Mastro de 2 Estagios - 360

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MASTRO DE 2 ESTÁGIOS
PARTE NO. 4092690 4000 SRM 1647
PRECAUÇÕES DE
SEGURANÇA MANUTENÇÃO E
REPAROS
• Os Manuais de Serviço são atualizados regularmente, mas podem não refletir alterações recentes no
projeto do produto. Informações de serviço técnico atualizadas podem estar disponíveis em seu
®
revendedor autorizado Hyster local . Os Manuais de Serviço fornecem diretrizes gerais para
manutenção e serviço e devem ser usados por técnicos treinados e experientes. A falha em manter
adequadamente o equipamento ou não seguir as instruções contidas no Manual de Serviço pode
resultar em danos aos produtos, ferimentos pessoais, danos materiais ou morte.
• Ao levantar peças ou conjuntos, certifique-se de que todas as eslingas, correntes ou cabos estejam
presos corretamente e que a carga que está sendo levantada esteja equilibrada. Certifique-se de que o
guindaste, cabos e correntes tenham capacidade para suportar o peso da carga.
• Não levante peças pesadas manualmente, use um mecanismo de elevação.
• Use óculos de segurança.
• DESCONECTE O CONECTOR DA BATERIA antes de fazer qualquer manutenção ou reparo em
empilhadeiras elétricas. Desconecte o cabo de aterramento da bateria em empilhadeiras de combustão
interna.
• Sempre use os blocos corretos para evitar que a unidade role ou caia. Veja COMO COLOCAR O

EMPILHADOR EM BLOCOS no Manual de Operação ou na seção Manutenção Periódica .
https://www.hypassonline.com/lib/service/US/EN/html/4000SRM1647.html 1/99
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• Mantenha a unidade limpa e a área de trabalho limpa e organizada.

• Use as ferramentas corretas para o trabalho.
• Mantenha as ferramentas limpas e em boas condições.
• Sempre use peças HYSTER APPROVED ao fazer reparos. As peças de reposição devem atender ou

exceder as especificações do fabricante do equipamento original.
• Certifique-se de que todas as porcas, parafusos, anéis elásticos e outros dispositivos de fixação foram

removidos antes de usar força para remover as peças.
• Sempre prenda uma etiqueta NÃO OPERAR nos controles da unidade ao fazer reparos ou se a

unidade precisar de reparos.
• Certifique-se de seguir as notas de ADVERTÊNCIA e CUIDADO nas instruções.
• Gasolina, Gás Líquido de Petróleo (GLP), Gás Natural Comprimido (GNC) e óleo diesel são
inflamáveis. Certifique-se de seguir as precauções de segurança necessárias ao manusear esses
combustíveis e ao trabalhar nesses sistemas de combustível.
• As baterias geram gás inflamável quando estão sendo carregadas. Mantenha fogo e faíscas longe da

área. Certifique-se de que a área esteja bem ventilada.
NOTA: Os seguintes símbolos e palavras indicam informações de segurança

neste manual:
AVISO
Indica uma situação perigosa que, se não for evitada, pode resultar
em morte ou ferimentos graves.
CUIDADO
Indica uma situação perigosa que, se não for evitada, pode resultar
em ferimentos leves ou moderados e danos materiais.
Na empilhadeira, o símbolo de AVISO e a palavra estão em fundo
laranja. O símbolo de CUIDADO e a palavra estão em fundo
amarelo.
"A
QUALIDADE
GUARDIÕES"
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HISTER
APROVADO
© 2016
HYSTER COMPANY
PEÇAS
ÍNDICE
Código de Série / Tabela de Referência de Designação de Modelo

Em geral
Descrição e operação
Sistema de mastro
Inclinação
Elevação
Operação
Válvulas de retenção operadas por piloto
Lubrificação da glândula
Válvula de Abaixamento de Emergência
Operação
Correntes de elevação
Alongamento por desgaste
Velocidade de desgaste
Desgaste da Altura da Placa
Lubrificação
Restaurando o filme a óleo
Manutenção
Mantendo a Presença do Petróleo
Proteção contra corrosão
Requisitos para Lubrificante de Corrente
Rolos de carga
Blocos de rolamento
Transporte
Carro padrão com posicionamento manual do garfo
Carro padrão com posicionamento de garfo hidráulico
Deslocamento Lateral de Função Dupla e Posicionamento do Garfo
(DFSSFP)
Deslocamento Lateral Integral
Válvula de transporte
Pressão alternada e tanque (P & T)
Pressão Fixa e Tanque (P & T)
Divisor de fluxo para posicionamento simultâneo do garfo
Válvula para dupla função com deslocamento lateral e posicionamento do
garfo (DFSSFP)
Pressão Fixa e Sistema de Tanque (P & T Fixo)
Garfos
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ÍNDICE
Procedimentos de segurança ao trabalhar perto do mastro
Antes de iniciar os reparos no sistema hidráulico, sempre:
Remover e substituir
Garfos
Remover
Instalar
Guia do garfo e pino do garfo
Remover
Instalar
Transporte
Remover
Instalar
Blocos de rolamentos de carro
Remover
Instalar
Rolos de Carga de Transporte
Substituir
Cilindro de Deslocamento Lateral
Remover
Desmontar
Limpar e inspecionar
Montar
Instalar
Cilindro Posicionador de Garfo
Remover
Desmontar
Montar
Instalar
Válvulas de transporte
Remover
Instalar
Válvula para Sistemas P&T Fixos
Remover e desmontar
Montar e instalar
Divisor de fluxo para válvula de posicionamento de garfo simultâneo
Substituição da Válvula Restritora e da Válvula de Alívio
Válvula de função dupla para deslocamento lateral e posicionamento do
garfo
Substituição da válvula solenoide
Substituição da válvula de alívio
Remover
Instalar
Mastro
Correntes de elevação e âncora de corrente superior
Remover
Instalar
Ancoragem de Corrente no Carro
Remover
Instalar
Polia de Corrente
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ÍNDICE
Remover
Instalar
Mangueiras de cabeçalho
Remover
Instalar
Mastro Elétrico
Remover
Instalar
Polia da Mangueira
Remover e desmontar
Montar e instalar
Montagem do Mastro
Remover
Desmontar
Montar
Instalar
Rolos de carga do mastro interno
Substituir
Blocos de rolamento de mastro
Remover
Instalar
Cilindros de elevação
Remover
Desmontar
Montar
Instalar
Cilindros de Inclinação
Remover
Desmontar
Montar
Instalar
Verificações e ajustes
Verificações gerais
Verificação da condição do mastro
Verificação da operação do mastro
Verificação da válvula de contrapeso (somente) J007 e H019
Inspeção e ajuste do garfo
Inspeção da Corrente de Elevação
Requisitos do Lubrificante da Corrente de Elevação
Procedimento de Lubrificação da Corrente de Elevação
Verificações de vazamento
Deslocamento Vertical do Mastro
Desvio de inclinação do mastro
Ajustes
Calço do Cilindro de Elevação
Corrente de elevação e ajuste de altura do garfo
Ajuste de Tensão da Mangueira da Plataforma
Ajuste de tensão do cabo do mastro elétrico
Ajuste da válvula de contrapeso
Ajuste do ângulo de inclinação do cilindro de inclinação para trás
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ÍNDICE
Ajuste da almofada de suporte do mastro
Solução de problemas
Introdução
Nenhum movimento hidráulico com o motor funcionando
Verificação básica inicial
Fornecimento Elétrico
Fornecimento hidráulico
Código de falha
Não é possível abaixar com o motor desligado
Movimento incorreto
Movimento irregular (agitação) ou leve movimento do carro ao dar partida no
motor
Movimento desigual do cilindro de inclinação esquerdo e direito
Velocidade de Elevação Insuficiente
Capacidade de Elevação Insuficiente
Velocidade de descida incorreta
Deslocamento do Cilindro de Elevação
Deslocamento do Cilindro de Inclinação
Esta seção é para os seguintes modelos:
Código de Série / Tabela de Referência de Designação de Modelo

Esta seção é para os seguintes modelos:
Código da Modelo Europeu Modelo das Américas

série
G019 H13.00-14.00XM, H16.00XM-6, H10.00-12.00XM- H300-330HD, H360HD, H360HD-
12EC EC
H007 H8.00-12.00XM H170-280HD
H019 H13.00-16.0XM-6, H10.00-12.0XM-12EC H300-360HD2, H360HD2-EC
J007 H8.00-12.00XM-6 H190-280HD2
J019 H13.00-16.00XM-6, H10.00-12.00XM-12EC H300-360HD2, H360HD2-EC
K007 H8.00-12.00XM-6, H10.00XMS-6 H190-280HD2, H230HDS
K019 H13.00-16.00XM-6 H210-250-48HD2, H300-360HD2
K019EC H6.00-7.00XM-12EC H360HD2-EC
L007 H8.00-12.00XM-6 H190-280HD2, H250HD2
Em geral
Este manual contém a descrição e os procedimentos de reparo para o mastro de dois estágios e seus
componentes. Os componentes do mastro incluem o mastro interno e externo, cilindros de inclinação e
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elevação, carro e garfos. O anexo de contêiner é descrito separadamente em Anexo de contêiner extensível
(Elme) 5000SRM1221 .
Descrição e operação
SISTEMA DE MASTRO
A função do conjunto do mastro é levantar uma carga verticalmente. Consiste em um mastro externo, mastro
interno e um carro. O mastro externo é fixado na estrutura do caminhão. Dentro dos canais do mastro externo,
o mastro interno se move para cima e para baixo, guiado por roletes. Dentro dos canais do mastro interno, o
carro se move para cima e para baixo guiado por roletes. Os garfos ou um acessório são montados no carro.
O movimento vertical do mastro interno e do carro é fornecido por dois cilindros de elevação e correntes de
elevação. A inclinação para frente e para trás do mastro é fornecida pelos cilindros de inclinação. Diferentes
opções de carro estão disponíveis para deslocamento lateral, posicionamento do garfo ou para acessórios.
Os mastros para caminhões H8.0-12.0XM-6 e H13.0-16.0XM são semelhantes e diferem apenas nas
dimensões de seus componentes.
INCLINAÇÃO
O mastro gira em pinos, que são aparafusados ao mastro externo. Os pinos giram em buchas que são
instaladas nas montagens do mastro na frente da estrutura. Ao estender ou retrair os cilindros de inclinação, o
mastro se inclina para frente ou para trás. Os ângulos de inclinação máximos são determinados pelas posições
do curso final dos cilindros de inclinação. O comprimento dos dois cilindros de inclinação deve ser ajustado
para evitar que os cilindros de inclinação girem o mastro na posição de inclinação máxima para trás.
A pressão hidráulica nos cilindros de inclinação é determinada pelo peso combinado do conjunto do mastro e
da carga, e pela distância horizontal entre os pinos do mastro e o ponto de gravidade combinado do mastro e
da carga.
Uma válvula é instalada na conexão com o lado da haste dos cilindros de inclinação para melhorar o controle
do movimento do cilindro de inclinação. Esta válvula pode ser uma válvula de contrapeso ou uma válvula de
alívio.
Uma válvula de contrapeso é instalada nas unidades J007 e H019 produzidas antes de novembro de 2012. A
válvula de contrapeso não tem restrição de fluxo de óleo ao inclinar para trás. A válvula de contrapeso atua
como uma válvula de alívio de 35 MPa (5076 psi) à medida que a pressão aumenta no lado da haste dos
cilindros de inclinação. Ao inclinar para frente, a pressão de alimentação no lado do pistão abre as válvulas de
contrapeso e alivia a pressão no lado da haste dos cilindros de inclinação. Para evitar a trasfega do mastro, as
válvulas de contrapeso devem ser ajustadas para obter pressões iguais nos dois cilindros ao inclinar para
frente.
Uma válvula de alívio é instalada em empilhadeiras fabricadas após novembro de 2012. Ao inclinar para
frente, deve-se aplicar pressão de óleo adicional no lado do pistão, acima da pressão necessária para a
inclinação. Esta pressão de óleo adicional é necessária para abrir as válvulas de alívio de 14 MPa (2031 psi)
.
ELEVAÇÃO
Os cilindros de elevação são apoiados na base do mastro externo. Quando os cilindros se estendem, eles
empurram o mastro interno para cima. As correntes são presas ao mastro externo e ao carro, e passam sobre
as roldanas da corrente no topo do mastro interno. Quando o mastro interno se move para cima, as correntes
puxam o carro para cima até duas vezes a distância que os cilindros de elevação se estenderam. Consulte a
Figura 1 .
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1. CILINDROS DE ELEVAÇÃO
2. MASTRO EXTERNO
3. MASTRO INTERNO
4. ROLDANA DE CORRENTE
5. CORRENTE DE ELEVAÇÃO
6. TRANSPORTE
Figura 1. Operação de um mastro de dois estágios
Operação
Os cilindros de elevação se estendem quando a pressão hidráulica aplicada é suficiente para levantar o peso
combinado da carga, garfos, carro e mastro interno. O abaixamento é obtido liberando a pressão hidráulica,
que é induzida pelo peso que repousa sobre a haste dos cilindros de elevação.
A velocidade de elevação e a velocidade de descida são controladas pela posição movida do carretel de
elevação na válvula de controle principal. A velocidade máxima de elevação é determinada pela alimentação
máxima da bomba. A velocidade máxima de descida é determinada pela válvula de controle de descida na
parte inferior de cada cilindro de elevação.
A válvula de controle de abaixamento é uma válvula de pressão compensada. Ele permite um fluxo crescente
com o aumento da pressão até que um fluxo máximo predefinido seja alcançado. O resultado é que são
obtidas velocidades de descida semelhantes para condições com carga e sem carga. A função principal da
válvula de controle de descida é limitar a velocidade de descida em caso de mau funcionamento da conexão
de alimentação/retorno. As diferentes capacidades de altura de elevação são determinadas pelas dimensões
dos vários conjuntos de mastro. A posição mais baixa dos garfos é determinada pelo ajuste das âncoras da
corrente.
Válvulas de retenção operadas por piloto
O carretel de elevação na válvula de controle principal não veda completamente na posição neutra. Para obter
vazamento zero, uma válvula de retenção operada por piloto é montada na válvula de controle principal entre
o carretel de elevação e o cilindro de elevação. Consulte a Figura 2 .
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Ao levantar o mastro, o suprimento de óleo passará por uma válvula de retenção na válvula de retenção
operada por piloto. Para baixar o mastro, a válvula de retenção operada por piloto deve ser movida para a
posição aberta. A posição da válvula de retenção operada pelo piloto é determinada pela pressão do óleo no
lado do cilindro da válvula de retenção e pela força combinada de uma mola e pressão do óleo no lado do
piloto da válvula de retenção. A força da mola manterá a válvula de retenção fechada quando existirem
pressões iguais no lado do piloto e no lado do cilindro da válvula de retenção.
A válvula de retenção operada pelo piloto abre quando a pressão no lado do cilindro da válvula excede a
força combinada da pressão da mola e do óleo no lado do piloto. A pressão do óleo no lado piloto da válvula
de retenção é aliviada para o tanque abrindo a válvula seletora operada pelo piloto. A válvula seletora operada
por piloto é aberta pela pressão piloto do carretel de elevação, quando o carretel de elevação se move para a
posição de abaixamento.
O abaixamento dos cilindros de elevação pode ser interrompido retornando o carretel de elevação para a
posição neutra, o que interrompe o fornecimento do piloto para a válvula seletora operada por piloto, fazendo
com que a válvula seletora se feche. A válvula seletora fechada permite que a pressão do cilindro de elevação
se acumule no lado da mola da válvula de retenção, fazendo com que a válvula de retenção operada por piloto
também feche. Consulte a Figura 2 .
1. VÁLVULA DE RETENÇÃO OPERADA POR PILOTO 4.

VÁLVULA SELETORA
OPERADA POR PILOTO
2.
VÁLVULA DE REDUÇÃO DE EMERGÊNCIA (SOMENTE NA
SEÇÃO DE ELEVAÇÃO ESQUERDA) 5. LADO DO CILINDRO
3. LADO PILOTO
Figura 2. Válvulas Operadas por Piloto - Esquema
Lubrificação da glândula
Para fornecer lubrificação às vedações na sobreposta, o lado da haste dentro do cilindro de elevação é
preenchido com óleo hidráulico. Quando o cilindro se estende para a posição mais alta, parte do óleo hidrata
as vedações da glândula.
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A área entre o casco e a haste é fechada por uma válvula de retenção de 1 MPa (145 psi) , localizada na
travessa inferior do mastro externo. A função da válvula de retenção de 1 MPa (145 psi) é reter a pressão do
ar no lado da haste.
Quando o cilindro se estende, o aumento da pressão do ar entre o casco e a haste empurra o óleo através dos
orifícios para dentro da haste. Quando o cilindro retrai, a redução da pressão do ar no lado do casco permite
que o óleo retorne da haste interna para a posição mais alta possível na parte externa da haste.
Válvula de Abaixamento de Emergência
Os cilindros de elevação NÃO abaixarão se a pressão do cilindro de elevação for insuficiente para superar a
força combinada da mola e a pressão do óleo no lado piloto da válvula de retenção. Esta situação ocorre, por
exemplo, quando o peso do carro foi removido dos cilindros de elevação. A válvula de descida de emergência
oferece a possibilidade de aliviar manualmente a pressão do cilindro de elevação para o tanque.
A válvula de descida de emergência combina três funções em um conjunto. A válvula anti-cavitação abre
quando a pressão do cilindro de elevação é inferior à pressão do tanque. A válvula de choque abre quando
(sob condições extremas) a pressão do cilindro de elevação excede 35 MPa (5076 psi) . Girando o volante
no sentido horário, abre a válvula de choque contra a força da mola. Consulte a Figura 3 .
Operação
A válvula de descida de emergência está localizada no lado esquerdo da válvula de controle principal.
Consulte a Figura 3 . O giro inicial do volante no SENTIDO HORÁRIO removerá a folga entre o fuso e a
válvula de choque. Continuar girando no sentido horário abre a válvula de choque contra a força da mola e
permite que o óleo dos cilindros de elevação seja drenado para o tanque. Consulte a Figura 4 .
1. VÁLVULA DE CONTROLE DE DESCIDA DE EMERGÊNCIA
Figura 3. Válvula de Controle de Abaixamento de Emergência - Localização
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UMA. PARA O TANQUE

B. DO CILINDRO
1. VÁLVULA DE CHOQUE
2. VÁLVULA ANTI-CAVITAÇÃO
3. MOLA DA VÁLVULA DE CHOQUE
4. MOLA ANTI-CAVITAÇÃO
5. FUSO
6. RODA DE MÃO
Figura 4. Conjunto da válvula de abaixamento de emergência
A válvula de descida de emergência fecha girando o volante no SENTIDO ANTI- HORÁRIO . Depois que o
fuso perder o contato com a válvula de choque, continue girando o volante no sentido anti-horário o máximo
possível. Isso permite que a válvula anti-cavitação abra quando necessário. Imediatamente depois, gire o
volante uma volta para trás para evitar danos caso o operador não esteja familiarizado com a direção correta
de rotação do volante.
Correntes de elevação
As correntes de elevação são correntes do tipo folha. Uma corrente de folha consiste em pinos e placas de
elos feitos de aço especial. O tratamento térmico e o processamento mecânico conferem aos pinos e placas
sua resistência final, mas também tornam esses componentes mais vulneráveis a fraturas por fadiga, se as
superfícies dos pinos e placas forem danificadas.
Os pinos de ligação são rebitados nas placas externas. O encaixe por pressão dos pinos de ligação nas placas
externas é essencial para a integridade da corrente.
As placas internas têm um ajuste deslizante apertado para uma área de transporte otimizada que também
permite a rotação sobre o pino de ligação. Consulte a Figura 5 .
As correntes são conectadas ao carro e ao mastro externo por meio de âncoras de corrente. O pino entre a
âncora da corrente e a corrente é fixado com um anel elástico.
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1. PLACAS EXTERNAS
2. PINO DE LIGAÇÃO (REBITADO ÀS PLACAS EXTERNAS
3. PLACAS INTERMEDIÁRIAS
4. PLACAS INTERNAS
5. LINK EXTERNO
6. LINK INTERNO
Figura 5. Componentes da Cadeia
Alongamento por desgaste
When the chain articulates, the inner plates rotate over the link pin and cause wear. Wear reduces the pin
diameter and enlarges the hole in the plate, which results in chain elongation. When elongation has reached
3%, the entire chain must be replaced.
Speed of Wear
The speed of wear of link pin and inner plates depends on the following factors:
• Load and impact load. The chain load depends on the weight lifted and the weight of the carriage
and forks. Impact loads occur, when the truck drives over uneven surfaces. The forces generated by an
impact load can be a multiple of those of normal chain load.
• Number of link movements. The number of link movements directly relates to the number of times
the chain passes over the sheave when the mast is raised or lowered. Chain elongation must therefore

be measured at that chain section that runs over the sheave most often. The chain section close to the
carriage will have the lowest number of articulations and is irrelevant for measuring chain elongation.
• Lubrication. An oil film at the contact area between link pin and inner plates reduces wear and
preserves the smooth surface of this contact area. The oil film is particularly important for new chains,
when the contact areas are being broken in. Therefore, it is essential that new chains are lubricated
with oil before they are put into service.
See Figure 6.
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A. CONTACT AREA
Figure 6. Contact Area Between Link Pin and Inner Plates.
Plate Height Wear
The chain plates also wear at the contact area between chain and chain sheave. When the chain moves onto
the sheave, the plates rotate slightly to follow the radius of the sheave. In combination with the high pressure
between chain plates and sheave, this movement causes wear, which affects the strength of the plates. The
maximum allowed wear is 5% of the original link plate height.
Lubrication
An oil film at the contact area between link pin and inner plates reduces wear and preserves the smooth
surface of this contact area. See Figure 6.
The oil film between pin and plates is pushed away under load conditions and must be allowed to restore
daily by removing the load and allowing oil to penetrate again. Restoring the oil film is effected by the
capillary action of oil. This process is to be considered separately from applying new oil to the chain.
Restoring The Oil Film
The capillary action of oil allows restoring the oil film between chain pin and inner plates, provided that
sufficient free flowing oil is present between the plates, and provided that chain tension is as low as possible
during a certain time.
The required time to maintain this low chain tension varies with chain cleanliness and availability of free
flowing oil between the plates. This time can be as short as 30 minutes or extend infinitely when conditions
are unfavorable.
Chain tension should not exceed the own weight of the chain when restoring the oil film. This means that
chains must be slack.
Interruption of the oil film between pin and chain outside reduces the capillary action, but also allows entry of
humidity. Humidity activates the formation of corrosion products, making it even more difficult for oil to
reach the pin contact area. This means that new fresh oil must be applied to the chain before the oil film on
the outside is interrupted.
Maintenance
The purpose of applying new oil to chain is to replenish free flowing oil and restore outside oil film. Adding
new oil will extend the proper conditions for restoring the oil film at the pin area.
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The interval for applying new oil depends on load applied, the number of chain articulations, and ambient
conditions like rain, temperature, presence of dust and dirt.
In many cases the simple application of oil on the chains is sufficient to cover the period until the next
planned service interval. Main pre-condition is that contamination has not progressed too far, which would
prevent oil to penetrate.
Periodically the chains will have to be removed from the truck for cleaning, inspection and re-lubrication by
immersion in oil. Cleaning must allow thorough visual inspection and must be aimed at the removal of wear
particles and used oil at pin contact area.
Maintaining The Presence of Oil
Insufficient lubrication permanently damages the smooth contact area between chain pin and inner plates. Re-
lubricating a damaged contact area afterwards, will not restore the smooth finish of the contact area. A
damaged contact area causes accelerated wear and increased friction.
Increased friction may allow the inner plates to rotate the pin in the outer plates. Once the pin has rotated in
outer plate, integrity of the chain structure is lost. Rotation of a pin in the outer plate is visible when the
beveled end of a pin no longer runs parallel to the length of chain. A chain must be replaced if a pin is at an
angle or if a pin has protruded.
Sufficient lubrication is particularly important for new chains, which require a breaking in of the contact area.
Proper breaking in also requires low load conditions during initial lifting and lowering. At least avoid lifting
high capacity loads initially.
Corrosion Protection
Link pins and chain leaves are made of a steel type that is vulnerable to corrosion. Corrosion causes pits
which are the starting point for fatigue fractures. Corrosion preventing coatings, e.g. paint or grease, cannot
be applied to the chain as these would obstruct the penetration of oil for re-lubrication.
Therefore, the applied lubricating oil must also serve as a protection against corrosion. This outside oil film
must always remain intact to make sure that humidity does not reach the components of the chain, and
certainly not the contact area between pin and plate.
Circumstances like temperature, dust and rain will dictate the frequency of re-application of oil to the chain to
restore a protecting film. Re-apply oil before the oil film is interrupted.
Requirements for Chain Lubricant
The chain lubricant must be a mineral or synthetic engine oil. Oil viscosity must match the ambient
temperature, so that the oil remains viscous and can penetrate contact area between link pin and intermediate
link.
• Use SAE 20W to 30W oil in ambient temperatures of −30 to 5°C (−22 to 41°F)
• Use SAE 40 oil in ambient temperatures of 5 to 45°C (41 to 113°F)
• Use SAE 50 oil in ambient temperatures above 45°C (113°F)
DO NOT use the following lubricant types:

• Lubrication products that contain solids such as graphite or molybdenum disulfide. Solids will not

penetrate between the plates, and over time, they will form a barrier that prevents oil penetration.
• Grease or lubrication products that stiffen or form a greasy film.
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Stiffening products do not penetrate sufficiently. Grease does not penetrate at all. Stiffening products
and grease form a barrier that prevents penetration of oil for re-lubrication. Without proper lubrication,
the service life of a lift chain is minimized.
• Penetrating fluids or aerosol spray lubricants containing penetrating fluids do not provide adequate

lubricity, adhesion or corrosion protection, and they do not form a film.
NOTE: If an aerosol spray lubricant is used, always check that it deposits an engine oil equivalent minimum
viscosity after the dispersing agent has evaporated.
Load Rollers
Movement of the inner mast within the outer mast, and movement of the carriage in the inner mast are guided
by load rollers to reduce friction. The load on the carriage causes forces on the load rollers in different
directions. The lower load rollers are pushed against the rear of the mast channels. The upper load rollers are
pushed against the front of the mast channels. See Figure 8.
When the mast is tilted completely backward and the carriage is raised, it is possible that the upper load
rollers of the inner mast start traveling on the rear side of the outer mast channel, instead of the front side. To
reduce this backward movement of the inner mast inside the outer mast, mast support pads are installed at the
top of the outer mast. See Figure 7.
1. OUTER MAST
2. INNER MAST
3. LIFT CYLINDER
4. MAST SUPPORT PAD
Figure 7. Mast Support Pads
Bearing Blocks
The carriage and inner mast are equipped with bearing blocks. These absorb sideways forces, which cannot
be absorbed by the load rollers. The bearing blocks are shimmed close to mast channels. Re-shimming is
required when sideways movement causes shocks that affect load handling.
The bearing blocks on the carriage are located just above the load rollers. On the mast the lower bearing
blocks are located above the lower rollers on the inner mast. The upper bearing blocks are at the upper
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channel end of the outer mast. See Figure 8.
1. LOAD ROLLER
2. BEARING BLOCK
3. INNER MAST
Figure 8. Bearing Blocks and Load Rollers on Inner Mast
CARRIAGE
Three types of carriages are available for different combinations of side-shifting and fork positioning.
• The standard carriage can have manual or hydraulic fork positioning.
• The carriage with integral side shifting has a separate apron, which carries a pin type carriage.
• The dual function carriage is provided with fork carriers, which allow side shifting under load.
Standard Carriage with Manual Fork Positioning
The pin-type forks are kept in position by two locking pins. A spring ball keeps the pins in place. An
attaching cable keeps the pins from being lost. Each side of the carriage has four holes to enable securing
forks at three different positions. The forks are repositioned manually after releasing the locking pins from the
carriage. See Figure 9.
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1. CABLE
2. LOCKING PIN
3. CARRIAGE
4. FORK
Figure 9. Standard Carriage with Manual Fork Positioning
Standard Carriage with Hydraulic Fork Positioning
The pin-type forks are positioned by fork guides that are attached to fork positioning cylinders. By activating
the directional control valve the cylinders move the guides and forks individually or simultaneously. See
Figure 10.
Sufficient grease must be present on fork pin and lower carriage bar to reduce wear and friction during fork
positioning.
1. CARRIAGE
2. FORK GUIDE
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3. FORK
4. FORK POSITIONING CYLINDERS
Figure 10. Standard Carriage with Hydraulic Fork Positioning
Dual Function Side Shift and Fork Positioning (DFSSFP) Carriage
Forks and fork guides for DFSSFP carriages are designed to side shift under loaded conditions. For this
purpose the fork has a bushing at the fork eye and each fork guide has a bearing block where it touches the
lower carriage bar. Both the bushing and bearing block are serviceable components. See Figure 11.
1. CARRIAGE
2. FORK GUIDE
3. FORK
4. FORK POSITIONING CYLINDERS
Figure 11. DFSSFP Carriage
Integral Side Shift
The carriage with integral side shift has a separate apron, which carries the forks. By activating the side shift
cylinder the entire apron is moved over the apron pins. To reduce friction during side shifting the apron has
bushings at the apron bracket and bearing blocks between apron and carriage. It is possible to have an apron
with or without hydraulic fork positioning. Construction and functionality of such aprons is similar to the
above described carriages. See Figure 12.
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1. CARRIAGE
2. APRON PIN
3. APRON BRACKET
4. FORK POSITIONING CYLINDER
5. SIDE SHIFT CYLINDER
6. FORK
Figure 12. Integral Side Shift
Carriage Valve
Different types of Valves can be installed depending on the number and type of hydraulic functions on the
carriage. Oil supply is through header hoses, for either a Fixed Pressure and Tank (P & T) system or for an
Alternating Pressure & Tank system. An electrical cable is routed over hose sheaves, parallel with header
hoses. For header hose connections see section Step 4.
Alternating Pressure and Tank (P & T)
Alternating P & T is applied when a limited number of functions allow the control valve on the truck to
determine direction of oil flow. Examples are: one single function, Simultaneous Fork Positioning only, and
Dual Function with Fork Positioning only.
For alternating P & T systems there are two header hoses, which are marked with two colored straps.
• Green-Yellow is connected with control valve port Aux A.
• Green-Green is connected with control valve port Aux B.
For alternating P & T systems, two different carriage control valves are used:
• Flow divider for simultaneous Fork Positioning
• Valve for Dual Function with Side Shift and Fork Positioning (DFSSFP)
Fixed Pressure and Tank (P & T)
Fixed P & T systems are applied when control valve on the carriage determines the direction of oil flow to
different functions. Fixed P & T systems require three header hoses, which have the following strap marking:
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• Green is connected with control valve port Aux A.

• Yellow is connected with control valve port T3.
• White-Yellow is connected with control valve port T Aux.
NOTE: Nomenclature for the right and left fork positioner cylinder can be confusing. The right fork
positioner cylinder moves the right fork, however, the right fork positioner is located at the left side of the
Flow Divider for Simultaneous Fork Positioning
Simultaneous cylinder movement of the fork positioner cylinders is controlled by a flow restrictor and two
relief valves in the Flow Divider Manifold. The flow restrictor provides an equal oil volume to the piston side
of fork positioner cylinders. The relief valves maintain an equal pressure at rod side of the cylinders when
they extend. When the cylinders retract, equal movement is controlled by flow restrictors only.
Differences in mechanical resistance of the two fork positioners and / or leakages may result in unequal
cylinder extension positions. Correction of the cylinder end positions is obtained by a continued activation of
this function until both cylinders have reached their end positions. See Figure 13 and Figure 14.
A. TO MAIN CONTROL VALVE PORT AUX B D.

TO PISTON SIDE LH FORK POSITIONER
CYLINDER
B. TO MAIN CONTROL VALVE PORT AUX A
E.
C. TO PISTON SIDE RH FORK POSITIONER TO ROD SIDE RH FORK POSITIONER
CYLINDER
CYLINDER F.
TO ROD SIDE LH FORK POSITIONER
CYLINDER
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1. FLOW RESTRICTOR 2. RELIEF VALVE
Figure 13. Flow Divider Port Connections - Schematic
A. TO MAIN CONTROL VALVE PORT AUX B

C. TO PISTON SIDE RH FORK POSITIONER CYLINDER
D. TO PISTON SIDE LH FORK POSITIONER CYLINDER
E. TO ROD SIDE RH FORK POSITIONER CYLINDER
F. TO ROD SIDE LH FORK POSITIONER CYLINDER
1. FLOW RESTRICTOR
2. RELIEF VALVE
Figure 14. Valve for Simultaneous Fork Positioning
Valve for Dual Function with Side Shift and Fork Positioning (DFSSFP)
Fork positioning is controlled by simultaneous activation of the Auxiliary spool in the main control valve and
activation of a fork positioner solenoid in the valve for Dual Function with Side Shift and Fork Positioning
(DFSSFP). Pressure will be applied to both cylinders, but only the selected cylinder will be able to move as
its return oil escapes through the selected solenoid.
The direction of cylinder movement is controlled by selecting the A-side or B-side of the Auxiliary spool in
main control valve.
Side shifting is controlled by connecting the piston sides of both cylinders and pressurization of one of the
cylinders at rod side. Oil extruding from the pressurized cylinder will move the piston of the second cylinder.
Activation of the Auxiliary A-spool activates side shifting to the left until one of the cylinders has reached its
end-position. Activation of the B-spool activates side shifting to the right.
Two relief valves limit supply pressure to 20 MPa (2901 psi) for each of the supply lines. Each solenoid valve
has impact relief valves to protect the system against pressure peaks. See Figure 15 and Figure 16.
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A. TO MAIN CONTROL VALVE PORT AUX B D.

TO PISTON SIDE LH FORK POSITIONER
CYLINDER
E.
C. TO ROD SIDE LH FORK POSITIONER TO PISTON SIDE RH FORK POSITIONER
CYLINDER
CYLINDER F.
TO ROD SIDE RH FORK POSITIONER
CYLINDER
1. SIDE SHIFT SOLENOID 3. RH FORK POSITIONER SOLENOID

2. LH FORK POSITIONER SOLENOID 4. RELIEF VALVE
Figure 15. Schematic for Dual Function Valve
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1. SIDE SHIFT SOLENOID (SS) - CONNECTOR CPS 153

2. LH FORK POSITIONER SOLENOID - CONNECTOR CPS 155
3. RELIEF VALVE
4. RH FORK POSITIONER SOLENOID - CONNECTOR CPS 154
5. PORT LEFT A - TO ROD SIDE RH FORK POSITIONER
6. PORT RIGHT A - TO ROD SIDE LH FORK POSITIONER
7. PORT LEFT B - TO PISTON SIDE RH FORK POSITIONER
8. PORT RIGHT B - TO PISTON SIDE LH FORK POSITIONER
9. PORT A1 - FROM CONTROL VALVE AUX A
10. PORT B1 - FROM CONTROL VALVE AUX B
Figure 16. Valve for Dual Function with Side Shift and Fork Positioning (K007/J019 Shown)
Fixed Pressure and Tank System (Fixed P & T)
Fixed P & T systems use a directional control valve which can have up to four valve sections to operate the
different functions through solenoid valves. The electric signal is provided by one wire harness for all
versions of this type of control valve. Unused harness connectors are folded back against the wire harness and
taped in. See Table 3 for the identification of functions, connectors and wire numbers.
Hydraulic operation of the directional valve is similar to operation of the main control valve. The difference
in this directional valve is the absence of a line sensing connection with the pump, the addition of a two stage
relief valve and addition of a pilot pressure supply valve.
The function of the two stage relief valve is to maintain supply pressure just above the required pressure as
signaled by the internal LS line. Oil supply pressure is regulated by relieving excess pressure through port T3
in the main control valve. Maximum supply pressure is regulated by the 19.5 MPa (2828 psi) relief valve,
which reliefs through Port T Aux in main valve.
The function of the pilot pressure supply valve is to maintain oil supply to a maximum pressure of
1.5 MPa (218 psi) for operation of auxiliary spools. See Figure 17 and Figure 18.
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1. HYDRAULIC FUNCTION 4. PILOT PRESSURE SUPPLY VALVE

2. INLET MODULE 5. SOLENOID
3. RELIEF VALVE 6. CYLINDER
Figure 17. Schematic for Fixed P& T Directional Control Valve
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1. PORT B
2. PORT A
3. PORT T0 = CONNECTS WITH T AUX
4. PORT T = CONNECTS WITH T3
5. PORT P = CONNECTS WITH A AUX
6. INLET MODULE
7. 3RD FUNCTION
8. 4TH FUNCTION
9. 5TH FUNCTION
Figure 18. Directional Control Valve, Fixed P & T Systems
Forks
Two different fork constructions are used, depending on type of carriage. The standard pin type fork is used
when the fork will not be moved under load. The application is for different versions of fork positioning. The
dual function fork has a bushing to allow side shifting under load. See Figure 19.
1. STANDARD PIN TYPE FORK

2. DUAL FUNCTION FORK
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Figure 19. Fork Types
SAFETY PROCEDURES WHEN WORKING NEAR MAST
The procedures below must be followed, when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast. Follow the repair procedures in this
section.
WARNING
Mast parts are heavy and can move. Distances 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 place any part of the body into or under the mast or carriage unless all parts are
completely lowered or a safety chain is installed. Also make sure that the power is OFF and
the key is removed. Place a DO NOT OPERATE tag in the operators compartment.
• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an

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

the mast.
• DO NOT use blocks to support the mast weldments nor to restrain their movement.
• Mast repairs can require disassembly and removal of parts and can require removal of the

mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there

is no movement in the mast. Make sure that all parts of the mast that can move are fully lowered.
OR
2. If parts of the mast must be in raised position, install 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 cross-member of the inner mast with a cross-member on the

outer mast. See Figure 20.
c. Use a 1/2 inch minimum safety chain with a hook to fasten the crossmembers together so the
movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is

completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or
chain sheaves, tubes, hoses, fittings, or other parts on the mast.
d. Lower the mast until there is tension in the safety chain and the free-lift cylinder (two-stage, full
free-lift, and three-stage masts only) is completely retracted. If running, stop the 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) between the top or bottom crossmember of the

carriage and a crossmember on the outer weldment.
3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the

key. Place a DO NOT OPERATE sign in the operator's compartment.
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1. OUTER
2. HOOK
Figure 20. Mast Safety Chains
BEFORE STARTING REPAIRS TO THE HYDRAULIC SYSTEM, ALWAYS:
1. Place the lift truck on a solid, level surface.
2. Apply the parking brake.
3. Tilt the mast completely forward.
4. Lower the carriage and inner mast completely. Make sure the lift cylinders are completely retracted.
5. Turn engine OFF.
6. Turn the key switch to the ON position.
7. Operate the lift and tilt levers completely forward and backward to remove any trapped hydraulic

pressure.
8. Apply the brake pedal until the brake lights do not longer come ON when the brake pedal is fully

depressed.
9. Turn the key switch to the OFF position.
10. Place blocks against both sides (front and back) of the tires to prevent movement of the lift truck.
Remove and Replace

FORKS
Remove
Table 1. Fork Sizes And Weights
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Table 1. Fork Sizes And Weights
Model Type Fork Size Shortest Shortest Longest Longest

Fork Fork Fork Fork
Length Weight Length Weight
H8-9XM (H170- Pin 65 x 200 mm 1220 mm 176 kg 2440 mm 266 kg
210HD 2) (2.6 x 7.8 in.) (48 in.) (388 lb) (96 in.) (586 lb)
H8-12XM Pin 75 x 200 mm 1220 mm 214 kg 2440 mm 336 kg
(H170-280HD2) (3 x 7.8 in.) (48 in.) (472 lb) (96 in.) (741 lb)
Pin, 75 x 200 mm 1220 mm 187 kg 1825 mm 228 kg
PFT* (3 x 7.8 in.) (48 in.) (412 lb) (71.9 in.) (503 lb)
DFSSFP 70 x 200 mm 1220 mm 208 kg 2440 mm 422 kg
(2.8 x 7.8 in.) (48 in.) (459 lb) (96 in.) (930 lb)
H13-16XM Pin 90 x 200 mm 1370 mm 292 kg 2440 mm 422 kg
(H300-360HD2) (3.5 x 7.8 in.) (54 in.) (644 lb) (96 in.) (930 lb)
DFSSFP 90 x 200 mm 1830 mm 374 kg 2440 mm 447 kg
(3.5 x 7.8 in.) (72 in.) (825 lb) (96 in.) (985 lb)
The approximate weight for alternative fork lengths can be calculated by extrapolation between shortest
and longest fork lengths. The indicated weights are for one fork. *PFT = Polished Fully Tapered
WARNING
The mast assembly and its components are heavy. To avoid causing damage or injuries, a
lifting device must be used during all service procedures.
1. On carriages with manual fork positioning: remove retainer pins that secure forks.
2. Position forks in front of hoist chains.
3. Place a pallet on a hydraulic jack or hand pallet wagon. Place pallet under one of the forks. Lift pallet

at least 5 cm (2 in.) off ground.
4. Place mast in a vertical position and lower mast until fork is stable on pallet.
5. Attach fork guide to a lifting device. The fork guide weighs 12 kg (26.4 lb). Put tension on lifting

device until it carries the weight of fork guide.
6. Remove capscrews and bracket that retain fork pin in carriage. See Figure 21.
WARNING
Only remove the fork pin when the fork is properly supported and when there is no tension
on the fork pin or damage and personal injury may occur.
NOTE: The fork pin weighs 55 kg (121.2 lb). For fork weights, see Table 1.
7. Use a hydraulic jack or hand pallet wagon to relieve tension from fork pin and move fork pin until its
end has reached the fork.
a. For carriages with manual fork positioning, attach a lifting device to fork pin with a sling and

move fork pin out of fork.
b. For carriages with hydraulic fork positioning, move fork pin just out of fork, but still inside

side plate of fork guide.
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8. Lower pallet with fork and move fork away from truck.
9. Return fork pin to its assembled position and install retainer bracket. Remove lifting strap from fork

guide.
10. Repeat Step 4 through Step 9 to remove remaining fork.
1. CAPSCREWS
2. WASHER
3. BRACKET
4. FORK PIN
5. RETAINER PIN
Figure 21. Fork - Remove
Install
1. Put mast in a vertical position and lower carriage almost completely.
2. Position fork guides in front of hoist chains.
3. Attach a lifting strap and lifting device to fork guide. The fork guide weighs 12 kg (27 lb). Put tension

on lifting strap until it carries weight of fork guide.
NOTE: The fork pin weighs 55 kg (121.2 lb). The fork weighs between 180 kg (396.8 lb) and
270 kg (595.2 lb).
4. Remove capscrews and bracket that retain fork pin to carriage. See Figure 21.
a. For carriages with manual fork positioning, attach a lifting device to fork pin with a sling about

one foot from inner end of the pin. Move pin until there is sufficient space to install fork.
b. For carriages with hydraulic fork positioning, move fork pin out of carriage until its inner end

is still inside the side plate of fork guide.
5. Place each fork on a separate pallet.
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6. Use a hydraulic jack or hand pallet wagon to position a fork in fork guide, while the back of fork
touches carriage.
7. Lift fork on pallet until fork pin aligns with the pin tube of fork.
8. Slide fork pin through fork pin tube to its final mounting position in carriage.
9. Install bracket with four capscrews that retain fork pin to carriage. Tighten bolts to 66 N•m (49 lbf ft).
10. Repeat Step 1 through Step 9 to install remaining fork.
11. Remove lifting devices.
FORK GUIDE AND FORK PIN
Remove
1. Position forks in front of hoist chains.
2. Attach a lifting device at rod side of fork positioner cylinder.
3. Remove securing pin and pin that connects the cylinder rod to fork guide. See Figure 22.
NOTE: The fork guide weighs 10 kg (22 lb) for fork positioners. The fork guide weighs 16 kg (35 lb) for
Dual Function Side Shift and Fork Positioning (DFSSFP) carriages.
4. Attach a lifting device to fork guide.
5. Remove fork. See section Forks, Remove.
6. Remove DFSSFP guide by sliding it off pin, lowering hanger approximately two inches and then

move guide on ground. Take care to not loosen wear pad at back of guide.
7. Remove standard guide for fork positioning by sliding it off fork pin and putting it on ground.
NOTE: The fork pin weighs 55 kg (121.2 lb).
8. Attach a lifting device to fork pin at carriage outside.
9. Have fork pin supported at both ends before it is removed entirely from carriage.
10. Remove fork pin and lower lifting device to put fork pin on a pallet.
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1. CAPSCREWS
2. WASHERS
3. BRACKET
4. FORK PIN
5. FORK GUIDE
6. CARRIAGE
7. FORK
Figure 22. Fork Guide And Pin
Install
NOTE: The fork pin weighs 55 kg (121.2 lb).
1. Use a lifting device to lift fork pin.
2. Install one end of pin into carriage until it is in front of hoist chains.
3. For Dual Function Side Shift and Fork Positioning (DFSSFP) fork guides, use a new wear pad if pad

thickness is 20 mm (0.79 in.) or less. Minimum allowable pad thickness is 15 mm (0.59 in.).
4. Put a layer of grease on wear pad to attach it to DFSSFP fork guide.
NOTE: The fork guide weighs 10 kg (22 lb) for fork positioners. The fork guide weighs 16 kg (35 lb) for
DFSSFP carriages.
5. Use a lifting device to position one ear of fork guide onto fork pin.
6. Install fork. See section Forks, Install.
7. Install pin and securing pin that connect cylinder rod of fork positioner cylinder to fork guide.
8. Remove lifting device.
CARRIAGE
Remove
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Table 2. Carriage Weights
Model Type Weight

H8-9XM (H170-210HD2) Standard 762 kg
(1680 lb)
Standard with fork positioner 970 kg
(2138 lb)
Side shift carriage 1266 kg
(2791 lb)
Side shift with fork positioner 1358 kg
(2987 lb)
(2994 lb)
(2552 lb)
(2557 lb)
(3150 lb)
(3047 lb)
(3197 lb)
(3993 lb)
(7683 lb)
NOTE: Carriage removal is necessary for inspection and replacement of load rollers and bearing blocks. All
other serviceable carriage components can be replaced with carriage installed in mast.
1. Remove forks. See section Forks, Remove.
2. Place lift truck on a solid, level surface.
3. Apply parking brake.
4. Tilt mast slightly backwards.
5. Turn engine OFF.
6. Turn key switch to ON position.
7. Operate lift and tilt levers completely forward and backward to remove any trapped hydraulic

pressure.
8. Apply brake pedal until brake lights do not longer come ON when brake pedal is fully depressed.
9. Turn key switch to OFF position.
10. Place blocks at front and back of all tires to prevent movement of lift truck.
11. Attach a lifting device to carriage. Make sure that lifting device is correctly positioned to pull carriage

in lifting direction of mast only.
12. Operate lifting device until lift chains of mast are slack.
13. Disconnect lift chains from anchor chain. Remove split pin and washer from chain pin, support chain

anchor and remove chain pin.
14. Attach a strap through lower end of each chain.
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15. Attach straps around inner mast below two upper mast roller stubs.
16. Connect a rope between strap at chain and inner mast. The ropes must have twice length of carriage

height.
17. Disconnect electric mast cable from carriage bracket and remove cable clamp. Place caps on all open

electrical connectors.
18. Tag and disconnect header hoses at carriage bracket. Place plugs and caps at open fittings.
19. Attach a 4 m (13 ft) long rope to header hoses and tie rope to upper part of inner mast. This is to
prevent hoses from being pulled over the sheave, and to give them sufficient slack when inner mast
goes up.
20. Start engine and operate lift cylinders to raise inner mast until mast channels are well above upper

bearing blocks of carriage.
21. Move lifting device with carriage away from mast and put carriage on blocks on the ground with load

rollers facing up.
22. Lower mast completely and shut down engine.
Install
1. Place blocks at front and back of all tires to prevent movement of lift truck.
WARNING
Use caution when removing or installing the snap rings used to fasten the load rollers to the
stub shafts. The snap rings can come loose with force if not properly removed or installed.
Wear eye and face protection when the snap rings are removed or installed.
2. Inspect rollers on carriage. If replacement is required, remove snap ring and load roller from stub

shaft. Install a new load roller and snap ring. See section Load Rollers, Replace.
3. Verify correct shimming of bearing blocks.
a. Measure distance between outer faces of bearing blocks on carriage.
b. Measure distance between inside of left and right hand channel of inner mast. Measure entire length
of inner mast to establish shortest distance. Establish shortest distance with an accuracy of
0.5 mm (0.02 in.). See section Mast Bearing Blocks, Install.
c. Calculate actual play between inner mast and bearing blocks by deducting distance between outer

faces of bearing blocks (3a), from distance between mast channels (3b).
d. Determine number of additional shims by deducting another 0.15 to 1.0 mm (0.006 to 0.039 in.)

from actual play as calculated in (3c).
e. Loosen four bolts that hold bracket to allow inserting required shims.
f. When dividing shims, make sure that left and right hand blocks extend a similar distance from

vertical carriage frame plates. Make sure that this distance is the same at the same plate.
g. Install a new bearing block if more than 5 shims are required for correct shimming.
h. When reinstalling a bearing block, tighten securing bolt to 9 N•m (79.7 lbf in).
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i. After bearing block assembly is correctly shimmed, tighten four bracket bolts to
44 N•m (32.5 lbf ft).
4. Attach a lifting device to carriage.
5. Lift carriage and move it in front of mast. Verify that upper and lower load rollers are parallel with

mast. Correct carriage position as necessary.
6. Start engine and operate lift cylinders to raise inner mast until mast channels are well above upper

bearing blocks. Tilt mast backward until mast and carriage have same tilt position.
7. Move carriage to position upper bearing blocks into inner mast channels.
8. Use the emergency lowering valve to lower mast slowly. DO NOT damage bearing blocks when they

enter mast channel. See Figure 3.
9. Lower mast further until lower load rollers and lower bearing blocks have entered. Lower mast

completely.
10. Reconnect lift chains to chain anchors.
11. Lower lifting device, detach and remove from carriage.
12. Adjust chain length. See section Lift Chain, Lift Chains Adjustment.
13. Use rope to lower header hoses and electric cable. Remove rope.
14. Remove caps and plugs and install header hoses to fittings on carriage bracket.
15. Maintain tension on electric mast cable while tightening cable clamp. See Figure 23.
16. Attach electrical connector. See Figure 23.
17. Start engine and operate hydraulic functions on carriage. Make sure that functions operate correctly.

Check for leaks.
18. Remove blocks that have been placed at both sides of tires.
1. HEADER HOSES
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2. ELECTRICAL CONNECTOR CLAMP

3. ELECTRIC MAST CABLE CONNECTOR
Figure 23. Carriage Bracket
Carriage Bearing Blocks
Remove
1. Remove carriage. See section Carriage, Remove.
2. If necessary, remove four capscrews and washers that retain bearing block bracket and shims to

3. Remove button head capscrew and nut that retain bearing block to bearing block bracket. See

Figure 25.
1. CAPSCREW
2. WASHER
3. CARRIAGE
4. SHIM
5. BEARING BLOCK
Figure 24. Carriage Bearing Block
1. CAPSCREW
2. WASHER
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3. SHIM
4. BEARING BRACKET
5. BEARING BLOCK
6. SPACER
7. WASHER
8. BUTTON HEAD CAPSCREW
Figure 25. Bearing Block Assembly
Install
NOTE: Install bearing blocks with curved side towards load roller.
1. Measure distance between inside of left hand and right hand channel of inner mast. Measure entire
length of inner mast to establish shortest distance. Establish shortest distance with an accuracy of
0.5 mm (0.02 in.). See Figure 26.
A. DISTANCE BETWEEN INNER MAST CHANNELS
Figure 26. Inner Mast Channel Measurement
2. Temporarily place new bearing blocks for carriage in bearing block brackets and measure distance

between outer faces of bearing blocks. See Figure 27.
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A. DISTANCE BETWEEN THE OUTER FACES OF THE BEARING BLOCKS
Figure 27. Bearing Block Measurement
3. Determine number of required shims by deducting distance as established in Step 2 from distance as

established in Step 1.
4. To obtain required clearance between mast and carriage deduct another 0.5 to 1.0 mm (0.02 to

0.04 in.) from distance as established in Step 3.
NOTE: A maximum of five shims can be added behind bearing block in case bearing block is reused. If
more than five shims are required, replace bearing blocks.
5. Divide shims equally between left and right bearing blocks. Shims are available in thicknesses of

0.5 mm (0.02 in.), 1.5 mm (0.06 in.), and 3.0 mm (0.12 in.).
Carriage Load Rollers
Replace
Starting 2014, the masts have been provided with greasable load rollers, which are retained by three bolts.
Masts built before 2014 have non-greasable load rollers, which are retained by a snap ring.
2. Remove dirt to allow inspection of load rollers. Do not clean.
3. Inspect rollers. The seals must be in good condition. Axial bearing play must be less than

0.7 mm (0.028 in.). Grease must still be present in bearing. The roller must allow smooth rotation.
WARNING
4. Remove the bolts or the snap ring from the stub shaft and remove the load roller. See Figure 28 and

Figure 29.
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5. Install a new load roller, install the bolts or a new snap ring.
6. Tighten the bolts to 40 N•m (29.5 lbf ft).
7. Install the carriage. See section Carriage, Install.
1. SNAP RING
2. LOAD ROLLER
3. STUB SHAFT
Figure 28. Carriage Load Rollers, Non-Greaseable
1. GREASE FITTING
2. BOLT
3. STUB SHAFT CAP
4. LOAD ROLLER
5. STUB SHAFT
6. CARRIAGE
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Figure 29. Carriage Load Rollers, Greasable
Side Shift Cylinder
Remove
1. Place lift truck on a solid level surface and apply parking brake.
2. Retract side shift cylinder by side shifting to left completely both cylinders by moving both forks to

center of truck.
3. Tilt mast completely backward and lower carriage and inner mast completely. Make sure lift cylinders

are completely retracted.
4. Turn engine OFF.
5. Turn key switch to the ON position.

pressure.
7. Apply brake pedal until brake lights no longer come ON when brake pedal is fully depressed.
8. Turn key switch to the OFF position.
9. Place blocks against both sides (front and back) of tires to prevent movement of lift truck.
10. Disconnect two hydraulic tubes from cylinder. See Figure 30.
11. Install caps on the fittings of cylinder and hydraulic tubes.
12. Connect a lifting device to side shift cylinder. The cylinder weighs 25 kg (55 lbf).
13. Remove nut from rod side of cylinder followed by nut at cylinder side.
14. Pull carriage to right hand side of truck and remove side shift cylinder.
1. SIDE SHIFT CYLINDER

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2. HYDRAULIC CONNECTIONS
3. LOCKNUTS
Figure 30. Side Shift Cylinder Remove
Disassemble
1. Place side shift cylinder on a clean, horizontal surface.
2. Remove outer snap ring on gland. See Figure 31.
3. Push gland into shell until retainer ring is exposed.
4. Remove retainer ring.
5. Pull rod assembly and gland from cylinder shell.
6. Remove gland from rod.
7. Remove and discard the wiper, seal, back-up ring and O-ring from gland.
8. Do NOT remove piston form rod unless there is a reason to replace seal between piston and rod.
9. Remove lock nut from rod and remove piston.
10. Remove and discard seal and back-up ring from piston.
11. Remove O-ring from rod at piston side.
1. LOCK NUT 8. EXTERNAL SNAP RING

2. PISTON 9. RETAINER RING
3. PISTON SEAL 10. WIPER
4. PISTON BACK-UP RING 11. SEAL
5. PISTON O-RING 12. BACK-UP RING
6. CYLINDER SHELL 13. GLAND O-RING
7. CYLINDER ROD 14. GLAND
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Figure 31. Side Shift Cylinder Assembly
Clean And Inspect
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using
cleaning solvents, always follow the solvent manufacturer’s recommended safety
precautions.
1. Clean all parts in a cleaning solvent and dry them with compressed air.
2. Inspect parts of side shift cylinder for damage, rust, or wear.
3. Inspect rod surface closely to make sure it is free of dents and scratches.
4. Make sure that internal stroke surface of cylinder shell and grooves for seals do not show any nicks,

scratches, or other damage.
5. Replace parts as needed.
Assemble
1. Place O-rings and seals in hydraulic oil.
2. If removed, install a new O-ring at piston end of rod.
3. Install piston on rod and tighten lock nut. Tighten nut to 260 N•m (192 lbf ft).
4. Install a new seal and back up ring onto piston.
5. Install new seals and back up rings to gland.
6. Apply hydraulic oil to inside of gland and slide it onto rod.
7. Apply hydraulic oil to outer diameter of piston and gland and carefully slide piston and gland into

shell.
8. Push gland into shell until retainer ring can be installed.
9. Install a new retainer ring and pull rod with piston out of shell until gland stops on retainer ring and

snap ring groove is exposed.
10. Install snap ring on retainer.
Install
1. Inspect and if necessary replace spherical bushing at rod side of cylinder.
2. Slide washer and spherical bushing on cylinder rod.
3. Connect a lifting device to cylinder. The cylinder weighs 25 kg (55 lb).
4. Lift cylinder and insert rod at apron side of carriage and install nut. DO NOT tighten nut.
5. Move apron and insert stud at cylinder end into carriage.
6. Install washer and nut, rotate cylinder into correct position and tighten nut to 300 N•m (221 lbf ft).
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7. Tighten nut at rod side to 300 N•m (221 lbf ft).
8. Connect two hydraulic tubes to cylinder.
9. Start engine and operate hydraulic system. Make sure that side shift cylinder works correctly.
Fork Positioner Cylinder
Remove
1. Place lift truck on a solid level surface and apply parking brake.
2. Retract both cylinders by moving both forks to center of truck.
3. Tilt mast completely backward and lower carriage and inner mast completely. Make sure lift cylinders

are completely retracted.
4. Turn engine OFF.

pressure.
10. Disconnect two hydraulic tubes from cylinder. See Figure 32.
11. Install caps on fittings of cylinder and hydraulic tubes.
12. Connect a lifting device to positioner cylinder. The cylinder weighs 25 kg (55 lb).
13. Remove split pin and pin retaining rod side of cylinder to fork guide.
14. Remove split pin and pin retaining rod side of cylinder to carriage.
15. Remove straps and hose from cylinder.
16. Remove cylinder and repeat Step 12 through Step 15 to remove other cylinder.
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1. FORK POSITIONER CYLINDER

2. SPLIT PIN
3. PIN
4. HYDRAULIC CONNECTIONS
5. STRAPS
Figure 32. Fork Positioner Cylinder
Disassemble
1. Place fork positioner cylinder on a clean, horizontal surface.
2. Insert a pin face spanner into bores in gland and remove gland from cylinder shell. See Figure 33.
1. CYLINDER SHELL 7. PISTON SEAL

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2. CYLINDER ROD 8. ROD SEAL

3. PISTON 9. WIPER
4. RETAINER 10. BACK-UP RING
5. NUT 11. O-RING
6. SPACER
Figure 33. Fork Positioner Cylinder Assembly
CAUTION
Keep the piston rod aligned with the center line of the cylinder shell during removal to avoid
damage to the cylinder parts.
3. Carefully pull piston rod out of cylinder shell.
4. Remove locking nut from piston retaining piston to piston rod.
5. Remove piston from piston rod.
6. Remove gland from piston rod.
7. Remove and discard piston seal from piston.
8. Remove and discard wiper, seal, back-up ring and O-ring from gland.
Clean and Inspect
WARNING
precautions.
1. Clean all parts in a cleaning solvent and dry them with compressed air.
2. Inspect parts of cylinder for damage, rust, or wear. Inspect rod surface closely to make sure it is free of

dents and scratches.
3. Make sure that internal stroke surface of cylinder shell and grooves for seals do not show any nicks,

scratches, or other damage.
4. Replace parts as needed.
Assemble
1. Place O-rings and seals in hydraulic oil.
2. Install wiper, seal, back-up ring and O-ring to gland.
3. Install seal to piston.
4. Lubricate piston rod with hydraulic oil and install gland onto piston rod.
5. Install spacer onto piston rod.
6. Install piston onto piston rod.
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7. Install locking screw that retains piston to piston rod. Tighten nut to 260 N•m (192 lbf ft).
CAUTION
Keep the piston rod aligned with the center line of the cylinder shell during installation to
prevent damage to the parts.
8. Carefully slide piston rod and gland into cylinder shell.
9. Insert a pin face spanner into holes of gland and install gland into cylinder shell. Tighten gland to

300 N•m (221.5 lbf ft).
Install
1. Connect a lifting device to cylinder.
2. Position cylinder onto carriage.
3. Install pin and split pin that retain rod side of cylinder to fork guide.
4. Install pin and split pin that retain cylinder side to carriage.
5. Connect two hydraulic tubes to cylinder.
6. Repeat Step 1 through Step 5 for other cylinder.
7. Start engine and operate hydraulic system. Make sure that side shift and fork positioner cylinders work

correctly.
Carriage Valves
Remove
NOTE: Most serviceable components can be replaced without removing the carriage valve. For replacement
of a section in a fixed Pressure & Tank (P & T) valve, it is necessary to remove and disassemble the entire
valve.
3. Tilt mast completely forward.
4. Lower carriage and inner mast completely. Make sure lift cylinders are completely retracted.
5. Turn engine OFF.

pressure.
11. Tag and disconnect electrical connectors from solenoids on the valve.
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• For Fixed P & T Valves, see Figure 34.

• For Simultaneous Fork Positioner Valves, see Figure 37.
• For Dual Function Side Shift and Fork Positioning (DFSSFP) Valves, see Figure 38.
12. Tag and disconnect hydraulic supply and return hoses from hoses that connect to the directional

control valve. Plug openings of hoses and valve.
13. The valve for DFSSFP carriages is mounted on bottom carriage bar. Remove three capscrews under

bottom carriage bar to remove valve.
14. All other valves are mounted on a bracket at the top carriage bar. Remove the two nuts and washers at
the upper side of the bracket. Lift the bracket with the valve vertically over the mounting studs, to
remove from the carriage. See Figure 35.
1. PORT B
2. PORT A
3. PORT TO = CONNECTS WITH T AUX
4. PORT T = CONNECTS WITH T3
5. PORT P = CONNECTS WITH A AUX
6. INLET MODULE
7. 3RD FUNCTION
8. 4TH FUNCTION
9. 5TH FUNCTION
Figure 34. Fixed P & T Valve Connections
Install
1. Mount the valve on the bracket with Torx screws.
2. Position the valve in the center on the top of the carriage.
3. Install the two cap screws and washers that retain the valve to the carriage. See Figure 35.
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4. Remove plugs and caps from the hydraulic lines and ports.
5. Connect the supply and return hoses.
6. Connect the hydraulic hoses between the valve and the hydraulic functions.
7. Connect the electrical connectors to the solenoids on the valve. See Figure 35.
1. NUT
2. WASHER
3. BRACKET
4. P & T VALVE
Figure 35. Bracket for Fixed P & T Valve
Valve for Fixed P & T Systems
Remove and Disassemble
1. Remove four torx screws that retain the P & T valve to bracket.
2. Place the valve on a clean, horizontal surface.
3. Remove four capscrews that retain electrical end cap to mid-section. See Figure 36.
4. Remove electrical end cap from mid-section.
5. Repeat Step 2 and Step 3 to remove remaining electrical end caps.
6. Remove four capscrews that retain the valve end cap to mid-section.
7. Remove the valve end cap from mid-section.
8. Repeat Step 5 and Step 6 to remove remaining valve end caps.
9. Remove the three nuts from the tie-rods.
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10. Carefully remove the tie-rods from the valve. See Figure 36.
11. Separate mid-sections and the end section.
12. Remove the O-rings from the mid-sections and the end section. See Figure 36.
A. PORT T0 = T AUX - ON MAIN CONTROL VALVE D. PORT A

B. PORT T = T3 - ON MAIN CONTROL VALVE E. PORT B
C. PORT P = A AUX - ON MAIN CONTROL VALVE
1. INLET MODULE 5. O-RING

2. END MODULE 6. VALVE HOUSING
3. TIE-ROD 7. SPOOL
4. SOLENOID 8. END CAP
Figure 36. Fixed P & T Valve Assembly
Clean and Inspect
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. If using
precautions. Compressed air can move particles and cause injury to the user or to other
personnel. Make sure compressed air path is away from all personnel. Wear eye protection.
1. Clean all parts of the fixed P & T valve with solvent and carefully dry the parts with compressed air.
2. Check the valve end caps and bores for defects. If a valve end cap or bore is damaged, replace the
valve section that contains the damaged part or parts. Make sure the bores and grooves for O-rings are
smooth and do not contain dirt or have defects.
3. Check the electrical end caps for damage and replace the damaged electrical end caps.
4. Check each tie-rods and nuts for thread damage and replace the damaged tie rods and nuts.
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Assemble and Install

NOTE: Lubricate all parts using hydraulic oil before assembly.
1. Install new O-rings to the valve housing and end caps. See Figure 34.
2. Place the three tie-rods in an end section.
WARNING
Be careful not to damage the threads of the tie-rods during assembly of the mid-sections
and end-sections.
3. Carefully place a mid-section over the three tie-rods against the end section.
4. Carefully place the remaining mid-sections over the three tie-rods against the first installed mid-

section.
5. Carefully place the second end section against the mid-section.
6. Install the three nuts onto the tie-rods and tighten to 26 to 30 N•m (230 to 266 lbf in).
7. Position a valve end cap to a mid-section.
8. Install the four cap screws that retain the valve end cap to the mid-section and tighten to 7.5 to

8.5 N•m (66.6 to 75.4 lbf in).
9. Repeat Step 7 to install the remaining valve end caps.
10. Position the electrical end cap against a mid-section.
11. Install the four cap screws that retain the electrical end cap to the mid-section and tighten to7.5 to

8.5 N•m (66.6 to 75.4 lbf in).
12. Repeat Step 10 and Step 11 to install the remaining electrical end caps.
13. Install the fixed P & T valve to the bracket using the four Torx screws.
Table 3. Spool Identification for Fixed P & T Systems
Function Hydraulic Connector Electrical Wire

Identification Code Identification Numbers
Side Shift 3rd function CPS 149 Aux 0 703-704
Left Fork 4th function CPS 150 Aux 1 705-706
Positioner
Right Fork 5th function CPS 151 Aux 2 709-710
Positioner
Auxiliary 6th function CPS 152 Aux 3 702-711
NOTE: For certain configurations, the functions Side shift and Fork Positioner can be replaced by an
auxiliary function. The auxiliary function will then receive the hydraulic and electrical identification of
the function that is being replaced.
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Flow Divider for Simultaneous Fork Positioning Valve
Restrictor Valve and Relief Valve Replacement
1. Remove valve from housing.
2. Instal new O-rings.
3. Install valve and tighten to 220 to

230 N•m (162 to 170 lbf ft). See Figure 37.
A. TO MAIN CONTROL VALVE PORT AUX B

C. TO PISTON SIDE RH FORK POSITIONER
D. TO PISTON SIDE LH FORK POSITIONER
E. TO ROD SIDE RH FORK POSITIONER
F. TO ROD SIDE LH FORK POSITIONER
1. FLOW RESTRICTOR
2. RELIEF VALVE
Figure 37. Valve for Simultaneous Fork

Positioning
Dual Function Valve for Side Shifting and Fork Positioning
Solenoid Valve Replacement
1. Remove connector from coil and remove the nut that retains the coil to the valve.
2. Inspect the valve for wear and damage.
3. If necessary clean the valve with a petroleum based solvent.
4. Use new O-rings for installation.
5. Install the valve and tighten to 35 to 40 N•m (310 to 354 lbf in).
6. Install the coil on the valve and tighten nut to 4 to 6 N•m (35 to 53 lbf in).
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7. Replace the harness connector.
1. SIDE SHIFT SOLENOID (SS) - CONNECTOR CPS 153

2. LH FORK POSITIONER SOLENOID - CONNECTOR CPS 155
3. RELIEF VALVE
4. RH FORK POSITIONER SOLENOID - CONNECTOR CPS 154
5. PORT LEFT A - TO ROD SIDE RH FORK POSITIONER
6. PORT RIGHT A - TO ROD SIDE LH FORK POSITIONER
7. PORT LEFT B - TO PISTON SIDE RH FORK POSITIONER
8. PORT RIGHT B - TO PISTON SIDE LH FORK POSITIONER
9. PORT A1 - FROM CONTROL VALVE AUX A
10. PORT B1 - FROM CONTROL VALVE AUX B
Figure 38. DFSSFP Valve
Relief Valve Replacement
Remove
1. Remove relief valve from housing.
Install
1. Use new O-rings for installation.
2. Install valve and tighten to 220 to 230 N•m (162 to 170 lbf ft).
MAST
Lift Chains and Top Chain Anchor
Remove
1. Place truck on a solid, level surface.
2. Place blocks of approximately 30 cm (1 ft) under carriage frame and lower mast until carriage rests on
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blocks.
3. Use the emergency lowering valve until the lift cylinders are retracted completely and the lift chains

are slack.
4. Turn the engine OFF.
NOTE: Lift chains are heavy. See Table 6 for weights of different chain lengths.
5. Attach a hook to one of the lift chains at top front side of mast, approximately two feet below chain
sheave. The hook must be strong enough to hold weight of chain. Lead hook through links of chain
and attach hook to a lifting device.
6. Remove split pin and washer from chain pins at carriage chain anchors and then remove chain pins.
7. Lift chain slightly until tension is removed from chain pin that connects with chain anchor at top of

mast.
8. Remove split pin and washer from chain pin at top chain anchor. See Figure 39.
9. Support chain anchor and remove chain pin.
10. Remove chain anchor.
11. Lower lifting device and put lift chain on a pallet.
12. Follow Step 6 through Step 11 to remove other lift chain.
1. SPLIT PIN
2. CHAIN PIN
3. CHAIN ANCHOR
Figure 39. Top Chain Anchor
Install
1. Attach a hook to one of the lift chains at approximately 1 m (3 ft) from chain end. The hook must be
strong enough to hold weight of chain. Lead hook through links of chain and attach hook to a lifting
device.
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2. Lift chain until it is in front of chain sheave.
3. Attach a rope at the end of chain and lead rope over sheave, through chain anchor hole in weldment at

top of mast. Pull rope to move chain end above chain anchor hole.
4. Mount chain anchor through hole. See Figure 39.
5. Inspect chain pin for damage.
6. Install chain pin to connect lift chain to chain anchor. Install split pin and washer to secure chain pin.
7. Remove rope.
8. Lower lifting device and remove hook from chain.
9. Install chain pin at lower end of chain into carriage chain anchor. Install washer and a new split pin.
10. Follow Step 1 through Step 9 to install other lift chain.
11. Start engine and raise inner mast to remove blocks under carriage.
12. Lower mast and turn key switch to OFF position.
13. Adjust chain length. See section Lift Chains, Lift Chains Adjustment.
14. Adjust tension of header hoses. See section Header Hose Tension Adjustment.
Chain Anchor On Carriage
Remove
2. Put blocks of approximately 30 cm (1 ft) under carriage frame and lower mast until carriage rests on

blocks.
3. Operate lever for lowering until lift cylinders are retracted completely and lift chains are slack.
4. Turn engine OFF.
5. Remove split pin and washer from chain pins at carriage chain anchors, and remove chain pins. See

Figure 40.
NOTE: Before removing nut, note position of nut on chain anchor.
6. Remove bolt that retains securing plate to carriage.
7. Bend securing plate and remove nuts and plate from chain anchor.
8. Remove chain anchor from carriage.
Install
1. Position chain anchor in carriage. See Figure 40.
2. Install large nut on chain anchor. If second chain anchor was not removed, turn large nut until it has

reached a similar position compared with nut on second anchor chain.
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3. Install securing plate to carriage and lock nut to chain anchor.
4. Inspect chain pin for damage.
5. Connect lift chain to chain anchor by installing chain pin. Install washer and a new split pin to secure

chain pin.
6. If second chain anchor was removed, repeat Step 1 through Step 3.
7. Install securing plate to carriage and lock nut to chain anchor.
8. Start engine and raise inner mast to remove blocks under carriage.
9. Lower mast completely and turn key switch to OFF position.
10. Adjust chain length. See section Lift Chains, Lift Chains Adjustment.
11. Bend fingers of securing plate around large nut.
12. Tighten bolt to secure plate to carriage.
13. Tighten lock nut.
1. SPLIT PIN
2. CHAIN PIN
3. WASHER
4. CHAIN ANCHOR
5. LARGE NUT
6. SECURING PLATE
7. LOCK NUT
8. NUT
9. WASHER
10. CAPSCREW
Figure 40. Chain Anchor on Carriage
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Chain Sheave
Remove
2. Put blocks of approximately 30 cm (1 ft) under inner mast and lower mast until inner mast rests on

blocks.
4. Turn engine OFF.
5. Remove lift chains. See section Lift Chains, Remove.
6. Guide a strap through opening above chain sheave and use strap to support sheave. The chain sheave

weighs approximately 4.4 kg (9.7 lb).
7. Remove capscrew and eye bolt from chain sheave pin. See Figure 41.
8. Remove chain sheave from mast together with spacers by lowering strap.
1. INNER MAST
2. SHEAVE PIN
3. EYE BOLT
4. WASHER
5. CAPSCREW
Figure 41. Chain Sheave
Install
1. Use a strap to position chain sheave in mast and insert spacers. See Figure 42.
2. Insert pin into sheave.
3. Install eye bolt and secure it with capscrews.
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4. Reinstall lift chains and adjust chain length. See section Bob.
1. SHEAVE PIN
2. SHEAVE
3. EYE BOLT
4. CAPSCREW
5. SPACERS
Figure 42. Sheave Spacer Location
Header Hoses
Remove
1. Place truck on solid, level surface.
2. Put blocks of approximately 30 cm (1 ft) under carriage frame and lower mast until carriage rests on

blocks.
4. Turn engine OFF.
5. Release hose clamps on upper mast bracket, by removing capscrews. See Figure 43.
6. Disconnect hydraulic hoses from fittings at lower mast bracket. Put caps on open fittings. See

Figure 44.
7. Open hose clamps which retain hoses to the right hand lift cylinder.
8. Disconnect hydraulic hoses from fittings on carriage bracket. Put plugs and caps on open fittings.
9. Remove hose cap.
10. Remove hoses.
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1. HOSE SHEAVES
2. SHEAVE CAP
3. SHEAVE BRACKET
4. UPPER MAST BRACKET
5. CAPSCREWS AND WASHERS
6. HOSE CLAMPS
Figure 43. Hose Sheaves and Clamps
Item Description Control Valve Carriage Valve Strap Color

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

Number Connection Connection Code
1 Supply Aux B B1 Green/Green
2 Supply Aux A A1 Green/Yellow
3 N/A
4 Breather N/A N/A White/Green
Hose
5 Electric N/A N/A CRP139/
Cable CPS148
A. MAST SIDE B. CARRIAGE SIDE
Figure 44. Header Hose Connections
Install
1. Place hydraulic hoses over hose sheaves.
2. Remove plugs and caps from hose fittings at carriage side.
3. Connect hydraulic hoses to fittings on carriage bracket.
4. Connect hydraulic hoses to fittings on lower mast hose bracket.
5. Lift mast to remove blocks under carriage. Lower carriage.
6. Put tension on hoses and reinstall clamps at upper mast bracket. See Figure 43.
7. Install hose clamps which retain hoses to right hand lift cylinder.
Electric Mast Cable
Remove
1. Turn engine OFF and disconnect battery cables.
2. Disconnect electric mast cable from frame harness.
3. Open hose clamps retaining electric cable to right hand lift cylinder.
4. Remove cable clamp at upper mast bracket. See Figure 45.
5. Remove cable from sheave.
6. Disconnect cable from carriage bracket. See Figure 44.
7. Remove electric cable.
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1. SHEAVE BRACKET
2. INNER MAST
3. UPPER MAST BRACKET
4. CAPSCREWS
Figure 45. Upper Mast Bracket and Sheave Bracket
Install
1. Put middle of electric cable over sheave.
2. Connect electric mast cable with connector at carriage bracket.
3. Install cable clamp at carriage bracket. Provide some slack at carriage side for event that electric mast

cable has to be repositioned.
4. Insert connector at mast side in mast bracket and install clamp ring. Reconnect mast cable with frame

harness. See Figure 44.
5. Install clamps that attach electric cable to mast.
6. Tension carriage side of cable and install clamp on upper mast bracket.
Hose Sheave
Remove and Disassemble
1. Remove header hoses and electric mast cable. See sections Header Hoses, Remove and Electric Mast

Cable, Remove.
2. Remove capscrew, spacer, washer, and hose sheaves.
3. Slide hose sheaves and spacers from pin. See Figure 46.
4. Inspect sealed bearings for wear. Replace entire sheave if damaged.
Assemble and Install
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1. Apply multipurpose grease to sheave pin.
2. Slide hose sheaves and spacers on pin. Both spacers and hose sheaves can be installed either way.
3. Put additional grease at end of pin and install capscrew with washer. Tighten capscrew to

120 N•m (88 lbf ft).
4. Install header hoses and electric mast cable. See sections Header Hoses, Install and Electric Mast

Cable, Install.
1. CAPSCREW
2. WASHER
3. SHEAVE PIN
4. SHEAVE BRACKET
5. SHEAVES AND SPACERS
6. SPACER
Figure 46. Hose Sheaves
Mast Assembly
Remove
Table 6. Mast Component Weights
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Table 6. Mast Component Weights
Unit Lift Height Mast Inner Mast Outer Mast

Assembly Weight Weight
Weight
H8-9XM-6 (H190-210HD2) 3686 mm 1510 kg 509 kg 677 kg
(145.0 in.) (3328.9 lb) (1122.1 lb) (1492.5 lb)
4586 mm 1670 kg 578 kg 728 kg
(180.5 in.) (3681.7 lb) (1274.3 lb) (1604.9 lb)
5336 mm 1840 kg 621 kg 838 kg
(210.0 in.) (4056.4 lb) (1369.0 lb) (1847.4 lb)
H10-12XM-6, H10XMS-6 (H230-280HD2, 3686 mm 2060 kg 762 kg 817 kg
H230HDS) (145.0 in.) (4541.5 lb) (1679.9 lb) (1801.2 lb)
4586 mm 2270 kg 838 kg 894 kg
(180.5 in.) (5004.4 lb) (1847.4 lb) (1970.9 lb)
5336 mm 2510 kg 902 kg 1121 kg
(210.0 in.) (5533.5 lb) (1988.5 lb) (2471.3 lb)
6130 mm 2670 kg 970 kg 1188 kg
(241.5 in.) (5886.2 lb) (2138.5 lb) (2619.0 lb)
6630 mm 2780 kg 1012 kg 1231 kg
(261.0 in.) (6128.7 lb) (2231.0 lb) (2713.8 lb)
H13-16XM-6, H10-12XM-12EC (H300- 3660 mm 2506 kg 938 kg 1217 kg
360HD2, H360HD2-EC) (144.0 in.) (5524.7 lb) (2067.9 lb) (2682.9 lb)
4560 mm 2771 kg 1068 kg 1309 kg
(179.5 in.) (6108.9 lb) (2354.5 lb) (2885.8 lb)
5310 mm 3118 kg 1144 kg 1561 kg
(209.0 in.) (6873.9 lb) (2522.0 lb) (3441.4 lb)
6110 mm 3313 kg 1225 kg 1649 kg
(240.5 in.) (7303.8 lb) (2700.6 lb) (3635.4 lb)
6610 mm 3439 kg 1276 kg 1704 kg
(260.3 in.) (7581.6 lb) (2813.1 lb) (3756.6 lb)
2. Lower inner mast and make sure lift cylinders are completely retracted.
3. Turn engine OFF.
5. Operate the lift and tilt levers completely forward and completely backward to remove any trapped

hydraulic pressure.
6. Apply and release the brake pedal until the brake lights do not longer come ON when the brake pedal

is fully depressed.
8. Disconnect mast lights harness from the mast harness connector and disconnect the frame harness

from the mast harness connector at header hoses bracket. See Figure 44.
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9. Tag and disconnect hoses that lead to header hose bracket.
10. Place plugs and caps on hoses and fittings on header hose bracket. See Figure 44.
11. Tag and disconnect hydraulic hose at base of each lift cylinder.
12. Install plugs and caps on fittings at base of lift cylinders and in hydraulic hoses.
NOTE: See Table 6 for the correct weights of the mast. Make sure the lifting device has the proper capacity
rating.
13. Strap lift chains and header hoses to lift cylinders to prevent them from moving while lowering mast.
14. Connect a lifting device to lifting eyes on outer mast. Position lifting device above lifting eyes. Put

tension on lifting device to have it carry weight of mast. See Figure 47.
1. LIFTING EYE
Figure 47. Lifting Eyes
WARNING
DO NOT push the cylinder pins out with your fingers. DO NOT permit the tilt cylinders to
drop and cause damage or personal injury.
15. Disconnect tilt cylinders from mast as follows:
a. Put a wooden block between front fender and tilt cylinder to support tilt cylinder.
b. At rod end, remove capscrew and eye bolt to unlock pin that retains tilt cylinder to mast. See

Figure 48.
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1. TILT CYLINDER
2. ROD END
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING
6. EYE BOLT
7. WASHER
8. LOCKING BOLTS
9. RELIEF VALVE (K007 ONLY)
10. HYDRAULIC LINES
11. PLUG
Figure 48. Tilt Cylinder Connections
c. Make sure wooden blocks are placed correctly on front fender and support the tilt cylinder.
d. Use a soft hammer to remove the tilt cylinder pin out of the tilt cylinder and the mast bracket.
e. Repeat Step a through Step d to disconnect other tilt cylinder from mast.
f. Start engine.
g. Completely retract tilt cylinders and stop engine.
16. Remove capscrews and washers from mast mounting pins that connect mast to frame. See Figure 49.
17. Use a soft hammer to remove the mast mounting pins.
18. Lift mast away from truck.
19. Lower mast on blocks so mast mounts and tilt cylinder mounts are facing up.
20. Place blocks under outer mast so that inner mast can move.
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1. MAST
2. CAPSCREWS
3. GREASE FITTING
4. SHIM
5. FRAME
6. BUSHING
7. MAST MOUNTING PIN
Figure 49. Mast Mounted to Frame
Disassemble
1. Remove straps which temporarily retain chains and header hoses.
2. Remove clamps that retain header hoses and electric cable to right hand lift cylinder.
3. Remove hoses and cable. See section Header Hoses, Remove.
4. Remove hoses connecting between lift cylinders at top and bottom. Put caps on all open fittings.
5. Remove lowering control valve from lift cylinder and put caps on open fittings.
6. Lead a hook through links of one of chains and attach hook to a lifting device.
7. Remove split pin end pin to release chain from upper chain anchor.
8. Remove chain and place it on a pallet.
9. Repeat Step 3 to Step 8 to remove other chain.
10. Remove isolator blocks at rear top side of outer mast.
11. If installed, remove bearing block assemblies at top of outer mast. See Figure 51.
12. Support lift cylinders to prevent them from falling or moving.
13. Remove capscrews and washers that secure lift cylinders to top of inner mast. See Figure 50.
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14. Attach a lifting device to top cross member of inner mast and pull inner mast half way out of outer

mast.
15. Attach any shim to cylinder if found installed at top of cylinder. Apply right hand and left hand

markings to cylinders according their installation.
16. Remove securing bolt at bottom of lift cylinders.
17. Attach a lifting device to lift cylinders and remove them from outer mast.
WARNING
See Table 2 for the correct weight of the inner mast. Make sure the lifting device has the
proper capacity rating.
18. Attach a lifting device to center of inner mast and remove inner mast from outer mast.
1. LIFT CYLINDERS
2. SMALL WASHERS
3. WASHERS
4. CAPSCREWS
Figure 50. Lift Cylinder Top
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1. CAPSCREWS
2. WASHERS
3. BEARING BLOCK ASSEMBLY
Figure 51. Bearing Block Bracket
Assemble
1. Inspect bushings for tilt cylinder pins in brackets of outer mast. Replace if worn or damaged.
2. When reinstalling bushings, at mast side, make sure that split in bushing is turned away by 45° from

centerline of tilt cylinder and is in virtually highest position. See Figure 52.
1. TILT CYLINDER PIN

2. BUSHING
3. BUSHING SPLIT
4. GREASE CHANNEL
Figure 52. Tilt Cylinder Bushings
3. Inspect load rollers on inner mast. If replacement is required see instructions under Inner Mast Load

Rollers.
4. Verify correct shimming of bearing blocks.
a. Verify correct shimming of bearing blocks.
b. Measure distance between inside of left and right hand channel of outer mast as shown in Figure 53.
Measure entire length of outer mast to establish shortest distance. Establish shortest distance with an
accuracy of 0.5 mm (0.02 in.).
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A. DISTANCE BETWEEN FACES OF OUTER MAST CHANNELS
Figure 53. Outer Mast Channel Measurement
c. Calculate actual play between outer mast and bearing blocks by deducting distance between outer

faces of bearing blocks (Step a), from distance between mast channels (Step b).
d. Determine number of additional shims by deducting another 0.5 to 1.0 mm (0.02 to 0.04 in.) from

actual play as calculated in Step c.
e. Loosen four bolts for each bracket to allow inserting required shims.
f. When dividing shims, make sure that left and right hand blocks extend a similar distance from inner

mast channel. Make sure that this distance is same at same channel.
g. Install a new bearing block if more than 5 shims are required for correct shimming.
h. When reinstalling a bearing block, tighten securing bolt to 9 N•m (80 lbf in).
i. Do not yet install bearing block at top of outer mast.
j. After bearing block assembly is correctly shimmed, tighten four bracket bolts to

44 N•m (32.5 lbf ft).
WARNING
See Table 6 for the correct weight of the inner mast. Make sure the lifting device has the
proper capacity rating.
5. Attach a lifting device to center of inner mast and install inner mast into outer mast until it is

approximately 1 m (3 ft) from completely retracted position.
6. Attach a lifting device to lift cylinders and install lower end into bottom cross member of outer mast.
7. Install securing washer with bolt at bottom of cylinders. Tighten bolt to 35 N•m (26 lbf ft).
8. Install bearing blocks at top of outer mast with correct number of shims for a total play of 0.5 to

1.0 mm (0.02 to 0.04 in.).
9. Support lift cylinder to align its top end with mounting hole in inner mast.
10. Install shims on lift cylinder if originally installed. If a different cylinder is installed, establish correct

shimming. See section Lift Cylinder, Install.
11. Retract inner mast to seat both lift cylinders.

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12. Install securing washer with bolt at top of lift cylinder. Tighten bolt to 200 N•m (148 lbf ft). See

Figure 50.
13. Install and shim isolator blocks to obtain a play of 0.5 to 1.5 mm (0.02 to 0.06 in.) between blocks and

inner mast channel. Tighten nut to 53 N•m (39 lbf ft).
14. Position hoist chains at top of mast and lead one chain end over sheave to top chain anchor.
15. Connect lift chain by installing chain pin and securing it with washer and a new split pin.
16. Install lowering control valve at bottom of lift cylinders.
17. Install hoses connecting between lift cylinders at top and bottom.
18. Install header hoses and electric cable provisionally over sheave and secure with straps.
Install
NOTE: Inspect mast pins and bushings for wear prior to install. Replace if required.
1. Install the bushings, grease the mast pin and insert the pin with the grease fitting pointing to the center

of the truck.
2. Apply grease to the mast shims to stick them against the RH hanger. Position one shim at the inside
and two or three shims at the outside of the RH hanger. Turn the shims with their opening facing up.
Do NOT install shims at the LH hanger.
3. See for the correct weight of mast. Make sure lifting device has proper capacity rating.
4. Connect a lifting device to lifting eyes on outer mast. See Figure 48.
5. Lift and position mast in front of lift truck.
6. Lower mast hangers on mast pins.
7. Connect mast pins with hangers using 4 capscrews.
Tighten capscrews to 435 N•m (321 lbf ft) for lift truck models H007, J007, and K007
Tighten capscrews to 522 N•m (385 lbf ft) for lift truck models G019, H019, and J019
8. Connect tilt cylinders to mast as follows:
a. Turn engine ON.
b. Extend tilt cylinders until rods are almost in correct position.
c. Lift tilt cylinders to align holes in rods with holes in mast.
d. Install tilt cylinder pins with lube fittings facing outside of truck. See Figure 54.
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1. TILT CYLINDER
2. ROD END
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING
6. EYE BOLT
7. WASHER
8. LOCKING BOLTS
9. RELIEF VALVE (K007 ONLY
10. HYDRAULIC LINES
11. PLUG
e. Install eye bolts and capscrews to secure tilt cylinder pins.
9. Disconnect lifting device from lifting eyes of outer mast.
10. Adjust backward tilt position. See section Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.
11. Remove plugs at end of hydraulic header hoses.
12. Remove caps from fittings at lower mast bracket.
13. Install the carriage. See Carriage, Install.
14. Connect header hoses to mast bracket. See Figure 55.
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1. SHEAVE PIN
2. SHEAVE
3. EYE BOLT
4. CAPSCREW
5. SPACERS
Figure 55. Sheave Location
15. Connect mast lights harness to the mast harness connector and connect the frame harness to the mast

harness connector at header hoses bracket.
16. Adjust tension of header hoses and electric cable after carriage has been installed.
WARNING
DO NOT try to locate hydraulic leaks by placing hands on pressurized hydraulic
components. Hydraulic oil can be injected into the body by pressure.
17. Check for leaks.
18. Remove blocks on both sides (front and back) of tires.
19. Lubricate the bushings for the mast pivot and the tilt cylinder.
20. Reinstall carriage. See Carriage, Install.
Inner Mast Load Rollers
Replace
Starting 2014, the masts have been provided with greasable load rollers, which are retained by three bolts.
Masts built before 2014 have non-greasable load rollers, which are retained by a snap ring.
1. Remove carriage. See Carriage, Remove.
2. Remove inner mast. See Mast Assembly, Remove.
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3. Remove dirt to allow inspection of the load rollers. Do not clean.
4. Inspect rollers. The seals must be in good condition. Axial play must be less than 0.7 mm (0.028 in.).

The roller must allow smooth rotation. Verify slight binding caused by the presence of grease.
WARNING
5. Remove the bolts or the snap ring from the stub shaft and remove the load roller. See Figure 56 and

Figure 57 .
6. Install a new load roller with the bolts or a new snap ring.
7. Tighten the bolts to 40 N•m (29.5 lbf ft).
8. Install inner mast. See Mast Assembly, Install.
9. Install carriage. See Carriage, Install.
1. SNAP RING
2. LOAD ROLLER
3. STUB SHAFT
Figure 56. Mast Load Rollers, Non-Greaseable
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1. GREASE FITTING
2. BOLT
3. STUB SHAFT CAP
4. LOAD ROLLER
5. STUB SHAFT
6. INNER MAST
Figure 57. Mast Load Rollers, Greaseable
Mast Bearing Blocks
Remove
2. Remove capscrew, washer and spacer which retain bearing block. Remove bearing block. See

Figure 58.
1. BEARING BLOCK ASSEMBLY

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2. SHIMS
3. CAPSCREWS
4. INNER MAST
Figure 58. Mast Bearing Block
3. Remove button head capscrew retaining bearing block and shims to bearing block bracket. See

Figure 59.
1. CAPSCREWS
2. WASHERS
3. SHIMS
4. BEARING BRACKET
5. BEARING BLOCK
6. SPACER
7. WASHER
8. BUTTON HEAD CAPSCREW
Figure 59. Bearing Block Assembly
Install
1. Measure distance between inside of left and right hand channel of outer mast as shown in Figure 60.
Measure entire length of outer mast to establish shortest distance. Establish shortest distance with an
accuracy of 0.5 mm (0.02 in.).
2. Install new bearing blocks in bearing block brackets. Tighten capscrew to 9 N•m (80 lbf in). DO NOT

overtighten.
3. Measure distance between outer faces of bearing blocks.
4. Determine number of required shims by deducting result distance in Step 3 from result distance in

Step 1.
5. To obtain required clearance between mast and carriage deduct another 0.5 to 1.0 mm (0.02 to

0.04 in.) from result distance in Step 4.
6. Divide shims equally between left and right bearing blocks. Shims are available in thicknesses of

0.75 mm (0.03 in.).
7. Loosen four bolts which retain bearing blocks to allow inserting correct number of shims.
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8. Tighten bolts to 44 N•m (32 lbf ft).
A. DISTANCE BETWEEN FACES OF OUTER MAST CHANNELS
Figure 60. Outer Mast Channel Measurement
LIFT CYLINDERS
Remove
1. Remove mast. See section Mast Assembly, Remove.
2. Unstrap chains and hoses from lift cylinders.
3. Remove bleeder hoses from lift cylinders. See Figure 61.
1. BLEEDER HOSES
Figure 61. Bleeder Hoses
4. Remove fittings at top of lift cylinders.
5. Remove base hose between right hand and left hand lift cylinder. See Figure 62.
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1. BALANCE LINE
2. LOWERING CONTROL VALVE
3. LIFT CYLINDERS
Figure 62. Lift Cylinder Base - Hoses
6. Remove lowering control valve at bottom of lift cylinders. Plug open ports.
7. Remove capscrews and washers that secure lift cylinders to lower weldment of outer mast. See

Figure 63.
1. CAPSCREWS
2. WASHERS
3. LIFT CYLINDERS
Figure 63. Lift Cylinder Base
8. Attach a lifting device to top cross member of inner mast.

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9. Pull inner mast out of outer mast gently, until load rollers touch t upper mast bearing blocks.
WARNING
The lift cylinder weight varies between 100 and 250 kg (221 and 551 lb), depending on the
truck model. Make sure the lifting device has the proper capacity rating.
10. Attach a lifting device to one of the lift cylinders.
11. For high lift masts, remove top bracket at upper weldment. See Figure 64.
NOTE:
* INDICATES FOR HIGH MAST LIFT TRUCKS ONLY.
1. CAPSCREWS* 6. PLATE*
2. WASHERS* 7. OUTER MAST
3. LIFT CYLINDER* 8. INNER MAST
4. HOSE* 9. TOP BRACKET
5. BRACKET*
Figure 64. Lift Cylinder and Mast Arrangement
12. Remove capscrew and washers that retain cylinder at top of inner mast. See Figure 65.
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1. LIFT CYLINDERS
2. SMALL WASHERS
3. LARGE WASHERS
4. CAPSCREWS
Figure 65. Lift Cylinder Top
13. Move cylinder towards bottom of inner mast, until it comes out of bracket at top weldment. See

Figure 64.
14. Move cylinder towards top of inner mast, slightly twisting to inner side of mast, until lower end of

cylinder has come out of upper weldment.
15. Remove cylinder from mast.
16. Repeat Step 10 to Step 14 to remove other lift cylinder.
Disassemble
1. Place lift cylinder on clean, horizontal surface.
2. Use a tool to remove gland from cylinder shell. See Figure 66.
1. CYLINDER SHELL 9. O-RING

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2. LOCK RING 10. BACKUP RING
3. HYDRAULIC CONNECTION 11. NOT SERVICEABLE PART
4. ROD END 12. WEAR BAND
5. ROD SEAL 13. SEAL
6. WIPER 14. WEAR BAND
7. NOT SERVICEABLE PARTS 15. BOTTOM END
8. WEAR BANDS
Figure 66. Lift Cylinder Assembly
CAUTION
Keep the piston rod aligned in the center of the cylinder shell during removal to avoid
damage to the cylinder parts.
3. Keep rod aligned with cylinder and pull piston rod out of cylinder shell.
4. Remove gland from piston rod. See Figure 66.
NOTE: Mark each seal and ring location and position to aid in assembly.
5. Remove wear band and seal from piston rod.
6. Remove O-ring, backup ring, wear band, rod seal, and wiper from gland.
Clean and Inspect
WARNING
procedures. Compressed air can move particles so they cause injury to the user or to other
personnel. Make sure that the path of the compressed air is directed away from all
personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
Clean all parts in solvent and dry with compressed air. Inspect parts of lift cylinders for damage, rust, or wear.
Carefully inspect rod surface to make sure it is free of dents and scratches. Make sure internal stroke surface
of cylinder shell and grooves for seals do not show any nicks, scratches, or other damage. Repair or replace
parts as needed.
Assemble
1. Apply packing lubricant and install wear band and piston seals onto piston and gland. See Figure 66.
2. Apply packing lubricant and install gland onto piston rod.
CAUTION
Keep the piston rod aligned in the center of the cylinder shell during installation to prevent
damage to the parts.
3. Carefully slide piston rod and gland into cylinder shell.
4. Use a tool to install gland into cylinder shell. Tighten gland to 550 to 625 N•m (406 to 461 lbf ft).
5. Turn cylinder, until upper port faces up.
6. Lubricate gland seals by adding 7 liter (7.4 qt) of hydraulic oil to breather port.
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7. Put a plug in upper port.
Install
1. Extend inner mast approximately 0.9 m (3 ft).
2. Attach a lifting device to lift cylinder. Make sure position of cylinder matches cylinder support at

bottom of mast.
3. Move top end of cylinder under top cross member to upper cylinder bracket.
4. Lower bottom end of cylinder and position it into cylinder support at bottom of outer mast.
5. Install large washer and capscrew provisionally at bottom of cylinder. Make sure there is
2 mm (0.08 in.) play between large washer and mast support. If required, add small sized washers
between cylinder cap and large washer. See Figure 67.
1. LARGE WASHER
2. CAPSCREW
3. SMALL WASHERS
4. LOWERING CONTROL VALVE
5. LIFT CYLINDER END CAP
6. CYLINDER SUPPORT
Figure 67. Lift Cylinder Bottom End
6. Repeat Step 1 to Step 4 to install second cylinder.
7. Lift top of cylinders to align them with upper bracket in inner mast and retract inner mast until both

cylinders are inserted.
8. Install washers and bolts that secure the top of lift cylinder to inner mast.
9. Tighten bolts at top and bottom of cylinder.
10. Remove plugs from cylinders, use new O-rings and install fittings for bleeder hose and lowering

control valves.
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11. Tighten lowering control valve to 150 to 165 N•m (111 to 122 lbf ft).
12. Install hose between left and right hand cylinder base. See Figure 62.
13. Install bleeder hose between lift cylinders and connect with bleeder hose leading to check valve at

lower cross member. See Figure 63.
14. Install mast as described in section Mast Assembly, Install.
15. Check shimming of hoist cylinders after mast has been installed. See section Lift Cylinder Shimming.
TILT CYLINDERS
Remove
NOTE: The following procedure is used to service one tilt cylinder at a time. If both cylinders are to be
serviced at once, mast must be secured with a lifting device.
3. Tilt mast completely forward.
4. Lower carriage and inner mast completely. Make sure lift cylinders are completely retracted.
5. Turn engine OFF.
6. Turn key switch to ON. position.

pressure.
8. Apply brake pedal until brake lights no longer come ON. when brake pedal is fully depressed.
9. Turn key switch to OFF. position.
10. Place blocks against both sides (front and back) of the tires to prevent movement of lift truck.
11. Disconnect hydraulic hoses from tilt cylinder. Put caps on hydraulic lines and ports.
12. For lift truck models K007 and J019 remove relief valve from tilt cylinder to prevent damage during

removal.
13. For lift truck models J007 and H019 remove counter balance valve from tilt cylinder to prevent

damage during removal.
WARNING
The tilt cylinder weighs between 39 kg (86 lb) and 45 kg (99 lb), depending on truck and mast
type. Verify the lifting device has the rated capacity to lift the tilt cylinder.
14. Install a lifting device to tilt cylinder to be removed and allow device to carry weight of cylinder.
15. At rod end, remove capscrew and eye bolt to unlock pin that retains tilt cylinder to mast. See

Figure 68.
WARNING
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Do not push the anchor pins out with your fingers. Do not permit the tilt cylinders to drop
and cause damage.
16. Use a soft hammer to remove pin from rod end of tilt cylinder.
17. Lift tilt cylinder into an upright position.
18. At frame side, remove capscrew and eye bolt to unlock tilt cylinder pin that retains tilt cylinder to

frame.
19. Use a puller tool to remove pin from cylinder end of tilt cylinder.
20. Lift tilt cylinder away from truck.
1. TILT CYLINDER
2. ROD END
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING
6. EYE BOLT
7. WASHER
8. LOCKING BOLTS
9. RELIEF VALVES (K007 ONLY)
10. HYDRAULIC LINES
11. LUBRICATION POINT
Disassemble
1. Put tilt cylinder in a vise with soft jaws, in a horizontal position.
2. Disassemble and remove rod end by removing two locking bolts/nuts. See Figure 68.
3. Loosen gland from shell.
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CAUTION
Be careful not to damage the smooth surface of the piston rod when removing the piston
rod from the cylinder shell in a horizontal position (parallel to the cylinder shell).
4. Pull piston rod assembly with gland out of cylinder shell.
CAUTION
Be careful not to damage the grooves when removing seals, wipers, and wear rings.
5. DO NOT remove piston from rod unless there is a reason to replace seal between piston and rod.
6. Disassemble and remove all seals, wipers, and wear rings.
Clean and Inspect
WARNING
procedures. Compressed air can move particles so they cause injury to the user or to other
personnel. Make sure that the path of the compressed air is directed away from all
personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
Clean all parts in solvent and dry with compressed air.
Inspect parts of tilt cylinder for damage, rust, or wear. Carefully inspect rod surface for dents and scratches.
Verify that internal stroke surface of cylinder shell and grooves for seals do not show any nicks, scratches, or
other damage. Replace parts as needed.
Assemble
NOTE: Verify that all parts are clean before assembly. Always use new seals and O-rings. Lubricate all parts
with clean hydraulic oil.
1. Assemble new seals, wipers, and wear rings according to Figure 68.
2. If removed, install the piston on rod using a new O-ring. Tighten nut to 950 to 980 N•m (700 to

725 lbf ft).
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1. ROD 7. CYLINDER SHELL

2. HOLE PLUG 8. PISTON
3. ROD WIPER 9. LOCK NUT
4. ROD SEAL 10. GUIDE RING
5. BACKUP RING 11. PISTON SEAL
6. O-RING 12. O-RING
Figure 69. Tilt Cylinder Assembly
CAUTION
Be careful not to damage the smooth surface of the piston rod when installing the piston rod
into the cylinder shell in a horizontal position (parallel to the cylinder shell).
NOTE: Keep the piston rod in the center of the cylinder shell during installation to prevent damage to the
parts.
3. Lubricate cylinder shell bore with clean hydraulic oil. Push piston rod assembly into cylinder shell.
4. Push gland onto cylinder shell. Lubricate threads of cylinder shell with clean oil and tighten gland to

550 to 600 N•m (400 to 450 lbf ft).
5. Assemble rod end onto rod.
Install
NOTE: The locking bolts on rod end of tilt cylinder should always be on bottom side with nuts towards
center of truck. See Figure 68.
1. Inspect bushings for tilt cylinder pins in brackets for frame and outer mast. Replace bushings if worn

or damaged.
2. When reinstalling bushings, make sure that, at mast side, split in bushing is turned away by 45° from

centerline of tilt cylinder and is in virtually highest position. See Figure 70.
3. Use a lifting device to move tilt cylinder to truck.
4. Align cylinder and frame brackets.
5. Grease tilt cylinder pin and insert it in frame bracket.
6. Install eye bolt and the capscrew. See Figure 69.
7. Align cylinder and mast brackets.
8. Grease tilt cylinder pin and insert the pin in the mast bracket using a soft hammer.
9. Install eye bolt and capscrew. See Figure 69.
10. Tighten capscrews on both eye bolts to 165 N•m (122 lbf ft).
11. Install relief valve at rod side port of tilt cylinder.
For lift truck models (K007) and (J019), install relief valve at rod side port of tilt cylinder.
For lift truck models (J007) and (H019), install counterbalance valve at rod side port of tilt cylinder.
12. Connect hydraulic lines to tilt cylinder.

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13. Operate tilt cylinders. Check for correct operation and leakage. See section Lift and Tilt Cylinders

Leak Check.
14. Adjust tilt cylinders as described in section Tilt Cylinder Stroke and Backward Tilt Angle

Adjustment.
15. Tighten nuts on rod end to 66 N•m (49 lbf ft).
16. Apply grease to grease fittings, until grease escapes from bushings.
1. TILT CYLINDER PIN

2. BUSHING
3. BUSHING SPLIT
4. GREASE CHANNEL
Figure 70. Tilt Cylinder Bushings
Checks and Adjustments

GENERAL CHECKS
Mast Condition Check
WARNING
Lower the lift mechanism completely. Never allow anyone under a raised carriage. Do not
put any part of your body in or through the lift mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED. Before making any repairs, use blocks and
chains on the inner and outer masts and carriage so that they cannot move. Make sure the
moving parts are attached to a part that does not move.
WARNING
Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by pressure.
1. Inspect welds on the mast and carriage for cracks. Make sure that capscrews and nuts are tight
2. Inspect forks. See section Forks, Fork Inspection and Adjustment.
3. Inspect lift chains and their adjustment. See sections Lift Chain Inspection and Step 2.
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4. Inspect chain anchors and chain pins for cracks and damage. Make sure lock nut on chain anchor is
locked.
5. Inspect rollers for wear or damage. Replace as necessary.
6. Check for leaks. Repair as necessary.
7. Check condition of hydraulic hoses and tubes. Check hose covers for cuts, cracks or exposed

reinforcement. Replace as necessary.
Mast Operation Check
1. Slowly raise and lower mast several times without a load. The mast components must raise and lower

smoothly in correct sequence. Repair as necessary.
2. Verify tensioning of header hoses and proper tracking over sheaves while lifting and lowering. Re-

adjust when required.
3. Verify inner mast lowers completely. The inner mast is lowered when lower side of inner and outer

mast channels are virtually flush with each other.
4. Verify carriage lowers completely. The carriage is completely lowered when forks almost touch the

ground when inner mast is completely lowered and in a vertical position.
5. Check controls for attachment operate functions of attachment as required. See Operating Manual.
6. Verify mast and carriage do not move when lift and tilt controls are in neutral position. Perform a leak

check (if any movement is observed), as described in section Leak Checks.
Counterbalance Valve Check (for J007 and H019 Only)
1. Verify hydraulic oil is at operating temperature 65°C (150°F).
2. Tilt mast fully backwards.
3. Apply tilt forward lever 50% of its possible stroke. Both tilt cylinders should start moving out

simultaneously.
4. Adjust counterbalance valve if one tilt cylinder has moved more than 3 mm (0.12 in.) before the other

tilt cylinder starts moving. See section Counterbalance Valve Adjustment.
Fork Inspection and Adjustment
WARNING
Do not try to correct the alignment of the fork tips by bending the forks or adding shims.
Replace damaged forks.
Never repair damaged forks by heating or welding. Forks are made of special steel using
special procedures. Replace damaged forks.
1. Inspect forks for cracks and wear. Check that fork tips are aligned within 3% of the length of forks.

Check that bottom of fork is not worn. See Figure 71.
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Fork Tip Alignment

Length of Forks 3% Dimension
1220 mm
(48 in.) 37 mm
(1.5 in.)
1830 mm
(72 in.) 55 mm
(2.2 in.)
2440 mm
(96 in.) 73 mm
(2.9 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 3. FORK PIN DAMAGE

2. CRACKS 4. MUST BE 90% OF DIMENSION X
5. FORK WEAR
Figure 71. Check the Forks
2. Replace any damaged or broken parts that are used to keep forks locked in position.
Lift Chain Inspection
WARNING
Never replace just the worn section of a chain. Replace the complete chain. Never replace
just one chain of a chain pair. Replace both chains. When replacing lift chains always
discard the old chain pins at the chain anchors and replace them with new ones.
Perform below inspections in the sequence listed. Re-lubricate chains after all inspections are successfully
passed. See section Lift Chain Lubrication Procedure.
1. Inspect for adequate chain lubrication. Check that the oil film is intact on the outside of the chain
and that oil at the links is still free flowing. When the oil film is found inadequate, there is an

increased risk for a chain failure caused by corrosion and/or friction. Increase the frequency of
lubrication.
2. Inspect chain cleanliness. Clean chains when dirt impedes penetration of lubricating oil into the
chain, or when dirt obstructs inspection. Only paraffin derivatives such as diesel fuel or petroleum
may be used as a cleaning agent. Use a brush to remove dirt and sand.
3. Measure chain elongation. Load the chain with the weight of an empty carriage and measure
distance over at least 6 pitches, from pin center line to pin center line. Measure at several locations on
the part of the chain that moves over the sheave. Replace the chain if elongation is 3% or more. For
two inch pitch chain a 3% elongation has been reached when pin distance over 6 links is
314 mm (12.36 in.) or more.
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4. Measure remaining plate height. A reduced plate height reduces strength of the chain. Measure the

height of the plate. Replace both chains if the height of any plate is 45.85 mm (1.80 in.) or less.
5. Check alignment between sheave and chain. Investigate if sheave and chain align properly. If they
do not align, one or both bearings in the sheave, or the pin, or the sheave itself may be damaged.
Disassemble sheave, check each part for wear and replace if necessary. See section Step 3.
6. Check for chain noise. Check if the chains produce a squeaking/squalling or grinding noise as the
mast is extended and lowered. Chain lubrication has been insufficient when such noise appears. As a

consequence the smooth surface between pin and plate is probably damaged. Increase frequency of
lubrication.
7. Inspect for signs of rust or brown lubricant. Brown lubricant indicates that corrosion has affected
chain pins and / or plates. The smooth surface between pin and plate is probably damaged. Rapid
chain wear is to be expected. When there are signs of rust, there is an increased risk for stiff links and
displaced link pins. Remove all exterior rust and dirt buildup with a brush and an oil based solvent.
Increase frequency of lubrication.
8. Inspect for stiff or tight chain links. Stiff articulation of a chain link indicates a bent pin and/or a
serious propagation of corrosion between pin and plate. A bent pin indicates an overload situation.
Replace both chains if any chain link suffers stiff articulation.
9. Inspect for turned or protruding link pins. Check if beveled ends of link pins run parallel to length
of chain. If bevels of a link pin end are at an angle to the length of the chain, the link pin has turned. A
turned link pin indicates excessive friction due to insufficient lubrication or an overload condition. If a
link is turned or protrudes, the integrity of chain is lost. Replace both chains if any link pin is turned or
protrudes. Increase frequency of lubrication.
10. Inspect for broken link pins. Check that all outer plates run parallel to each other. A link pin is
probably broken if outer plates are at an angle to each other. A broken link pin indicates an overload
situation. Replace both chains if any link pin is found broken.
11. Inspect for broken or missing chain link plates. Corrosion or an overload condition can initiate

fatigue fractures in plates. Replace both chains if any plate is found broken or missing.
12. Inspect for damaged plates or pins. Impacts by other objects may damage or deform plates or pins.
Deformation increases risk for fatigue fractures. Replace both chains if any deformation exceeds 5%
of the pin diameter or plate thickness.
Lift Chain Lubricant Requirements
Chain lubricant must be a mineral or synthetic engine oil. Oil viscosity must match ambient temperature, so
that oil remains viscous and can penetrate to contact area between link pin and intermediate link.
• Use SAE 20W to 30W oil in ambient temperatures of −30 to 5°C (−22 to 41°F).
• Use SAE 40 oil in ambient temperatures of 5 to 45°C (41 to 113°F).
• Use SAE 50 oil in ambient temperatures above 45°C (113°F).
The most practical oil to use is SAE 15W-40 multi grade engine oil.
NOTE: If an aerosol spray lubricant is used, always check that it deposits an engine oil equivalent, with
minimum viscosity as listed under Viscosity, after the dispersing agent has evaporated.
DO NOT use the following lubricant types:

• Lubrication products that contain solids such as graphite or molybdenum disulfide. Solids will not
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penetrate between plates, and over time, they will form a barrier that prevents oil penetration.
• Grease or lubrication products that stiffen or form a greasy film. Stiffening products do not penetrate
sufficiently. Grease does not penetrate at all. Stiffening products and grease form a barrier that

prevents penetration of oil for re-lubrication. Without proper lubrication, the service life of a lift chain
is minimized.
• Penetrating fluids or aerosol spray lubricants containing penetrating fluids do not provide adequate

lubricity, adhesion or corrosion protection, and they do not form a film.
Lift Chain Lubrication Procedure
To achieve proper lubrication the following requirements must be met.

• Remove the load from chain completely. Put a support under carriage and slacken chains.
• Clean the chain. Make sure that any debris, grease or thick oil between chain outside and link pin is

removed.
• Dry the chains. Make sure that any trapped water or condensation, especially at the pin area, is

removed.
• Lubricate with a mineral or synthetic based engine oil. See section Lift Chain Lubricant Requirements.
• Make sure applied layer of oil protects the entire chain surface against corrosion.
• Allow sufficient time for oil to penetrate and facilitate oil penetration by articulating the chain several

times with the lowest possible load after oil has been applied.
Complete relaxation of chains between shifts significantly contributes to the re-lubrication of chain pins,
provided that the oil film on outside of chain is intact.
Leak Checks
Mast Vertical Creep
1. Place a capacity load on forks and raise and lower load several times until hydraulic oil has reached

65°C (150°F).
2. Raise forks approximately 1 m (3.3 ft) above ground, put lift controls in neutral position and measure

vertical creep during 10 minutes.
3. Mast Vertical Creep must be limited to 100 mm (3.94 in.) in 10 minutes for trucks up to 10 tons lifting

capacity.
4. Mast Vertical Creep must be limited to 200 mm (7.87 in.) in 10 minutes for trucks above 10 tons

lifting capacity.
5. If mast vertical creep exceeds maximum allowed value, determine if an internal leak is present at lift

cylinder or at control valve.
6. Check lift cylinders for internal leaks.
7. Remove load from forks. Install a gate valve in each of separate supply lines between lift cylinder and
control valve. Place again a capacity load on forks, raise forks approximately 1 m (3.3 ft) above

ground and close both gate valves. If creep speed is similar to the measurement in Step 2, lift cylinders
need to be resealed.
8. Check functionality of Emergency Lowering Valve. Replace Emergency Lowering Valve to verify if
its replacement solves the problem. If creep speed is still too high, replace relevant control valve
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section. Individual control valve section components are not separately available.
Mast Tilt Drift
1. Place a capacity load on forks and tilt mast several times forward and backward until hydraulic oil has

reached 65°C (150°F).
2. Attach an inclinometer to mast, put mast in a vertical position, and raise load at 2.5 m (8.2 ft) height.
Put controls in a neutral position and measure mast tilt drift. Mast tilt drift must remain within 5

degrees during a 10 minute period. If maximum forward tilt angle is less than 5 degrees, measured
time period must be proportionally reduced.
3. If mast tilt drift exceeds maximum allowed value, determine if an internal leak is caused by tilt

cylinder or by control valve.
4. Check tilt cylinders for internal leaks.
5. Remove load from forks. Install a gate valve between rod side of tilt cylinders and divider block. Place
again a capacity load on forks, raise forks approximately 1 m (3.3 ft) above ground and close both gate
valves. If creep speed is similar to measurement in Step 2, tilt cylinders need to be resealed.
6. Check control valve for internal leaks.
7. Check functionality of 28 MPa (4061 psi) pressure relief valve in tilt section of control valve. Replace
relief valve to verify if its replacement solves problem. If creep speed is still too high, replace tilt
valve section.
The creep and drift rates reduce with a factor of about 1.5 for every 10°C (18°F) that actual oil temperature in
cylinder is lower. Make sure to have reached required oil temperature of 65°C (150°F) in cylinders for
accurate test results.
ADJUSTMENTS
Lift Cylinder Shimming

NOTE: Lift cylinders must be shimmed to make sure that they equally support the inner mast in the
completely lowered position. The purpose is to prevent twisting the inner mast when driving with a load in
the completely lowered position.
1. Put mast in a vertical position and lower carriage completely. Make sure forks do not touch ground.
2. Open emergency lowering valve. See Figure 72.
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A. EMERGENCY LOWERING VALVE
Figure 72. Emergency Lowering Valve Location
3. Use a personnel lift and measure clearance between upper cylinder support and cylinder rod. Use a pry

bar to make sure that cylinder rods cannot lower any further.
4. Shimming is required when clearance exceeds 1 mm (0.04 in.). See Figure 73.
A. SHIMMING GAP
1. CAPSCREW
2. SMALL WASHER
3. LARGE WASHER
4. OUTER MAST
5. INNER MAST
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Figure 73. Lift Cylinder Shimming
5. Remove securing bolt and washers from cylinder, which requires shimming.
6. Use a lifting device to lift inner mast just enough to install shim on cylinder rod.
7. Lower inner mast and install washers and securing bolt. Tighten bolt.
8. Close emergency lowering valve.
Lift Chain and Fork Height Adjustment
CAUTION
The carriage can be set higher and lower on the lift chain anchor, however the carriage load
rollers must remain within the inner mast channel both in the lowest and in the highest
carriage positions to avoid damage to the lift truck.
NOTE: The purpose of lift chain adjustment is to align the carriage in the inner mast and to position the
forks at the required height when the carriage is completely lowered.
Carriage alignment is required when
chains, chain anchors or the carriage is replaced. Carriage alignment is also required when the carriage does
not lift and lower smoothly. A symptom is that one of the chains has a lower tension and shows bigger
deflection compared with the other chain. Incorrect carriage alignment causes premature wear of the bearing
blocks. Alignment of the carriage is obtained by adjusting the two chain anchors individually.
1. Put mast in a vertical position and lower carriage completely.
2. Side shift the carriage until it is at the center line of the mast.
3. Make sure that both forks are in an equally extended position.
4. Measure the distance between the carriage bar and the inner mast at two locations. The two locations

must be at 50 cm (2 ft) from each other. See Figure 74, measuring point (A) and (B).
5. Align the carriage if the two distances vary more than 0.5 mm (0.025 in.).
6. Make sure that both forks have at least 1 cm (0.40 in.) clearance with the ground.
7. If adjustment is required, loosen the chain anchor lock nut and bend the fingers of the securing plate to

release the large nut. See Figure 75.
8. Tighten the large nut of the chain anchor that is in the lowest position to align the vertical carriage bar

with the inner mast channel.
9. Turn both large nuts with the same angle until the required ground clearance has been obtained.
10. After adjustments are complete, bend the fingers of the securing plates around the large nut and

tighten the lock nut.
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A. MEASURING POINT A
B. MEASURING POINT B
1. CARRIAGE
2. INNER MAST
3. OUTER MAST
Figure 74. Carriage Alignment
1. SPLIT PIN
2. CHAIN PIN
3. WASHER
4. CHAIN ANCHOR
5. LARGE NUT
6. SECURING PLATE
7. LOCK NUT
8. SMALL NUT
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9. WASHER
10. CAPSCREW
Figure 75. Chain Anchor On Carriage
Header Hose Tension Adjustment
1. Make sure that lift chains are tensioned and correctly adjusted.
2. Release hose clamp on upper mast bracket by loosening capscrew.
3. Verify that header hoses are in good condition. Un-tensioned hoses are to be of equal length. Replace

any defective hose.
4. Pull and tension hoses which are clamped on same bracket. The required elongation is between 1%

and 2%.
5. Tighten capscrew to clamp hoses. See section Step 3.
Electric Mast Cable Tension Adjustment
1. Make sure that lift chains are tensioned and correctly adjusted.
2. Loosen cable clamp at carriage bracket.
3. Pull and hold cable at same tension as header hoses.
4. Tighten cable clamp at carriage bracket.
Counterbalance Valve Adjustment
1. Establish which tilt cylinder moves out first. See section Counterbalance Valve Check (for J007 and

H019 Only).
2. Adjust the counterbalance valve which is at the opposite side of the valve connection for cylinder

moving out first. See Figure 76.
3. Adjust the valve by loosening the adjustment nut one full turn and subsequently rotate the setscrew ¼

turn counter clockwise.
4. Retighten adjustment nut by using a 17 mm wrench.
5. Check again simultaneous cylinder movement. See section Counterbalance Valve Check (for J007 and

H019 Only).
6. Repeat adjustment procedure until both tilt cylinders start moving simultaneously when tilting

forward.
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1. COUNTERBALANCE VALVE 4. LOCK NUT

2. VALVE TO ADJUST LH CYLINDER 5. SET SCREW
3. VALVE TO ADJUST RH CYLINDER
Figure 76. Counterbalance Valve Adjustment
Tilt Cylinder Backward Tilt Angle Adjustment
1. Slowly tilt mast backward until one rod is against its stop. Adjust opposite cylinder if it stops more

than 1.0 mm (0.04 in.) later.
2. To adjust tilt cylinder, loosen nuts on rod end and turn cylinder rod out of rod end until both rods stop

at same time.
3. Repeat procedure to make sure cylinder rods stop at the same time within 1.0 mm (0.04 in.).
4. Check tilt angles are correct as specified on nameplate of lift truck. A limited tilt angle correction can

be made by turning both cylinder rods the same amount.
5. Verify thread of cylinder rod extends approximately 48 mm (1.89 in.). See Figure 77. Turn both rods

into the rod end if one of the threads extends more than 50 mm (1.97 in.).
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NOTE: X = ROD END THREAD DISTANCE

1. ROD
2. WRENCH FLAT
3. NUTS
4. ROD END
Figure 77. Tilt Cylinder Adjustment
6. When adjustments are complete, turn rods until wrench flats are at upper and lower side. Having

wrench flats at sides of rods increases stress level.
7. Tighten nuts on rod end to 66 N•m (49 lbf ft).
Mast Support Pad Adjustment
1. Tilt mast slightly forward and measure clearance between wear plate and inner mast. Clearance should

be between 0.5 and 1.5 mm (0.020 and 0.059 in.).
2. For re-shimming, remove capscrews and install shims as necessary between wear plate and outer mast.
3. Tighten capscrews to 60 N•m (44.3 lbf ft). See Figure 78.
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A. 6 mm
(0.24 in.)
MAXIMUM
1. OUTER MAST
2. INNER MAST
3. CAPSCREWS
4. PLATE
5. WEAR PLATE
6. SHIM
Figure 78. Mast Support Pad Adjustment
Troubleshooting
INTRODUCTION
This troubleshooting list does not cover every possible problem. It is intended to help finding the cause of
problem in the mast system.
Before searching for the cause of a problem, make sure that all daily condition checks and fluid level checks
have been performed and that required repairs have been completed. See Periodoc Maintenance SRM.
If a problem occurs directly after a repair, verify if assembly instructions have been followed correctly. If a
problem has aggravated, verify if hydraulic oil cleanliness meets 21/17/13 according ISO 4406.
For diagnosing and verification of settings, make use of the Hydraulic User Interface ProgrammeSRM.
See Hydraulic Control SystemSRM.
Follow each step in the sequence shown in one of the three main search criteria:
• No Hydraulic Movement with Engine Running
• No Lowering Possible with Engine OFF
• Incorrect Movement
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If this troubleshooting list did not help solving your problem, read the Description and Operation section in
this SRM to find further possible causes of failure.
NO HYDRAULIC MOVEMENT WITH ENGINE RUNNING
Initial Basic Check
Make sure the Transmission Calibration Switch is in the OFF position.
Turn the Key Switch to the ON position to verify that all warning lights and indicator lights on the instrument
panel will light up.
After two seconds all indicator lights must be OFF, except for the Wait to Start Light, Central Warning Lights
and Brake System Low Pressure Warning Light.
Start the engine after the Wait to Start Light is OFF.

• If any of the above steps fail, follow the steps mentioned under Electrical Supply
• If the Brake System Low Pressure Warning Light is still ON after 10 seconds, follow the steps

mentioned under Hydraulic Supply.
• If the Central Warning Lights are ON and a fault code is displayed, follow the steps mentioned under

Fault Code.
Electrical Supply
Determine which fuse and/or relay connect with the failed function and replace as necessary. See
DiagramsSRM and Fuses and Relays in Electrical System SRM.
• Investigate and resolve the root cause for the failed fuse and/or relay.
• Replace the failed fuse and/or relay.
Hydraulic Supply
Operate the steering system with the engine running. Hydraulic pump supply is sufficient when steering
requires normal effort.
• If abnormal effort is required, repair the steering system and/or investigate why hydraulic pump

supply is insufficient. See Steering SystemSRM.
Make sure that the Transmission Calibration Switch is in the OFF position.
Verify that the Operator Presence System (OPS) functions correctly.

• Hydraulic functions should operate normally when the operator is seated, the engine is running and

the transmission calibration switch is in the OFF position.
• Hydraulic functions should be interrupted when the operator is not seated.
• The OPS needs repair when hydraulic functions can only be operated with the hydraulic service

switch in the ON position.
• To repair the OPS, check functionality of OPS fuse, seat switch, seat belt switch, and operator

presence relay. Replace any failed OPS component.
Fault Code
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Look up the fault code and determine the location of the indicated component on the truck. See
DiagramsSRM and Electrical SytemSRM.
• Check functionality of the component and repair as required.
If a fault code suggests checking a Directional Control Valve or an Actuation Valve, verify if partial or
complete replacement is required.
Move the spool by rotating the actuator axle about 15 degrees with a spanner.
• When the spool moves smoothly, replace the failed Electrical Actuation Module only.
• When the spool sticks, disassemble and clean the spool section.
• If components of the spool section are damaged after disassembly, replace the spool section.
NO LOWERING POSSIBLE WITH ENGINE OFF
Make sure the lift cylinders are extended and the lift chains carry at least the weight of the carriage.
• If the carriage is not installed, use the emergency lowering control valve to lower the mast.
Turn the key switch to the ON position.
Move the hoist lever into the lowering position.

• If fault code H2664 is displayed, resolve the open circuit or short circuit situation for the (emergency)

Lowering Selector Valve [B].
Attach a pressure gauge to port MPLT.
Read the pressure gauge at port MPLT with the key switch in the ON position and the hoist lever in the
lowering position.
• If pressure is lower than 1 MPa, investigate proper functioning of the Pilot Supply Valve [F] and the

Lowering Selector Valve [B]. Repair or replace as necessary.
INCORRECT MOVEMENT
Irregular (shaking) Movement or

Slight Carriage Movement When Starting Engine
De-aerate system by operating the affected function(s) several times.

• Activate for one second and reverse cycle. Repeat a few times.
• When the problem re-occurs, search for entry of air in pump suction line.
Unequal Movement of Left And Right Tilt Cylinder
Verify and correct tilt cylinder adjustment and condition of pivot points.
Establish and repair internal leaks in the tilt cylinders.
Verify and correct relief pressure setting of the individual tilt relief valves.
Insufficient Lifting Speed
Measure pilot pressure at port MPLT.

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

• Measure Load Sense pressures. See Hydraulic SystemSRM.
• Inspect hydraulic pump and repair as required.
Insufficient Lifting Capacity
Verify correct relief valve pressures.

• Pressure at Port MP should reach 33 +/- 0.5 MPa for Full Flow Relief Valve [G].
• Pressure at Port MLS2 should reach 22.5 +/- 0.5 MPa for Load Sense Relief Valve [H].
• Replace relief valves as necessary.
Velocidade de descida incorreta
Verifique as configurações de controle de fluxo hidráulico e corrija conforme necessário. Consulte Sistema
de Controle Hidráulico SRM .
• Substitua a(s) válvula(s) de controle de abaixamento nos cilindros de elevação se as configurações do

controlador hidráulico parecerem corretas.
Deslocamento do Cilindro de Elevação
Siga as instruções descritas em Deslocamento vertical do mastro .
Deslocamento do Cilindro de Inclinação
Siga as instruções descritas em Desvio de inclinação do mastro .

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PARTE NO. 4092690 4000 SRM 1647

• Mantenha a unidade limpa e a área de trabalho limpa e organizada.

NOTA: Os seguintes símbolos e palavras indicam informações de segurança

Código de Série / Tabela de Referência de Designação de Modelo

Esta seção é para os seguintes modelos:

Código de Série / Tabela de Referência de Designação de Modelo

Código da Modelo Europeu Modelo das Américas

Figura 1. Operação de um mastro de dois estágios

Válvulas de retenção operadas por piloto

1. VÁLVULA DE RETENÇÃO OPERADA POR PILOTO 4.

Figura 2. Válvulas Operadas por Piloto - Esquema

Válvula de Abaixamento de Emergência

1. VÁLVULA DE CONTROLE DE DESCIDA DE EMERGÊNCIA

Figura 3. Válvula de Controle de Abaixamento de Emergência - Localização

UMA. PARA O TANQUE

Figura 4. Conjunto da válvula de abaixamento de emergência

Figura 5. Componentes da Cadeia

Alongamento por desgaste

Figure 6. Contact Area Between Link Pin and Inner Plates.

Plate Height Wear

Restoring The Oil Film

Maintaining The Presence of Oil

Requirements for Chain Lubricant

DO NOT use the following lubricant types:

Figure 7. Mast Support Pads

channel end of the outer mast. See Figure 8.

Figure 8. Bearing Blocks and Load Rollers on Inner Mast

Standard Carriage with Manual Fork Positioning

Figure 9. Standard Carriage with Manual Fork Positioning

Standard Carriage with Hydraulic Fork Positioning

Figure 10. Standard Carriage with Hydraulic Fork Positioning

Dual Function Side Shift and Fork Positioning (DFSSFP) Carriage

Figure 11. DFSSFP Carriage

Integral Side Shift

Figure 12. Integral Side Shift

Alternating Pressure and Tank (P & T)

Fixed Pressure and Tank (P & T)

• Green is connected with control valve port Aux A.

Flow Divider for Simultaneous Fork Positioning

A. TO MAIN CONTROL VALVE PORT AUX B D.

1. FLOW RESTRICTOR 2. RELIEF VALVE

Figure 13. Flow Divider Port Connections - Schematic

A. TO MAIN CONTROL VALVE PORT AUX B

Figure 14. Valve for Simultaneous Fork Positioning

A. TO MAIN CONTROL VALVE PORT AUX B D.

1. SIDE SHIFT SOLENOID 3. RH FORK POSITIONER SOLENOID

Figure 15. Schematic for Dual Function Valve

1. SIDE SHIFT SOLENOID (SS) - CONNECTOR CPS 153

Fixed Pressure and Tank System (Fixed P & T)

1. HYDRAULIC FUNCTION 4. PILOT PRESSURE SUPPLY VALVE

Figure 17. Schematic for Fixed P& T Directional Control Valve

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

1. STANDARD PIN TYPE FORK

Figure 19. Fork Types

SAFETY PROCEDURES WHEN WORKING NEAR MAST

WHEN WORKING NEAR THE MAST ALWAYS:

a. Put the mast in a vertical position.

Figure 20. Mast Safety Chains

BEFORE STARTING REPAIRS TO THE HYDRAULIC SYSTEM, ALWAYS:

1. Place the lift truck on a solid, level surface.

2. Apply the parking brake.

3. Tilt the mast completely forward.

5. Turn engine OFF.