VISTA MAST, REPAIR

GENERAL operation of the masts. The repair information for the lift
cylinders is in the section LIFT CYLINDERS, 4000
This section has the repair procedures for the Vista SRM 135.
Two–Stage, Free–Lift, Three–Stage, and Four–Stage
masts and for the side–shift carriage. Checks and Ad- WARNING
justments and Troubleshooting are at the end of this sec- Before working on or near the mast, read SAFETY
tion. See the section VISTA MASTS, DE- PROCEDURES WHEN WORKING NEAR THE
SCRIPTION, 4000 SRM 222, for the description and MAST.
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)
The following procedures must be used when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast. See the correct Service Manual sec-
tion for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious
injury or death can result if part of the body is hit by parts of the mast or the carriage.
• Never put any part of the body into or under the mast or carriage unless all parts are completely
lowered or a safety chain is installed. Also make sure that the power is off and the key is removed.
Put a “DO NOT OPERATE” tag in the operator’s compartment. Disconnect the battery on electric
lift trucks and put a tag or lock on the battery connector.
• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.
• DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the
mast.
• DO NOT use blocks to support the mast weldments nor to restrain their movement.
• Mast repairs require disassembly and removal of parts and can require removal of the mast or
carriage. Follow the repair procedures in the correct Service Manual for the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there
is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.
OR
• If parts of the mast must be in a raised position, 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.

5 6
8
7 8

1
5
7

1
2

TWO–STAGE
MAST 2

FREE–LIFT
MAST

1
 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)
b. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with
a crossmember on the outer weldment (1). On the two–stage and free–lift mast, the moving part is the inner
weldment (2). On the three–stage mast it is the intermediate weldment (3). On the four–stage mast it is the
first intermediate weldment (4).
c. Use a 3/8 inch minimum safety chain with a hook (5) to fasten the crossmembers together so that the movable
member can not lower. Put 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 (6) (free–lift, three–stage
and four–stage masts only) is completely retracted. If running, stop the engine. Apply the parking brake. Install
a “DO NOT REMOVE” tag on the safety chain(s).
e. Install another safety chain (3/8 inch minimum) between the top or bottom crossmember of the carriage (7)
and a crossmember on the outer weldment (8).
• Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put
a “DO NOT OPERATE” tag in the operator’s compartment. Disconnect the battery on electric lift trucks and
put a tag or lock on the battery connector.

5 5
6 6

1
1

3 4

THREE–STAGE FOUR–STAGE
MAST MAST

FORKS (See FIGURE 1.)
The identification of a fork describes how the fork is
connected to the carriage. The series of lift trucks that
use this mast normally have hook forks. See FIGURE 1.
Hook forks are connected to the carriage by hooks and
lock pins. These lock pins are installed through the top
fork hooks and fit into slots in the top carriage bar. Sepa-
rate the forks as much as possible for maximum support
of the load. Hook forks will slide along the carriage bars
to adjust for the load to be lifted. Raise the lock pin in
each fork to slide the fork on the carriage bar. Make sure
2
the lock pin is engaged in the carriage bar to lock the fork
in position after the width adjustment is made.
Forks, Removal And Installation
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance.
WARNING
Do not try to move a fork without a lifting device.
Each hook fork for these lift trucks can have a weight
of 45 kg to 115 kg (100 to 250 lb).
 3 4

3
5

3
2
1 3
1545

1. FORK REMOVAL NOTCH 4. LOCKING PIN ASSEMBLY

2. FORK 5. CARRIAGE
3. HOOK
FIGURE 1. HOOK FORK
carriage. Engage the lock pin with a notch in the upper
1. CARRIAGE
carriage bar.
BARS
2. HOOK FORK CARRIAGE (See FIGURE 1.)
3. BLOCKS
1 Removal
2 1. Lower the carriage and forks on blocks so that the lift

ÉÉÉ
ÉÉÉ ÉÉÉ
chain, or chains, become loose.

ÉÉÉ ÉÉÉ 3
FIGURE 2. REMOVE A HOOK FORK
Hook Fork (Removal). Slide a hook fork to the fork re-
moval notch on the carriage. See FIGURE 1. Lower the
fork on to blocks so that the bottom hook of the fork
moves through the fork removal notch. See FIGURE 2.
Lower the carriage further so that the top hook of the
fork is disengaged from the top carriage bar. Move the
carriage away from the fork, or use a lifting device to
move the fork away from the carriage.
Hook Fork (Installation). Move the fork and carriage
so that the top hook on the fork can engage the upper car-
riage bar. Raise the carriage to move the lower hook
through the fork removal notch. Slide the fork on the
carriage so that both upper and lower hooks engage the
WARNING
When disconnecting the lift chains, control the ends
to prevent the lift chains from falling from the
sheaves and causing an injury or damage. Use wire
to temporarily connect the ends of the lift chains to
the mast.
2. Remove the pin from each chain anchor at the car-
riage. Disconnect the lift chains from the carriage.
3. Put a one–quarter capacity load on the forks. The load
must give the carriage stability so that the carriage can-
not fall when it is disconnected from the mast.
WARNING
Make sure that the carriage has stability when the
inner weldment is above the load rollers of the car-
riage.
4. Use the lift cylinders to raise the inner weldment.
Carefully raise the inner weldment until it is above the
3
load rollers of the carriage. If the hydraulic system can-
not be used, connect a crane to the top of the inner weld-
ment. Carefully raise the inner weldment until it is
above the load rollers of the carriage.
5. Move the lift truck from the carriage. If the forks are
removed, put the carriage on the floor so that the load
rollers are up.
6. If any of the load rollers must be replaced, make a note
of the location of the shims.
Installation
1. Use the hydraulic system of the lift truck or a crane to
raise the inner weldment. Raise the inner weldment until
it is above the load rollers of the carriage. Carefully low-
er the inner weldment until it engages all of the load roll-
ers.
2. Check the clearance of the load rollers. See Checks
and Adjustments in this section.
3. Install the lift chains. (Some masts have only one lift
chain.) Use new cotter pins in the anchor pins. See
Checks and Adjustments in this section.
MASTS
Removal (See FIGURE 3.)
1. Fully lower all of the mast weldments.
NOTE: If the mast must be disassembled, remove the
forks and carriage.
2. Raise the front of the lift truck. Put blocks under the
frame behind the drive wheels.
3. Tilt the mast fully backward. Remove the caps for the
mast pivots.
4. Tilt the mast fully forward. Connect a crane to the top
of the mast with chains. Make sure all the weldments are
fastened together. Make sure the chains will not damage
the sheaves, tubing or other parts of the mast. Make sure
the crane has a capacity of at least 1600 kg (3500 lb).

1. OUTER WELDMENT
1 2. MAST PIVOT
3. MAST PIVOT CAP
4. BUSHING
5. TILT CYLINDER
7 6. GREASE FITTING
7. CAPSCREW
H2.00–3.00XL 8. PIN
4
(H40–60XL) 9. MOUNT BRACKET, DRIVE AXLE
6

9
1

5 5
1

3 6
2 11369

A = H1.25–1.75XL
4 (H25–35XL)
4
6 B = E/S1.25–1.75XL
(E/S25–35XL) E/S2.00–3.00XL
10672 3 3 (E/S40–60XL)

FIGURE 3. MAST MOUNTS

4
5. Put a drain pan under the area of the hydraulic fittings.
Disconnect the hydraulic line at the external lowering
control valve on the outer weldment.
WARNING
Use a driver, not your fingers, to push the anchor
pins from the clevises on the tilt cylinders. The cylin-
der or mast can move and cause serious injury.
6. Remove the cotter pins and anchor pins at the tilt cyl-
inder mounts on the mast.
7. Use the crane to lift the mast assembly from the lift
truck. Put the two–stage mast on the floor so that the
front of the mast is on the floor. Put the free–lift or the
three–stage mast on blocks so that the back of the mast is
toward the floor. Put the four–stage mast on the floor so
that the front of the mast is on the floor. Use blocks under
the top of the inner weldment to protect the sheave on
the free–lift cylinder.
Disassembly
TWO–STAGE AND FREE–LIFT MASTS
(See FIGURE 4., FIGURE 5., and FIGURE 6.)
1. Clean the area around the hydraulic fittings for the lift
cylinders. Disconnect the fittings at the lift cylinders
and put caps on the open lines.
NOTE: On the free–lift mast, remove the nuts, bolts,
and spacers from the mounts for the free–lift cylinder.
Remove the free–lift cylinder. Turn the mast over so that
the front of the mast is on the floor.
2. Remove the snap rings and washers from the top of
each lift cylinder. Remove the nut, bolt and spacer at the
mount near the top of each lift cylinder.
NOTE: On the free–lift mast, remove the hydraulic fit-
tings from the top of the main cylinder. Use a wrench to
hold the hydraulic fitting and turn the cylinder rod to re-
move the hydraulic fitting.
3. Slide the outer weldment from the inner weldment
approximately 30 cm (12 in) to disengage the lift cylin-
ders from the inner weldment. Remove the lift cylinders
from the mount plates at the bottom of the outer weld-
ment.
WARNING
The weldments can slide when the mast is moved. A
weldment that suddenly slides can cause an injury.
Use a crane to turn the mast slowly and carefully.
4. Turn the mast over.
5. Slide the inner weldment from the bottom of the outer
weldment approximately 30 cm (12 in). Remove the
strip bearings and load rollers. Make a note of each shim
or spacer arrangement. The shim and spacer configura-
tions will be approximately the same during assembly.
6. Slide the inner weldment half–way out of the top of
the outer weldment. Connect a crane to the center of the
inner weldment. See FIGURE 6. Slide the inner weld-
ment out of the outer weldment until the stub shafts are
in the notches of the channels. Remove the inner weld-
ment from the outer weldment.
7. Remove the sheaves and disassemble the sheaves and
the load rollers as necessary for repair and cleaning.
5
 6
4
5 2

3 3 3

1 4
1

10641
10640

1. MAIN LIFT CYLINDER (2) 1. OUTER WELDMENT

2. LIFT CHAIN (2) 2. INNER WELDMENT
3. OUTER WELDMENT 3. MAIN LIFT CYLINDER (2)
4. CHAIN SHEAVE (2) 4. FREE–LIFT CYLINDER
5. INNER WELDMENT 5. EXTERNAL LOWERING CONTROL VALVE
6. EXTERNAL LOWERING CONTROL VALVE 6. LIFT CHAIN

The S1.25–1.75XL (S25–35XL) mast is shown. The S2.00–3.00XL (S40–60XL) mast is shown.
The masts for other models are similar The masts for other models are similar

FIGURE 4. TWO–STAGE MAST FIGURE 5. FREE–LIFT MAST

6
 8

8558 2

FIGURE 6. INNER WELDMENT 7

THREE–STAGE MAST (See FIGURE 7.)

1. Disconnect and remove the hydraulic lines from the

free–lift cylinder. Disconnect and remove the lift chain.
Remove the nuts, bolts, and spacers that hold the lift cyl-
inder to the inner weldment. Remove the lift cylinder.

2. Disconnect the main lift chains from the chain an-

chors at the top of the outer weldment. Push the inner
weldment toward the bottom of the mast assembly until
5 5
the top and bottom load rollers are seen.

3. Remove the load rollers. Make a note of each shim or

spacer configuration. The shim and spacer configura- 1
tions will be approximately the same during assembly.

4. Disconnect the main lift chains from the chain an-

chors at the bottom of the inner weldment. Remove the
lift chains. Remove the chain anchors from the inner
6
weldment. Remove the sheaves for the chains.

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

the intermediate weldment. Connect a crane to the cen- 11372

ter of the inner weldment. See FIGURE 6. Slide the in-

ner weldment out of the intermediate weldment until the 1. OUTER WELDMENT
2. INTERMEDIATE WELDMENT
stub shafts are in the notches of the intermediate weld- 3. INNER WELDMENT
ment. Remove the inner weldment from the intermedi- 4. FREE–LIFT CYLINDER
ate weldment. 5. MAIN LIFT CYLINDER (2)
6. EXTERNAL LOWERING CONTROL VALVE
6. Remove the snap rings and washers at the top of the 7. MAIN LIFT CHAIN (2)
8. FREE–LIFT CHAIN
main lift cylinders. Remove the nut, bolt and spacer at
the mount near the top of each lift cylinder. FIGURE 7. THREE–STAGE MAST
7
7. Push the intermediate weldment to disengage the lift
cylinders. Remove the lift cylinders.
8. Slide the intermediate weldment from the bottom of
the outer weldment approximately 30 cm (12 in). Re-
move the strip bearings. Remove the snap rings from the
load rollers on both weldments. Make a note of each
shim configuration. The shim configurations will be
approximately the same during assembly.
9. Slide the intermediate weldment half–way out of the
top of the outer weldment. Connect a crane to the center
of the intermediate weldment. See FIGURE 6. Slide the
intermediate weldment out of the outer weldment until
the stub shafts are in the notches of the outer weldment.
Remove the intermediate weldment from the outer
weldment.
10. Disassemble the sheaves and the load rollers as nec-
essary for repair and cleaning. Remove the hydraulic
lines and fittings from the weldments as necessary.
FOUR–STAGE MAST (See FIGURE 8.)
The following instructions are for the complete disas-
sembly of the mast. Disassemble the mast only as neces-
sary to make repairs.
1. Put the mast on the floor so that the inner weldment is
on the floor. Use blocks under the inner weldment to
protect the sheave on the free–lift cylinder.
2. Disconnect the free–lift chain at the anchor on the in-
ner weldment. Remove the chain. Loosen the nuts for
the clamp that holds the free–lift cylinder, but do not re-
move the nuts.
3. Disconnect the smaller chains at the anchors in the top
of the second weldment. On the inner weldment, mea-
sure the length of an anchor below the nut. Make a note
of the length for assembly. Remove the anchors and
chains.
4. Disconnect the return line at the fitting in the top of
each cylinder.
5. Disconnect the tube at the port in the bottom of each
cylinder. Remove the bolts from the bracket for the low-
ering control valve. Remove the valve block and tubing
as an assembly.
8
6. Disconnect the hydraulic tube for the free–lift cylin-
der at the fitting on the hose.
7. Remove the screws with flanges, washers, and clamp
that fasten the hose to the bracket on the inner weldment.
Disconnect the hose at the fitting in the cylinder rod. Re-
move the hose.
8. Remove the hose sheave from the bracket on the third
weldment.
9. Use the following procedure to remove the main cyl-
inders:
a. Remove the locknut, washer, and bolt from the
anchor pin in each cylinder rod. If necessary for
access, mark the position of the nuts on the chain
anchors and remove the chain anchors. Remove
the anchor pins from the cylinder rods.
b. Remove the cylinder rods from the second weld-
ment by sliding the outer weldment toward the
bottom of the mast.
c. Use a sling to support the cylinder as it is re-
moved. The cylinders are removed from the bot-
tom of the mast.
d. Remove the clamp from the cylinder. Keep the
soft washers with the clamp.
e. Pull the cylinder from the base of the outer weld-
ment. Remove the cylinder.
NOTE: Check for spacers on the base of each cylinder.
If spacers are found, make sure the spacers are installed
when the cylinders are installed.
f. Repeat steps c, d, and e to remove the second cyl-
inder.
10. Disconnect the chains at the anchors on the outer
weldment. On the third weldment, measure the length of
an anchor below the nut. Make a note of the length for
assembly. Remove the anchors and chains.
WARNING
The weldments can slide when the mast is moved. A
weldment that suddenly slides can cause an injury.
Use a crane to turn the mast slowly and carefully.
 11. Turn the mast over so that the pivots are on the floor.
12. Remove the clamp for the free–lift cylinder from the
inner weldment. Remove the cylinder and tube.
6
1 13. Push the inner weldment toward the bottom of the
mast so that the load rollers show.
14. Remove the snap rings and the rollers from both
2 weldments. When a roller is removed, make a note of the
location of the shims or spacers. Attach the shims and
spacers to the roller and put a label on the roller for
installation again.
3 7
15. Remove the sheaves for the chains from the third
weldment. Keep the spacers with the sheaves.
1. INNER WELDMENT 8
2. FREE–LIFT CYLINDER 9 16. Slide the inner weldment half–way out the top of the
3. THIRD WELDMENT 10 third weldment. Connect a crane to the center of the in-
4. SECOND WELDMENT ner weldment. See FIGURE 6. Slide the inner weldment
5. OUTER WELDMENT
6. FREE–LIFT CHAIN 11 until the stub shafts are in the notches of the channels.
7. TUBE Remove the inner weldment.
8. LIFT CHAIN (2)
9. HOSE 17. Push the third weldment toward the bottom of the
mast so that the load rollers show. Lift the top of the
4
weldment a small amount for clearance at the second
weldment.
18. Remove the snap rings and the rollers from both
weldments. When a roller is removed, make a note of the
12 location of the shims. Attach the shims to the roller and
put a label on the roller for installation again.
19. Use a punch or a screwdriver to remove the strip
5 bearings and shims from the third weldment. Make a
note of the number of shims with each bearing. Keep a
bearing and shims together.
20. Remove the sheaves for the chains from the second
weldment. Keep the spacers with the sheaves.
13
21. Slide the third weldment half–way out the top of the
second weldment. Connect a crane to the center of the
third weldment. Slide the third weldment until the stub
shafts are in the notches of the channels. Remove the
third weldment.
12288
22. Remove the second weldment. See steps 13, 14, 15,
and 21 for procedures.
10. LIFT CHAIN (2)
11. HOSE SHEAVE
23. Remove the strip bearings and shims from the outer
12. MAIN LIFT CYLINDER weldment.
13. LOWERING CONTROL VALVE (EXTERNAL)
24. Disassemble the sheaves and load rollers for clean-
FIGURE 8. FOUR–STAGE MAST ing or for repair.
9
 Cleaning and Inspection
pitch Total length of WEAR LIMIT
20 links(pitch) The maximum 1. Inspect the sheaves and load rollers for wear or dam-
of new chain length of 20
links age. DO NOT use steam to clean the lift chains, sheaves
mm (inch) mm (inch) mm (inch) or load rollers. The bearings in the sheaves and load roll-
12.7 (0.50) 254.0 (10.0) 261.6 (10.3) ers are sealed and lubricated.
15.9 (0.625) 317.5 (12.5) 327.0 (12.88)
19.1 (0.75) 381.0 (15.0) 392.4 (15.45)
25.4 (1.00) 508.0 (20.0) 523.25 (20.6) WARNING
31.8 (1.25) 635.0 (25.0) 654.1 (25.75)
44.5 (1.75) 889.0 (35.0) 915.7 (36.05) Commercial cleaning solvents can be flammable,
50.8 (2.00) 1016.0 (40.0) 1046.5 (41.2) poisonous, and can cause severe skin irritation.
When using cleaning solvents, always use the solvent
manufacturer’s recommendations and safety pre-
cautions.
2. Clean the lift chains with solvent. Inspect the lift
chains for wear or damage. See FIGURE 9. A lift chain
becomes longer when it is worn. If a chain is 3% longer
1 than a new lift chain, the lift chain must be replaced. If a
chain scale is available, check the lift chain as shown in
FIGURE 9. If a chain scale is not available, measure 20
links of the lift chain. Compare the measurement with
the lengths shown in FIGURE 9. Lubricate the chains
with SAE 30 engine oil.

WARNING
Never replace just the worn section of a chain. Re-
place the complete chain. Never replace just one
chain of a chain pair. Replace both chains.

12174 3. Inspect the chain anchors and pins. Replace any parts
that are worn or damaged.
1. CHAIN WEAR SCALE
NOTE: The instructions for measuring chain
wear are shown on the Chain Wear Scale.
WARNING
Be careful when cleaning with steam. Steam can
1 cause serious burns. Wear protective clothing and
7
gloves so that your skin is not burned by steam.
4. Clean the mast weldments with steam or solvent.
5. Inspect the sliding surfaces for wear or damage. In-
5
spect the contact surfaces for the load rollers for wear or
6 damage. Inspect all welds for cracks.
2
4
3 WARNING
DO NOT weld on the masts. Get information from
your dealer for Hyster lift trucks before welding on
6705
the masts.
1. WORN PIN
2. CRACKS 5. LOOSE LEAVES
3. EDGE WEAR 6. DAMAGED PIN Assembly
4. HOLE WEAR 7. CORROSION
NOTE: The shims and spacers for the load rollers keep
FIGURE 9. CHECK THE LIFT CHAINS the weldments parallel and give correct clearance. Dur-
10
ing assembly, the shim arrangement will be approxi-
mately the same as before disassembly. Check the clear-
ance and adjust the shims for wear or for changes caused
by repairs. The strip bearings are also adjusted by using
shims. See Checks and Adjustments in this section for
the adjustment procedures.
NOTE: S/H1.25–1.75XL (S/H25–35XL) and E1.25–
1.75XL (E25–35XL). If the mast pivots were removed,
install them on the outer weldments. (See FIGURE 3.)
Use an adhesive sealant (Hyster Part No. 264134) on the
threads of the capscrews. Tighten the capscrews to 555
N.m (410 lbf ft). The mast pivots are fastened to the in-
side of the mounts on the outer weldment. The mast piv-
ots have an identification mark. The mast pivots with an
“A” are for the H–series lift trucks. The mast pivots with
a “B” are for the S and E–series lift trucks.
TWO–STAGE AND FREE–LIFT MAST
(See FIGURE 4. and FIGURE 5.)
1. Connect a crane to the center of the inner weldment.
Fit the stub shafts through the notches in the outer weld-
ment. Slide the inner weldment into the outer weldment
so that the stub shafts are seen at the top and bottom of
the weldments.
2. Install the strip bearings and the shims on the outer
weldment. Apply grease to the bearing surface. See
FIGURE 10.
3. Install the load rollers and shims on both weldments.
Check the clearance of the load rollers and strip bearings
as described in Checks and Adjustments.
4. Install the main lift cylinders. Push the inner weld-
ment to engage the rods of the lift cylinders. On the two–
stage mast, install the washers and snap rings at the top
of the lift cylinders. Install the spacers, nuts and bolts at
the mounts for the lift cylinders. Tighten the bolts to 40
N.m (30 lbf ft).
5. On the Two–Stage mast, do the following:
a. Install the lowering control valve on the outer
weldment. Tighten the nuts for the lowering con-
trol valve to 33 N.m (24 lbf ft). Connect the hy-
draulic lines and fittings between the lowering
control valve and the lift cylinders.
b. Install the chain sheaves and brackets. Connect
the lift chains to the chain anchors at the inner
weldment. Attach wires between the ends of the
lift chains and the crossmember to control the lift
chains during installation.
1
2
3
10121
1. STRIP BEARING
2. SHIMS
3. TOP OF OUTER WELDMENT
FIGURE 10. STRIP BEARINGS
6. On the free–lift mast, do the following:
a. Install the free–lift cylinder in the inner weld-
ment. Install the spacers, washers, nuts and bolts
at the lift cylinder mounts. Install the chain
sheave and brackets to the lift cylinder rod.
b. Install the tubes and fittings at the top and bottom
of the main lift cylinders. Install the lowering
control valve. Tighten the nuts for the lowering
control valve to 33 N.m (24 lbf ft). Install the hy-
draulic fitting in the end of the rod of the right–
hand main cylinder. Turn the cylinder rod to
tighten the hydraulic fitting. Install the tube be-
tween the main lift cylinders and the free–lift cyl-
inder.
c. Install the lift chain to the free–lift cylinder. At-
tach a wire between the end of the lift chain and
the bottom of the mast to control the lift chain
during installation.
THREE–STAGE MAST (See FIGURE 7.)
1. Put the outer weldment on the floor with the mast piv-
ots toward the floor. Connect a crane to the center of the
intermediate weldment. Fit the lower stub shafts of the
intermediate weldment into the notches in the top of the
outer weldment. Slide the intermediate weldment into
11
the outer weldment so that the stub shafts are seen at the
top and bottom of both weldments.
2. Install the strip bearings and the shims on the channels
of the outer weldment. See FIGURE 10. Apply grease
to the bearing surfaces.
3. Install the load rollers and the shims on the outer and
intermediate weldments. Before doing the next step, ad-
just the intermediate weldment as described in Checks
and Adjustments.
d. Connect a length of wire, approximately two me-
ters (six feet), to the end of each lift chain as
shown in FIGURE 11. Make sure that each lift
chain will be pulled vertically.
e. Use the wire to pull the inner weldment into the
intermediate weldment. Remove the wire. Con-
nect each lift chain to the chain anchors on the
outer weldment.
8. Install the free–lift cylinder in the inner weldment.

4. Install the main lift cylinders. Push the intermediate

weldment to engage the lift cylinders. Install the wash-
ers and snap rings to the cylinder rods. Install the
spacers, washers, nuts and bolts at the cylinder mounts.
Tighten the bolts to 40 N.m (30 lbf ft).

5. Connect a crane to the center of the inner weldment. 2 1 2

Slide the inner weldment into the intermediate weld-
ment so that the stub shafts are seen at the top and bottom
of both weldments.

6. Install the strip bearings and the shims on the channels

of the intermediate weldment. Apply grease to the bear-
ing surfaces. Install the load rollers and the shims on the
intermediate and inner weldments. Install the anchors
and sheaves for the chains Before doing the next step,
adjust the inner weldment as described in Checks and
Adjustments.

7. Install the outer lift chains:

a. Slide the inner weldment toward the bottom of

the mast assembly just enough for access to the
chain anchors.
b. Connect a piece of wire approximately one meter
(three feet) in length to the end of each lift chain.
Use the wire to pull each lift chain into position
between the channels of the inner and intermedi-
ate weldment. Connect the ends of the lift chains
to the chain anchors at the bottom of the inner
weldment. Use new cotter pins when installing
the anchor pins.
c. Use the wires to pull the chains up between the
chain sheaves and the load rollers on the inter-
mediate weldment. Look between the channels to
check the position of the lift chains. If necessary,
use a screwdriver to put each lift chain on to the
inside edge of the channel of the inner weldment.
Remove the wires.
12
10119
1. WIRE
2. OUTER LIFT CHAINS
FIGURE 11. INSTALLING THE OUTER LIFT
CHAINS
S/H1.25–1.75XL (S/H25–35XL). Install the spacers,
washers, nuts and bolts at the lift cylinder mounts.
S/H/E/J2.00–3.00XL (S/H/E/J40–60XL). Install the
bracket that holds the free–lift cylinder to the inner
weldment.
Install the chain sheave and brackets to the lift cylinder
rod. Install the sheave for the hydraulic hose to the free–
lift cylinder.
9. Install the lowering control valve to the outer weld-
ment. Install the tube between the lowering control
valve and the top of the outer weldment. Install the tubes
to the main lift cylinders and the lowering control valve.
Install the tube at the base of the free–lift cylinder.
Install the hydraulic hose from the free–lift cylinder to
the top of the outer weldment. Make sure the line is on
the hose sheave.
10. Install the lift chain to the free–lift cylinder. Attach a
wire between the end of the chain and the bottom of the
mast to control the lift chain during installation.
FOUR–STAGE MAST (See FIGURE 8.)
1. Put the outer weldment on the floor so that the pivots
are on the floor.
2. Install the strip bearings and the shims on the channels
of the outer weldment. See FIGURE 10. Apply multi–
purpose grease to the bearings.
3. Connect a crane to the center of the second weldment.
Fit the stub shafts on the bottom of this weldment into
the notches in the top of the outer weldment. Slide the
second weldment into the outer weldment until the stub
shafts are can be seem at the top and the bottom of the
weldments.
4. Install the load rollers and shims on the top of the out-
er weldment. Repeat this procedure on the bottom of the
second weldment. See Checks and Adjustments to ad-
just the second weldment.
5. Install the strip bearings and the shims on the channels
of the second weldment. Apply multi–purpose grease to
the bearings.
6. Connect a crane to the center of the third weldment.
Fit the stub shafts on the bottom of this weldment into
the notches in the top of the second weldment. Slide the
third weldment into the second weldment until the stub
shafts are exposed at the top and the bottom. Lift the top
of the weldment a small amount for clearance at the se-
cond weldment.
7. Install the spacers and large sheaves on the stub shafts
in the second weldment.
8. Install the load rollers and shims on the top of the se-
cond weldment. Repeat this procedure on the bottom of
the third weldment. See Checks and Adjustments to ad-
just the third weldment.
9. Install the larger chains:
a. Put the chains into the mast over the cross–mem-
ber of the outer weldment. The position for the
chain anchors is near the bottom of the mast.
b. Attach a soft wire to the top of a chain.
c. Put the wire around the sheave and through the
hole in the plate.
d. Use the wire to pull the chain around the sheave
and through the hole.
e. Remove the wire. Connect the chain to the anchor
on the outer weldment.
f. Repeat steps 2, 3, 4, and 5 to install the second
chain.
10. Install the strip bearings and the shims on the chan-
nels of the third weldment. Apply multi–purpose grease
to the bearings.
11. Connect a crane to the center of the inner weldment.
Fit the stub shafts on the bottom of this weldment into
the notches in the top of the third weldment. Slide the in-
ner weldment into the third weldment until the stub
shafts are seen at the top and the bottom of the weld-
ments.
12. Install the spacers and small sheaves on the stub
shafts in the third weldment.
13. Install the load rollers and shims on the top of the
third weldment and on the bottom of the inner weld-
ment. See Checks and Adjustments to adjust the inner
weldment.
14. Install the smaller chains:
a. If necessary, install the chain anchors on the se-
cond weldment.
b. Install the anchors that are attached to the chains.
Install these anchors and the chains on the back of
the inner weldment.
c. Lift the end of a chain over a sheave. Pull the
chain around the sheave and connect the chain to
the anchor. Install the second chain.
15. Install the free–lift cylinder on the base of the inner
weldment. If the hydraulic tube was removed, install it
on the cylinder. Do not fully tighten the hydraulic fitting
on the tube.
16. Turn the cylinder and tube as necessary to align the
tube with the location for the hose clamp. Install the
clamp that holds the free–lift cylinder.
13

WARNING
The weldments can slide when the mast is moved. A
weldment that suddenly slides can cause an injury.
Use a crane to turn the mast slowly and carefully.
17. Temporarily fasten the large chains in a position that
will prevent damage. Turn the mast over so that the inner
weldment is on the floor. Use blocks under the inner
weldment to protect the sheave on the free–lift cylinder.
18. Connect the anchors on the large chains to the back
of the third weldment.
19. Install the main lift cylinders:
a. If necessary, install the isolators on the brackets
for the cylinder clamps.
b. If spacers were removed from the cylinder bases,
make sure the spacers are installed again.
c. Install the cylinder for the hose on the left–hand
side of the mast. The port in the rod must be oppo-
site the port in the top of the cylinder. Install the
base of the cylinder in the outer weldment. Slide
the outer weldment toward the bottom of the mast
to get clearance for cylinder installation.
d. Install the clamp, soft washers, flat washers, and
locknuts. The clamp must prevent rotation of the
cylinder. Tighten the locknuts, but do not com-
press the soft washers too much.
e. When both cylinders are installed, put the rods in
the second weldment. To move the rods, slide the
outer weldment toward the top of the mast.
f. Install the anchor pins in the rods. Install the
bolts, washers, and locknuts for the anchor pins.
20. Install the lowering control valve and tubes on the
bracket on the outer weldment. Do not tighten the lock-
nuts.
21. Connect the tubes to the ports in the cylinders. Tight-
en the locknuts on the bracket.
22. Connect the return line to the top of each cylinder.
23. Install the hose sheave on the upper side of the brack-
et on the third weldment. Put the locknut and the washer
on the top. Do not fully tighten the nut.
24. Connect the hose to the port in the cylinder rod. Put
the hose on the sheave and connect the hose to the hy-
14
draulic tube. Install the clamp on the collar of the hose
fitting. Tighten the nut on the hose sheave.
NOTE: The hose sheave can be adjusted on the bracket
to change the tension of the hose.
25. Pull the free–lift chain through the sheave and con-
nect the chain to the anchor. Make sure the clamp on the
cylinder is tight. The clamp must prevent the cylinder
shell from rotating. Temporarily fasten the loose end of
the chain to the mast.
26. Tighten the hydraulic tube on the free–lift cylinder.
Installation
1. Connect a crane to the top of the mast assembly. Make
sure all the weldments are fastened together. Make sure
that the chains do not damage any of the hydraulic lines
or other parts.
2. Raise the mast assembly to a vertical position. Move
the mast assembly into position on the lift truck.
3. Lubricate the pivots and bushings with multi–purpose
grease. Install the pivot caps. Tighten the capscrews to
the following torque:
S/H1.25–1.75XL, E1.25–1.75XL 66 N.m
(S/H25–35XL, E25–35XL) (49 lbf ft)
S2.00–3.00XL, E2.00–3.00XL 165 N.m
(S40–60XL, E40–60XL) (122 lbf ft)
H2.00–3.00XL 90 N.m
(H40–60XL) (66 lbf ft)
4. Connect the hydraulic line to the mast assembly.
5. Connect the tilt cylinders to the outer weldment.
S/H1.25–1.75XL (S/H25–35XL) and E1.25–1.75XL
(E25–35XL). The holes for the tilt cylinder pins have
identification marks. Location “A” is for the H–Series
lift trucks. Location “B” is for the S and E–series lift
trucks.
Install the tilt limiters, if necessary. Install the bushings,
anchor pins, and cotter pins. The lock bolt on the rod end
of the tilt cylinder must be toward the floor. The nut for
the lock bolt must be toward the outside of the lift truck.
Tighten the nuts to 90 N.m (66 lbf ft).
6. Adjust the lift chains, carriage and tilt cylinders as de-
scribed in Checks and Adjustments.
 1
3
4

6 7
6

5
1. CARRIAGE 10907
2. TOP BAR, STANDARD CARRIAGE 5. CARRIAGE HOOK
3. TOP BAR, SIDE–SHIFT CARRIAGE 6. ANCHOR PIN (2)
4. BEARING 7. SIDE–SHIFT CYLINDER

FIGURE 12. SIDE–SHIFT CARRIAGE (EARLIER DESIGN)

SIDE–SHIFT CARRIAGE
(EARLIER DESIGN)
There are two Hyster Company designs of side–shift
carriages for this mast. The design shown in
FIGURE 12. is used on lift trucks manufactured
through 1993. During the second half of 1993, the se-
cond design shown in FIGURE 14. was installed on lift
trucks. The operation of the two designs are similar, but
the components are different.
4. Remove the two carriage hooks from the bottom bar
of the side–shift carriage.
5. Lift the side–shift carriage from the standard carriage.
Remove the bearings at the top of the standard carriage.
Repairs
The side–shift cylinder is the only component in the
side–shift carriage that normally needs repair. See
FIGURE 13.

NOTE: See the section, MAIN CONTROL VALVE,
2000 SRM 77, for information about the control valve
linkage for the side–shift carriage.
Removal
1. Remove the forks as described in the section under
Forks.
2. Connect a crane to the top bar of the side–shift car-
riage.
3. Disconnect the hydraulic lines at the side–shift cylin-
der. Put caps on the open lines. Remove the anchor pins
and cotter pins from the side–shift cylinder. Remove the
side–shift cylinder.
1. Remove the capscrews from the cover. Remove the
retaining ring.
2. Pull the rod and piston assembly from the shell. Re-
place seals, O–rings or back up rings as necessary.
3. Lubricate all parts with clean hydraulic oil. Tighten
the nut for the piston to 122 to 135 N.m (90 to 100 lbf ft).
Install the retainer, piston and rod assembly in the shell.
4. Install the retaining ring, cover and capscrews. Tight-
en the capscrews to 8 to 16 N.m (6 to 12 lbf ft).
Installation
1. Install the bearings on the carriage. Lubricate the
bearings with grease.
15
2. Use a crane and install the side–shift carriage on the position in the bottom bar. Tighten the capscrews to 165
standard carriage. N.m (122 lbf ft).

3. Install the two carriage hooks on the bottom bar of the
side–shift carriage. Check the clearance between the
carriage hooks and the bottom bar of the standard car-
riage. See FIGURE 12. If the clearance is more than 4.0
mm (0.16 in), move the hooks to the upper mounting
4. Install the side–shift cylinder in position. Install the
anchor pins and cotter pins. Connect the hydraulic lines
to the side–shift cylinder.
5. Install the forks.

1. SHELL 13
2. NUT
3. ROD SEAL
4. BACK–UP RING
5. PISTON 10906
6. ROD
7. O–RING 6
8. BACK–UP RING
1
9. RETAINER
10. ROD SEAL 10 12
11. RETAINING RING
12. COVER 6 11
9
13. CAPSCREW
5 8
4 7
3

1 2

FIGURE 13. SIDE–SHIFT CYLINDER FOR EARLIER DESIGN

SIDE–SHIFT CARRIAGE 4. Disconnect the hydraulic lines at the side–shift cylin-

(1993 AND LATER DESIGN) der. Put caps on the open lines. Remove the cylinder
mount bracket from the carriage. If necessary, remove
Removal the threaded rods and shims to remove the side–shift
cylinder.
1. Lower the carriage completely and remove the forks.

2. Connect a lifting device to the lifting eye on the side–
shift carriage.
3. Remove the two upper capscrews from the bottom
carriage bar. Slowly loosen the two bottom capscrews,
but do not remove them. The holes have slots that will
permit the bottom carriage bar to move down so that the
side–shift carriage can be removed. Carefully lift the
side–shift carriage from the standard carriage. The side–
shift cylinder mounting bracket and cylinder will stay
on the standard carriage. Remove the bushings.
16
Repairs (See FIGURE 15. and FIGURE 16.)
1. Do the following procedure to repair the side–shift
cylinder:
a. Remove the retainers from the shell. Pull the rod
from the shell.
b. Replace the seals, O–rings or back–up rings as nec-
essary.
c. Lubricate all internal parts with clean hydraulic oil.
 3
1
4
2

1. STANDARD CARRIAGE
2. TOP BAR, SIDE–SHIFT CARRIAGE
3. TOP BUSHING
4. CYLINDER MOUNT BRACKET
5 5. BOTTOM BUSHING
12797 7 6. SIDE–SHIFT CYLINDER
7. BOTTOM BAR, SIDE–SHIFT CARRIAGE

FIGURE 14. SIDE–SHIFT CARRIAGE (1993 AND LATER DESIGN)

d. Install the piston and rod in the shell. Apply Installation

Loctite 242 to the threads of the retainers. Install the
retainers and tighten them to 27 N.m (20 lbf ft).
2. Use new bushings if the old bushings are worn or
damaged.
1. Install the side–shift cylinder in the bracket. Use an
equal number of shims on both sides of the cylinder to
limit side–to–side movement within the bracket. Maxi-
mum movement is 0.6 mm (0.024 in). Install the
threaded rods to hold the cylinder in position.

2. Install the cylinder mount bracket on the standard car-

2
3 riage, and make sure it is engaged in the center notch in
5 4
6 the top carriage bar. Connect the hydraulic lines to the
8 side–shift cylinder. Put grease on the ends of the cylin-
7 der rod.
6
3. Install the top bushing on the mounting bracket. Lu-
bricate the outer surface of the bushing with multi–pur-
pose grease.

4. Connect the top and bottom carriage bars by installing

5 the two bottom capscrews. Do not tighten the cap-
2 3 4 screws. Lubricate the outer surface of the bottom bush-
1 ing with multi–purpose grease. Install the bottom bush-
1. SHELL 5. RETAINER
ing in the bottom bar of the side–shift carriage.
2. O–RING 6. WIPER
3. BACK–UP RING 7. PISTON AND ROD
5. Make sure the standard carriage is completely low-
4. ROD SEAL 8. PISTON SEAL ered. Connect a lifting device to the lifting eye. Install
the side–shift carriage on the standard carriage. Put
FIGURE 15. SIDE–SHIFT CYLINDER blocks under the bottom bar of the side–shift carriage so
17
that the bottom bushing is moved tight against the stan-
dard carriage.
6. Install the two top capscrews. On 2.00 to 2.75 ton
(4000 to 5500 lb) lift trucks, tighten all of the capscrews
to 435 N.m (320 lbf ft). On 3.00 to 3.20 ton (6000 to
6500 lb) lift trucks, tighten all of the capscrews to 755
N.m (557 lbf ft). Remove the lifting device. Lubricate
the top bushing at the grease fittings.
7. Install the forks.

2
1

3
4

HYDRAULIC CONNECTIONS –
6 TWO–STAGE, LIMITED FREE–LIFT
10

7
8

1. TOP BUSHING 6. GREASE FITTING

2. CYLINDER MOUNTING 7. TOP CARRIAGE BAR
BRACKET 8. BOTTOM BUSHING HYDRAULIC CONNECTIONS –
3. THREADED ROD 9. BOTTOM CARRIAGE TWO–STAGE, FULL FREE–LIFT AND
4. SHIM BAR THREE–STAGE, FULL FREE–LIFT
5. SIDE–SHIFT CYLINDER 10. LIFTING EYE

FIGURE 16. SIDE–SHIFT CARRIAGE

CHECKS AND ADJUSTMENTS

CHECK FOR LEAKS IN THE LIFT AND
TILT SYSTEM
WARNING
During the test procedures for the hydraulic system,
use chains to fasten the load to the carriage to pre-
vent it from falling. Keep all people away from the
lift truck during the tests.
1. Leaks Outside of the Hydraulic Lift System:
Operate the hydraulic system. Put a capacity load on the
forks and raise and lower the load several times. Lower
18
the load and tilt the mast forward and backward several
times. Check for leaks.
2. Leaks Inside of the Hydraulic Lift System:
a. Put a capacity load on the forks. Raise the car-
riage until all the weldments are extended. If the
carriage lowers slowly with the control valve in a
neutral position, there is a leak inside of the hy-
draulic system. Maximum lowering of the car-
riage because of inside leakage in the lift system
is 33 mm (1.3 in) per 10 minutes. This maximum
lowering is when the hydraulic oil is 30°C (86°F).
If the oil temperature is 60°C (140°F), the maxi-
 mum lowering of the carriage is 146 mm (5.8 in)
per 10 minutes.
b. Check the lift cylinder for internal leaks. Install a
gate valve in the supply line between the main
control valve and the lift cylinder. Put an 80 to
90% capacity load on the forks. Raise the car-
riage until all the weldments are extended. Close
the gate valve. If the carriage or mast weldments
lower slowly, the seals in the lift cylinders have
leaks.
WARNING
During the test procedure for the hydraulic system,
use chains to fasten the load to the carriage to pre-
vent it from falling. Keep all persons away from the
lift truck during the test.
rod ends for the tilt cylinders as shown in FIGURE 17.
There must be no twist in the mast weldments. Tilt the
mast fully backward. Measure the tilt angle (See Name-
plate for tilt angles.) Do the following procedure to ad-
just the tilt cylinder stroke and the tilt angle:
a. The cylinder that stops last when tilting back-
ward has a shorter rod adjustment. Adjust the rod
length by loosening the rod end and turning the
cylinder rod. Both cylinders must have the same
stroke.
b. The cylinder that stops last when tilting forward
has a longer rod adjustment. Adjust rod length as
described in Step a.
c. Adjust the tilt angle by adjusting the cylinder rod
as necessary to get the correct tilt angle.

c. The method for checking internal leaks in the tilt
system is similar to step a above. Tilt the mast for-
ward by a small amount with an 80 to 90% capac-
ity load on the forks. Return the control valve to
the neutral position. If the mast continues to tilt
slowly forward, there is an internal leak in the tilt
system. Maximum rod extension because of in-
ternal leaks is 11 mm (0.4 in) per 10 minutes. This
maximum is when the hydraulic oil is 30°C
(86°F). If the oil temperature is 60°C (140°F), the
maximum rod extension is 50 mm (2.0 in) per 10
minutes.
d. After the cylinder stroke and the tilt angle are ad-
justed, tighten the capscrews on the rod ends.
WARNING
Make sure the tilt limit spacers are installed if the lift
truck has them. See the sections for LIFT CYL-
INDERS and for TILT CYLINDERS for additional
instructions and specifications,
2
“A”
1

d. To check for internal leaks in the piston seals of

the tilt cylinder, tilt the mast fully forward. Dis-
connect the hydraulic line from the front of the tilt
cylinder. Leave the cylinder port open. Put a cap
on the open hydraulic line. Operate the hydraulic 1. ROD END
2. ANCHOR PIN
system and move the control lever so that the
mast is tilted against the forward stops. Leaks MODEL DIM. “A”
from the open cylinder port indicate that the pis-
S/H/E1.25–1.75XL
ton seals leak. (S/H/E25–35XL)
TWO–STAGE, FREE–LIFT, 26 to 28 mm
ADJUST THE TILT CYLINDER STROKE AND THREE–STAGE (1.0 to 1.1 in)
AND THE BACKWARD TILT ANGLE OTHER MODELS:
(See FIGURE 17.) TWO–STAGE, FREE–LIFT,
THREE–STAGE, AND 14 to 16 mm
1. Check the tilt cylinder stroke by slowly tilting the FOUR–STAGE (0.55 to 0.63 in)
mast fully forward and backward several times. Each tilt
cylinder must stop its stroke at the same time. Adjust the FIGURE 17. TILT CYLINDER ADJUSTMENTS

19
LIFT CHAIN ADJUSTMENTS
WARNING
When working on or near the mast, see SAFETY
PROCEDURES WHEN WORKING NEAR THE
MAST.
During the test procedures for the mast, use chains to
fasten the load to the carriage to prevent it from fall-
ing. Keep all people away from the lift truck during
the tests.
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 com-
pletely lowered and the power is OFF.
When the chains are correctly adjusted:
• The tension will be the same on each chain of a
chain set. Check tension by pushing on both
chains at the same time.
• The chain length will be correct. On the three–
stage and the four–stage masts, the tops of the
weldments will be level.
• The chains will travel freely through the com-
plete cycle.
1. When adjusting the two–stage or the free–lift mast,
start with step 2. Do the following steps first to adjust the
three–stage or the four–stage mast.
CAUTION
Adjust the four–stage mast carefully and keep it cor-
rectly adjusted. Wrong adjustment can cause dam-
age to the free–lift hoses.
a. Adjust the chain anchors on the outer weldment
so that the top of the inner (or third) weldment is
level with the top of the outer weldment. The tol-
erance is +1.5 mm (0.06 in).
b. On the four–stage mast, adjust the chain anchors
on the second weldment so that the top of the in-
ner weldment is level with the top of the outer
weldment. The tolerance is +1.5 mm (0.06 in).
2. Put a load on the forks. Lower the forks as much as
possible. Tilt the mast fully backward. Check the
amount that the bottom carriage roller extends below the
inner channel of the mast. See FIGURE 18. No more
than one–third of the roller can extend below the inner
weldment. If the rollers are too low, adjust the chain an-
20
chor, or anchors. Make sure each chain anchor is ad-
justed the same amount.
3. Remove the load from the forks. On the two–stage
mast, check the clearance of the carriage when the mast
is fully extended. On an mast with a free–lift cylinder,
make this check after extending the weldments a short
distance. The carriage stops must not touch the stop on
the top crossmember of the inner weldment. The chains
are too tight if the carriage touches the crossmember. Put
the mast in a vertical position and lower the carriage
completely. The bottom of the fork heel should be 3 to 6
mm (0.12 to .38 in) above floor level. Adjust the chain
anchors accordingly. Make sure each anchor is adjusted
the same amount.
NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain an-
chors are completely engaged. Make sure that all of the
adjustment is not removed from the chain anchors so
that they can not move in their sockets.
1
3
4
4691
2
1. TILT MAST FULLY BACKWARD
2. CARRIAGE ROLLER
3. FORK
4. CARRIAGE ROLLER MUST NOT
EXTEND MORE THAN 34 mm (1.3 in)
BELOW THE MAST CHANNEL
FIGURE 18. LIFT CHAIN ADJUSTMENTS
MAST ADJUSTMENTS (See FIGURE 19.)
NOTE: Shims are installed on both sides of the load
roller. Do not add or remove shims from the stub shafts.
To change the position of the roller on the stub shaft,
move the shims from one side of the load roller to the
other.
During assembly, the shim configuration will be
approximately the same as before disassembly. Check
the clearance and adjust for wear or change because of
repairs.
1. The load rollers control the alignment of the mast
weldments. The alignment conditions are given on a list
below with the most important condition first. See
FIGURE 19.
a. The vertical channels must be parallel to decrease
wear.
b. The maximum clearance between the load roller
and the channel at the tightest fit is 0.8 mm (0.030
in).
c. The number of shims under a load roller must be
approximately the same as the stub shaft in the
opposite side of the weldment. The weldments
will be approximately in the center.

UPRIGHT CARRIAGE
TOP VIEW FRONT VIEW FRONT VIEW
1 6
7

2 9
2

10

11
3

4 5
5 4690
8 8
1. CHANNEL (WELDMENT) 7. 0.1 TO 0.8 mm (0.004 to 0.030 in)
2. LOAD ROLLER 8. EQUAL SPACE
1.5 mm (0.060 in)
3. STUB SHAFT 9. PARALLEL
4. SNAP RING 10. INSTALL ALL SHIMS ON THE OUTSIDE OF THE ROLLER UNDER
5. SHIMS* THE SNAP RING
6. PARALLEL 11. USE SHIMS TO ADJUST 0.13 to 0.5 mm (0.005 to 0.020 in) AT
POINT OF TIGHTEST FIT*

*MOVE SHIMS FROM ONE SIDE OF THE ROLLER TO THE OTHER SIDE TO CHANGE THE POSITION
OF THE ROLLER ON THE STUB SHAFT.
USE SHIMS TO KEEP THE CARRIAGE AND THE MAST WELDMENTS PARALLEL, TO GIVE APPROXI-
MATELY EQUAL SPACE BETWEEN BOTH SIDES OF THE CARRIAGE AND THE WELDMENTS AND TO
GIVE THE CORRECT CLEARANCE AT THE TIGHTEST FIT.
FIGURE 19. MAST AND CARRIAGE ADJUSTMENTS

21
2. Adjust the mast load rollers as follows:

a. Use a prybar to move the weldments from side to 2

side to measure the amount of movement. Repeat 1
in a minimum of three different positions of the 2
weldments.
10106
b. Separate the weldments and change the shim con-
figurations as needed. Assemble the weldments.
Slide the weldment all the way to the top and bot-
1. STRIP BEARING
tom to find the tightest fit. 2. LOAD ROLLER
3. WELDMENTS
c. Repeat steps a and b until the maximum clearance 4. SHIMS
at the point of tightest fit is 0.8 mm (0.030 in). 3 5. O–RING

d. Measure the distance between the channels of the 1

weldments on the top and bottom. Change shims
to keep the distance equal between the top and
bottom of the weldments. Also make sure that the
weldments are parallel within 1.5 mm (0.060 in).

3. Adjust the strip bearings. Install or remove shims be-

tween the strip bearing and the channel. Adjust the strip
bearings so that the maximum clearance at the point of
tightest fit is 0.8 mm (0.030 in). See FIGURE 20. 1

CARRIAGE ADJUSTMENT 4 4
(See FIGURE 19.)
4692

1. Install the load rollers on the carriage. Install the 5

shims for the rollers in the same sequence on the stub
FIGURE 20. ADJUSTMENT OF THE STRIP
shaft as before disassembly. Do not put any shims under
BEARINGS
the top load rollers.

2. Use a crane to raise the carriage up the inner channel.

Find the tightest fit between the load rollers and the in-
ner channels.
3. Remove the carriage from the mast. Adjust the shim
arrangement for each roller for clearance between the
roller and the inner weldment. Maximum clearance is
0.5 mm (0.020 in) at the tightest fit. Repeat steps 2 and 3
if necessary.
4. Keep the shim arrangement on each side of the car-
riage approximately equal. The carriage must be paral-
lel with the inner mast channel within +1.5 mm (0.060
in).
CAUTION
Too much grease will cause the rollers to slide and
wear flat areas on the rollers.
5. After adjustment, lubricate the channels with a thin
layer of grease.
HEADER HOSE ARRANGEMENTS
Some lift trucks have auxiliary hydraulic functions that
are fastened to the carriage. Examples of these auxiliary
functions are a side–shift carriage or a roll clamp. These
auxiliary functions need arrangements of header hoses
for their operation. Most lift trucks with these auxiliary
functions will have either one pair or two pairs of header
hoses as shown in FIGURE 21. through FIGURE 26.
These arrangements normally do not require adjust-
ments after removal and installation.

22
 FRONT VIEW OF HYDRAULIC
LINES AT COWL (TYPICAL)

S/H/J1.25–1.75XL
(S/H/J25–35XL)
S2.00–3.00XL and
(S40–60XL) H2.00–3.00XL
(H40–60XL)
3 FUNCTION

4 FUNCTION

E1.25–1.75XL 3 FUNCTION
(E25–35XL)
4 FUNCTION

NOT USED
E/J2.00–3.00XL (E/J40–60XL)

FIGURE 21. HEADER HOSE CONNECTIONS AT COWL

Two–Stage Header Hoses
(See FIGURE 22. and FIGURE 23.)
Some early production lift trucks have the header hose
arrangement shown in FIGURE 23. If your lift truck has
this header hose arrangement, use the following proce-
dure with FIGURE 23. for checks and adjustments.
1. Adjust the hose guide rollers so that the rollers are
centered over the chain sheave.
2. Adjust the rollers to a 0.5 to 1.5 mm (0.02 to 0.06 in)
clearance between the roller and the header hoses. Mea-
sure this clearance when there is no hydraulic pressure
in the hoses.
free–lift and the three–stage masts. On the four–stage
mast, hose reels are used with both pairs of hoses. The
hose reel has a spring to keep the hoses tight.
WARNING
A hose reel has a strong spring. Prevent injury by
keeping the hoses under control when disconnecting
the hoses at the carriage. The spring is compressed
inside the hose reel when the reel is unwound. Never
disassemble a hose reel without complete knowledge
of the manufacturer’s recommendations and proce-
dures.

Header Hoses For The Free–Lift,
Three–Stage, and Four–Stage Masts (See
FIGURE 24., FIGURE 25., and FIGURE 26.)
A hose reel is used with the second pair of hoses on the
When the header hoses are installed, wind the hose reel
five turns for the correct hose tension. Wind a right–
hand reel clockwise. Wind a left–hand reel counter-
clockwise.

23
 1. CHAIN SHEAVE
2. HOSE SHEAVE
3. HEADER HOSES
4. HYDRAULIC TUBES
5. INNER CHANNEL
6. OUTER CHANNEL

VIEW FROM THE REAR OF THE MAST.

ALL FOUR HOSE LOCATIONS ARE SHOWN.

12125

FIGURE 22. HEADER HOSE ARRANGEMENT, TWO–STAGE MAST

1 1
6
1 1 7

0.5 to 1.5 mm
(0.02 to 0.06 in)

8
2
2
9
3

11458
10
1. ROLLER, HOSE GUIDE 6. NUT
2. HEADER HOSE 7. WASHER
3. LIFT CHAIN 8. SPECIAL BOLT
4. WASHER 9. BUSHING
5. SHIMS 10. CHAIN SHEAVE

FIGURE 23. ADJUSTMENT, HEADER HOSE ROLLERS, EARLY PRODUCTION LIFT TRUCKS

24
NOTE: The arrangement for the E/S/H2.00–3.00XL (E/S/H40–60XL) is shown. The arrangement for the
1.25–1.75 (25–35XL) capacity lift trucks are similar. See FIGURE 21. for the cowl connections.

SIDE VIEW FRONT VIEW

1. HOSE REEL (RH)

2. HOSE (2)
3. HOSE
4. STRAIN RELIEF
5. BRACKET
6. HYDRAULIC TUBES
7. HOSE GUIDE
8. HOSE
9. HOSE
10. HOSE SHEAVE
11. FREE–LIFT CYLINDER
12. HOSE GUIDE

ALL FOUR HOSE LOCATIONS ARE SHOWN

FIGURE 24. HEADER HOSE ARRANGEMENT, FREE–LIFT MAST

25
 NOTE: The arrangement for the E/S/H2.00–3.00XL (E/S/H40–60XL) is shown. The arrangement for the
1.25–1.75 (25–35XL) capacity lift trucks are similar. See FIGURE 21. for the cowl connections.

1. HOSE REEL (RH)

2. OUTER CHANNEL
3. HOSE (2)
4. HOSE
5. STRAIN RELIEF
6. HOSE
7. HOSE SHEAVE
8. HYDRAULIC TUBES
9. HOSE (2)
FRONT VIEWS 10. HOSE SHEAVE (INTER-
MEDIATE WELDMENT)

ALL FOUR HOSE LOCATIONS ARE SHOWN

FIGURE 25. HEADER HOSE ARRANGEMENT, THREE–STAGE MAST

26
NOTE: See FIGURE 21. for the E/S2.00–3.00XL (E/S40–60XL) cowl connections.

1. HOSE REEL (RH)

2. HOSE (2)
3. HOSE
4. STRAIN RELIEF
5. HOSE REEL (LH)
6. HOSE (2)

FRONT VIEW

ALL FOUR HOSE LOCATIONS ARE SHOWN

FIGURE 26. HEADER HOSE ARRANGEMENT, FOUR–STAGE MAST

27
 TROUBLESHOOTING
PROBLEM
No movement of the lift cylinders.
Slow action of the lift cylinders.
Rough movement of the mast assembly.
The movement of the tilt cylinders is slow or not
smooth.
The tilt cylinders permit mast movement when the
control lever is in the NEUTRAL position.
The tilt cylinders tilt the mast forward and backward
too slowly.
No movement of the side–shift cylinder
Slow movement of the side–shift cylinder.
Rough movement of the side–shift carriage.
Side–shift cylinder moves the carriage in the opposite Hydraulic lines are not correctly connected.
direction as indicated by the control lever.
28
POSSIBLE CAUSE
Lift control linkage is disconnected.
No hydraulic oil or not enough hydraulic oil to the lift
cylinders.
Hydraulic leaks, worn or damaged hydraulic pump, or
damaged hydraulic pump drive.
Relief valve pressure is set too low or the check valve
does not close.
Not enough hydraulic oil to the lift cylinders.
Bad seal in the lift cylinders.
Lift cylinders have internal or external leaks.
Relief valve pressure is set too low.
Air in the hydraulic system.
Bent cylinder rod or damaged cylinder shell.
The lowering control valve function does not operate
correctly.
The mast assembly is damaged or needs alignment.
No hydraulic oil or not enough hydraulic oil to the tilt
cylinders.
Bad seals in the tilt cylinders.
Restriction in the hydraulic lines of the tilt system.
Air in the hydraulic system.
The tilt cylinders have internal damage.
The seals in the tilt cylinders are worn or damaged.
The main control valve is damaged or has an internal
leak.
There are leaks in the hydraulic system.
The main control valve is worn or damaged.
There is a leak in the hydraulic system.
The relief valve for the hydraulic system is not correct.
Linkage at the control valve is disconnected.
No oil or not enough oil in the hydraulic tank.
Relief valve is not set correctly.
Hydraulic pump does not operate or is damaged.
No oil or not enough oil to the side–shift cylinder.
Cylinder has internal or external leaks.
Relief valve is not set correctly.
There is a restriction in a hydraulic line.
Load is more than capacity.
There is air in the hydraulic system.
Lift cylinder(s) is damaged.
Bushing(s) are damaged or not installed correctly.
Bushings are not lubricated correctly.