLEL TO CYLINDER
6. 23 N.m (17 FT LBS) TORQUE_
FIGURE 12. GUIDE SHOE ADJUSTMENT

17
 FULL FREE LIFT

NOTE: GRIND CARRIAGE

LIFTING BLOCK TO OBTAIN
CLEARANCE ABOVE FOR
FREE OPERATION

INTERMEDIATE
FREE-LIFT

.
1 0.1 to 2.5 mm (0.005 to 0.100 INCH) ADD SHIMS TO CUSHION
CLEARANCE FOR NO INTERFERENCE
2. 0.5 to 1.0 mm (0.020 to 0.040 INCH) WHEN LATCHES ROTATE
3. CAPSCREWS
4. CUSHION 4062
5. SHIMS ADD SHIMS TO CUSHION SO THAT THE TOPS
6. CUSHION BRACKET OF INNER AND OUTER CHANNELS ARE EVEN
FIGURE 13. LATCH ADJUSTMENT

CARRIAGE ADJUSTMENT

1. Installthe six load rollers on the carriage. (There are

four load rollers on 5000 to 7000 kg ( 11,000 to 15,000
lb) capacity lift trucks). Installthe shims for the rollers
in the same sequence on the stub shaft before disas¬
sembly.

2. Use a crane to raise the carriage up the inner chan¬

nel. Find the tightest fit between the load rollers and
the inner channels.

1. LATCH CRANK
2. LATCH LUG T (3312
3. Remove the caniage from the mast. Adjust the shim
3. CARRIAGE arrangement for each roller for clearance between the
roller and the inner channel. Maximumclearance is 0.8
FIGURE 14. LUG AND CRANK ALIGNMENT
mm (0.030 in) at the tightest fit. Repeat steps 2. and3.
(FULL FREE-LIFT MAST ONLY)
if necessary.

18
4. Keep the shim arrangement on each side of the car¬
riage approximately equal. The carriage must run par¬
allel with the inner mast channel.
5. After adjustment, lubricate the channels with a thin
layer of grease.
A CAUTION
Too much grease will cause the rollers to slide and
wear flat areas on the rollers.
6. Carriage adjustment for the full free-lift mast: See
FIGURE 14.
a. Follow the procedure for CARRIAGE AD¬
JUSTMENT steps 1. to 4.
b. Check so that the latch lug on the carriage enters
the latch crank smoothly and correctly.
c. If necessary, move the roller shims to move the
carriage to one side of the mast. For frill free-lift
masts, the operation of the latch mechanism is
more important than equal spacing between the
channels. The carriage must be parallel to the
channels.
d. The inner channel must also be in position so
that the back lug on the outer channel enters the
rear crank smoothly and correctly.
7. Adjust the hydraulic hoses and make sure the con¬
nections are correct if the carriage is equipped with hy¬
draulic attachments.
19
 TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE PROCEDURE OR ACTION
No movement of the lift or tilt cylin¬ Linkage at the control valve is Connect and adjust linkage.
ders. disconnected.
No oil or not enough oil in the Fill tank. Check for leaks.
hydraulic tank.
Relief valve is not set correctly. Adjust or install new relief valve.
Hydraulic pump does not operate or Repair or install new pump.
has damage.
Slow movement of the lift or tilt cyl¬ No oil or not enough oil to the lift Fill tank. Check for leaks.
inders. cylinders.
Cylinders have internal or external Repair leaks. Install new parts.
leaks.
Relief valve is not set correctly. Adjust or install new relief valve.
There is a restriction in a hydraulic Remove restriction. Install new
line. parts.
Load is more than capacity. Reduce load.
Hydraulic control linkage is Adjust the linkage.
incorrectly adjusted.
Rough movement of the mast as¬ There is air in the hydraulic system. Remove air. Check for loose
sembly. connections or breaks in lines.
Lift cylinder(s) is damaged. Repair or install new lift cylinder.
Mast weldments are damaged or Align weldments. Install new parts.
not aligned.
Mast weldments are not lubricated Correct lubrication.
correctly.
Lift or tilt cylinders extend or retract Load check valve/s and spool/s Repair or install new load check
when the control valve lever (spool) have damage. valve and spool.
is in the Neutral position.
Cylinder seals have leaks. Install new seals.
Hydraulic lines have leaks. Repair leaks. Install new parts.
Remove air from the system.
Leaks between the spool and the Install new spool and O-ring seals.
bore.

20
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
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