Mast Repair (S/N B551, B555, AND B559) : Maintenance

Maintenance
MAST REPAIR (S/N

B551, B555, AND B559)
2- AND 3-STAGE MASTS
ERC16-20VA (ERC030-040VA) [A969]
PART NO. 550025859 4000 YRM 1441

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Safety Procedures When Working Near Mast .......................................................................................................... 1
Fork Replacement .................................................................................................................................................... 3
Standard Carriage and Integral Sideshift Carriage ............................................................................................... 3
Remove .............................................................................................................................................................3
Install .................................................................................................................................................................5
Checks .............................................................................................................................................................. 5
Fork Positioner Carriage ....................................................................................................................................... 6
Carriages Repair .......................................................................................................................................................6
Standard Carriage .................................................................................................................................................6
Remove .............................................................................................................................................................6
Repair ................................................................................................................................................................8
Install .................................................................................................................................................................8
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 .................................................. 8
Remove .............................................................................................................................................................8
Clean and Inspect ........................................................................................................................................... 11
Repair ..............................................................................................................................................................12
Install ...............................................................................................................................................................13
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 .................... 13
Remove ...........................................................................................................................................................13
Disassemble ....................................................................................................................................................16
Assemble ........................................................................................................................................................ 17
Install ...............................................................................................................................................................17
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After ...............................................18
Remove ...........................................................................................................................................................18
Disassemble ....................................................................................................................................................21
Assemble ........................................................................................................................................................ 22
Install ...............................................................................................................................................................22
Fork Positioner, Lift Trucks Manufactured Before December, 2016 ....................................................................23
Remove ...........................................................................................................................................................23
Disassemble and Assemble ............................................................................................................................27
Install ...............................................................................................................................................................27
Fork Positioner Hydraulic Hose Adjustment ................................................................................................28
Fork Positioner, Lift Trucks Manufactured December, 2016 and After ................................................................30
Remove ...........................................................................................................................................................30
Disassemble and Assemble ............................................................................................................................33
Install ...............................................................................................................................................................33
Fork Positioner Hydraulic Hose Adjustment ....................................................................................................34
Mast Repair ............................................................................................................................................................ 35
Remove ...............................................................................................................................................................35
Two-Stage LFL and Two-Stage FFL Masts, Disassemble ..................................................................................38
Three-Stage FFL Mast, Disassemble ................................................................................................................. 43
Clean and Inspect ............................................................................................................................................... 45
Two-Stage LFL and Two-Stage FFL Mast, Assemble ........................................................................................ 46
Three-Stage FFL Mast, Assemble ...................................................................................................................... 47
Mast, Install .........................................................................................................................................................48
Header Hose Arrangement .....................................................................................................................................50
Two-Stage LFL ....................................................................................................................................................51
©2019 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Two-Stage FFL ................................................................................................................................................... 57
Three-Stage FFL .................................................................................................................................................64
Adjustment .......................................................................................................................................................... 72
Lift Chains Adjustment ............................................................................................................................................72
Carriage Adjustments ............................................................................................................................................. 73
Mast Adjustments ................................................................................................................................................... 75
Load Roller Adjustment .......................................................................................................................................76
Mast Side Kicking Adjustment ............................................................................................................................ 77
This section is for the following models:
ERC16-20VA (ERC030-040VA) [A969]
ii
4000 YRM 1441 General
General
This section has the repair procedures for the Two-
WARNING Stage, Limited Free-Lift (LFL); Two-Stage, Full Free
Before working on or near the mast, see the Lift (FFL); and Three-Stage, Full Free-Lift (FFL); masts
section Safety Procedures When Working Near and carriages.
Mast in this YRM .
Safety Procedures When Working Near Mast

The following procedures MUST be used when If parts of the mast must be in a raised
•
inspecting or working near the mast. Additional position, install a safety chain to restrain the
precautions and procedures can be required when moving parts of the mast. Connect moving
repairing or removing the mast. parts to a part that does not move. Follow
these procedures:
WARNING 1. Put mast in vertical position.

Mast parts are heavy and can shift. Distances
2. Raise mast to align bottom crossmember of mast
between parts are small. Serious injury or death
upright that moves in outer mast with
can result if part of the body is hit by parts of the
crossmember on outer mast. On the two-stage
mast or the carriage.
mast, the moving part is the inner mast. On the
• Never put any part of the body into or under three-stage mast, it is the intermediate mast. See
the mast or carriage unless all parts are Figure 1.
completely lowered or a safety chain is
installed. Also make sure that the power is
3. Use a 10 mm (3/8 in.) minimum safety chain with
OFF and the key is removed. Put a DO NOT
OPERATE tag in the operator's a hook to fasten the crossmembers together so
compartment. Disconnect the battery and the movable member cannot lower. Put hook on
put a tag or lock on the battery connector. back side of mast. Make sure hook is completely
engaged with a link in the chain. Make sure safety
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause chain does not touch lift chains or chain sheaves,
an injury. tubes, hoses, fittings, or other parts on the mast.
• DO NOT climb on the mast or lift truck at any 4. Lower mast until there is tension in safety chain
time. Use a ladder or personnel lift to work
and free-lift cylinder (full free-lift models) is
on the mast.
completely retracted.
• Mast repairs require disassembly and
removal of parts and can require removal of NOTE: Apply the parking brake. After lowering or
the mast or carriage. Follow the repair
restraining the mast, shut off the power, and remove
procedures in this section.
key. Put a DO NOT OPERATE tag in the operator's
WHEN WORKING NEAR THE MAST ALWAYS: compartment. Disconnect battery and put a tag or lock
• Lower the mast and carriage completely: on battery connector.
Turn the key switch to the ON position and 5. Install another safety chain (10 mm (3/8 in.)
push the lift/lower control lever forward until minimum) between the top or bottom bar of the
there is no movement in the mast. Make sure
carriage (6) and a crossmember on the outer
that all parts of the mast that move are fully
lowered. mast as a secondary safety device. Install a DO
NOT REMOVE tag on the safety chain(s).
OR
1
Safety Procedures When Working Near Mast 4000 YRM 1441
Figure 1. Safety Chaining the Mast
2
4000 YRM 1441 Fork Replacement
Legend for Figure 1.
A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST

B. TWO-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER

2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK
Fork Replacement
STANDARD CARRIAGE AND INTEGRAL NOTE: Forks are to be replaced in sets by trained
SIDESHIFT CARRIAGE personnel only. DO NOT replace forks individually.
On lift trucks equipped with a standard carriage or an 1. Slide fork to fork removal notch on bottom bar of
integral sideshift carriage, the forks are held on the carriage. See Figure 2.
carriage by hooks. Forks are held in position by pins
that fit through the top fork hooks and into slots in top 2. Lower fork onto blocks (see Figure 3), so bottom
carriage bar. hook of fork moves through fork removal notch.
If pin does not remain engaged in carriage slot, 3. Lower carriage further so top hook of fork is
replace with new pin. Always check that pins for forks disengaged from top carriage bar. See Figure 2.
keep forks in position on carriage. Replace damaged
fork pin parts. 4. Move carriage away from fork or use a lifting
device to move fork away from carriage.
Remove
WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
3
Fork Replacement 4000 YRM 1441
1. LOAD BACKREST 6. SPRING

2. CARRIAGE 7. PIN (FORK LATCH)
3. FORK(S) 8. FORK REMOVAL NOTCH
4. KNOB 9. LOWER HOOK
5. PIN RETAINER 10. UPPER HOOK
Figure 2. Carriage and Forks
4
4000 YRM 1441 Fork Replacement
Never repair damaged forks by heating or welding.

Forks are made of special steel using special
procedures. Replaced damaged forks. Forks are to
be replaced only in sets and not individually.
1. Inspect forks for cracks and wear. Check that fork

tips are aligned as shown in Table 1. Check that
bottom of fork is not worn (item A, Figure 5).
CAUTION
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment.
2. Replace any damaged or broken parts that are

used to keep forks locked in position.
1. CARRIAGE BARS 3. Inspect forks for cracks and wear. Ensure the
2. HOOK FORK heel wear is not more than 10% of original
3. BLOCKS
thickness. If fork wear is more than 10%, the fork
Figure 3. Hook Fork, Remove must be replaced or rerated. Perform the fork
wear inspection using a BOL256N1 caliper ruler,
Yale P/N 550088603 , as follows. See Figure 4
Install
a. Determine the normal thickness of the "N" of
WARNING the fork using the scale or ruler portion of the
DO NOT try to remove a fork without a lifting caliper ruler. Measurement has to be done on
device. Each hook fork for these lift trucks can the fork shank using the caliper ruler.
weigh 45 to 115 kg (99 to 254 lb).
b. Position the caliper at the end of the heel
NOTE: Forks are to be replaced in sets by trained internal radius (item A, Figure 5) with the
personnel only. DO NOT replace forks individually. opening corresponding to the measure
thickness of the fork shank in Step a above
1. Move fork and carriage so top hook of fork can (e.g. N 1.75 use N 1.75 opening). This is
engage upper carriage bar. See Figure 3. typically the section of the fork where wear is
the greatest. Note that the opening distance
2. Raise carriage to move bottom hook of fork
has been reduced by 10% from the nominal
through fork removal notch.
thickness.
3. Slide fork on carriage so both upper and lower
c. If the fork enters the opening, it is mandatory to
hooks engage carriage bars. See Figure 2.
replace it. DANGER OF BREAKING.
Furthermore, a 10% reduction in fork blade
4. Install latch pin in top hook and notch in upper
thickness results in 20% reduction in operating
carriage bar. See Figure 2.
capacity.
Checks
WARNING
DO NOT try to correct fork tip alignment by
bending the forks or adding shims. Replace bent
forks.
5
Carriages Repair 4000 YRM 1441
Table 1. Fork Tip Alignment (Continued)

Fork Tip Alignment Specifications
1372 (54) 41 (1.61)
1524 (60) 46 (1.81)
*Difference of alignment between fork tips must be no
more than 3% of the total fork length.
Figure 4. Fork Wear Check
4. Check alignment of fork tips. Differences in height

of fork tips must be less than three percent of fork
length. See Table 1 and Figure 5
A. HEEL OF FORK (MUST BE 90% OF DIMENSION
B)
Table 1. Fork Tip Alignment B. ORIGINAL FORK THICKNESS (DIMENSION B)
Fork Tip Alignment Specifications
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
Standard Fork Lengths Maximum Fork Tip FORK LENGTH)
Difference* 2. CRACKS
3. MAXIMUM ANGLE 93°
mm (in.) mm (in.) 4. FORK REMOVAL NOTCH
5. CARRIAGE
914 (36) 27 (1.08)
1000 (39) 30 (1.17) Figure 5. Fork Checks
1067 (42) 32 (1.26)
FORK POSITIONER CARRIAGE
1100 (43) 33 (1.29)
If lift truck is equipped with a fork positioner, go to
1200 (47) 36 (1.42) Carriages Repair for procedures to remove forks.
1219 (48 37 (1.46)
Carriages Repair
STANDARD CARRIAGE 2. Remove four capscrews, washers, nuts, and load
backrest from carriage. See Figure 6.
Remove
1. Remove the forks. See section Fork
Replacement.
6
4000 YRM 1441 Carriages Repair
1. CAPSCREW
2. WASHER NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
3. NUT
4. CARRIAGE 1. CARRIAGE
5. LOAD BACKREST 2. SNAP RING
3. SHIM
Figure 6. Load Backrest Removal 4. LOAD ROLLER
5. CHAIN ANCHOR
3. Connect a lifting device to the carriage. Lift 6. CHAIN PIN
7. COTTER PIN
carriage so that lift chains become loose. 8. ANCHOR PIN
9. SPACER
WARNING Figure 7. Standard Carriage

When disconnecting the lift chains, keep control of
the ends. Use wire to temporarily connect the ends
of the lift chains to the mast. This procedure will WARNING
prevent the lift chains from falling from the To help prevent possible injury, make sure the
sheaves and causing an injury or damage. carriage is stable when the inner mast is above the
load rollers of the carriage.
4. Remove pin from each chain anchor at the
carriage. See Figure 7. Disconnect lift chains from 5. Use lift cylinders to raise the inner or intermediate
carriage. Use wire to connect ends of lift chains to mast. If hydraulic system cannot be used,
a part of the mast. Make sure chains can move disconnect lift cylinders from inner or intermediate
freely when inner mast is raised. mast. See section Cylinder Repair (Mast S/N
B551, B555, B559) 2100YRM1440.
NOTE: Crane capacity must be at least

681 kg (1501 lb).
7
6. Connect a crane to the top of inner mast. Disconnect crane, if attached, and reconnect lift
Carefully raise inner mast until it is above load cylinders. See section Cylinder Repair (Mast
rollers of carriage. Install safety chains to secure S/N B551, B555, B559) 2100YRM1440.
mast in its extended position and disconnect
crane. See section Safety Procedures When 3. Check clearance of load rollers. See Carriage
Working Near Mast. Adjustments in this section.
7. Move lift truck away from carriage. Completely NOTE: Use new cotter pins each time anchor pins are
lower inner mast so it cannot move. removed.
4. Connect lift chains to chain anchors at carriage.
Repair Install cotter pins in anchor pins. Adjust lift chains
NOTE: The carriage can have four or six load rollers. as described in Carriage Adjustments.
When carriage has four load rollers, shims are used
behind all of the load rollers. When the carriage has 5. Install backrest and four capscrews on carriage.
six load rollers, shims are installed on bottom and Tighten capscrews to 195 N•m (144 lbf ft).
middle rollers only. See Figure 7.
6. Install forks. See Fork Replacement.
NOTE: If any load rollers must be replaced, make a
note of the location and number of shims. INTEGRAL SIDESHIFT CARRIAGE, LIFT
1. Replace shims, load rollers, and snap rings. See TRUCKS MANUFACTURED PRIOR TO
Carriage Adjustments for correct adjustment of DECEMBER, 2016
the load rollers.
Remove
1. Remove forks. See Fork Replacement.
WARNING
Improper welding procedures can damage the 2. Lower carriage completely. Remove capscrews,
structure of the mast or cause incorrect function washers, nuts, and load backrest extension. See
of the mast. Consult your Yale ® lift truck dealer for Figure 6.
more information before welding on the mast.
2. If carriage bars have any protruding welds or WARNING

damaged notches, repair by grinding, filing, or Always wear the proper protective equipment
welding. including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
Install wash oil from exposed areas of skin as soon as
NOTE: Crane capacity must be at least possible.
681 kg (1501 lb). The hydraulic oil is hot at normal operating
1. Use hydraulic system of lift truck or a crane to temperatures. Be careful when draining the oil.
raise inner mast. Connect a crane to top of the Never check for leaks by putting hands on
inner mast. Carefully raise inner mast until it is hydraulic lines or components under pressure.
above load rollers of carriage. Install safety Hydraulic oil under pressure can be injected into
chains to secure mast in its extended position and the skin.
disconnect crane. See Safety Procedures When
Working Near Mast.
CAUTION
2. Move lift truck toward carriage until inner mast is
Protect the hydraulic system from dirt and
aligned with carriage rollers. If inner mast has
contaminants when servicing the hydraulic
been raised and secured using a crane and
system.
safety chains, connect crane, raise inner mast,
and remove safety chains. Carefully lower inner NOTE: Tag hydraulic lines prior to disconnecting to
mast until it engages all of load rollers. insure correct connection during installation.
8
3. Disconnect hydraulic lines at sideshift cylinder. NOTE: Crane capacity must be at least 38 kg (84 lb)
Put caps on open hydraulic lines.
6. Use a crane to lift outer frame away from inner
frame. Lay outer frame flat on a pallet or
4. Remove lower mounting hooks and four
workbench.
capscrews from outer frame. See Figure 8.
5. Remove sideshift cylinder from inner frame. See

Cylinder Repair (Mast S/N B551, B555, B559)
2100YRM1440 for procedures.
9
NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.
1. INNER CARRIAGE 13. PIN

2. OUTER FRAME 14. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 15. SNAP RING
4. UPPER BEARING 16. PIN
5. LOWER BEARING 17. COTTER PIN
6. LOWER HOOK 18. LOAD ROLLER
7. CAPSCREW 19. SHIMS
8. WASHER 20. SPACER
9. CLEVIS PIN 21. SNAP RING
10. HAIRPIN 22. SPACER
11. PIN 23. FORK REMOVAL NOTCH
12. LUBE FITTING
Figure 8. Integral Sideshift Carriage
10
Clean and Inspect 2. Clean and inspect carriage bars for damage and
smoothness. Ensure bars are parallel and ends
1. Inspect lower mounting hooks for wear. Replace are flush.
hooks if they are worn beyond wear limit. The
wear limit clearance range is 0.76 mm (0.03 in.) 3. Clean bearing areas. See Figure 8. Inspect
minimum and 1.52 mm (0.06 in.) maximum. See sideshift bearings for wear as follows:
A in Figure 9.
a. Remove upper bearings from upper carriage
bar. If either upper bearing is worn to less than
2.5 mm (0.1 in.) thickness, replace both upper
bearings by driving upper bearings from upper
b. Remove lower bearings from lower carriage

bar. If either lower bearing is worn to less than
2.5 mm (0.1 in.) thickness, replace both lower
bearings by driving lower bearings from lower
A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND

1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
Figure 9. Lower Mounting Hooks Wear Limit and

Clearance Adjustment
11
A. MINIMUM THICKNESS 2.5 mm (0.1 in.)
1. LOWER BEARINGS 3. UPPER BEARINGS

2. CARRIAGE BARS
*Bold Arrows Indicate Which Side To Apply Grease.
Figure 10. Upper and Lower Bearings
4. Inspect the sideshift cylinder. See section a. To install new upper bearing, align the pins on
Cylinder Repair (Mast S/N B551, B555, B559) the bottom side of bearing to notches on top
2100YRM1440 for procedures. carriage bar and slide into place on top
carriage. See Figure 10.
Repair
b. To install new lower bearing, align the circular
NOTE: If any load rollers must be replaced make a pins on backside of lower bearing to holes on
note of location and number of shims. See Figure 8. lower carriage bar and tap bearing into place
1. Replace shims, load rollers, and snap rings. See on lower carriage bar using a rubber or brass
section Carriage Adjustments for correct hammer. See Figure 10.
adjustment.
NOTE: Use a wood block or a plastic hammer to fully WARNING

seat the upper bearings onto the inner frame. Proper Improper welding procedures can damage the
lower hook clearance requires the upper bearings be structure of the mast or cause incorrect function
fully seated. of the mast. Consult your Yale lift truck dealer for
2. Apply a 1 mm (0.040 in.) layer of multipurpose more information before welding on the mast.
grease to upper and lower bearing surfaces.
Install the upper and lower bearings onto inner 3. If carriage bars have any protruding welds or
frame: damaged notches, repair by grinding, filing, or
welding.
12
4. Repair sideshift cylinder as indicated in section

Cylinder Repair (Mast S/N B551, B555, B559) WARNING
2100YRM1440. Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious
Install injury can occur if pressure is not relieved from
1. Install sideshift cylinder on inner frame. See hydraulic system prior to disconnecting hydraulic
Cylinder Repair (Mast S/N B551, B555, B559) hoses.
2100YRM1440.
3. Relieve hydraulic pressure to the sideshift
NOTE: Crane capacity must be at least 38 kg (84 lb) cylinder by moving sideshift lever in both
directions several times.
2. Using a crane, install outer frame on inner frame.
3. Install lower mounting hooks and four capscrews

WARNING
on outer frame. Tighten capscrews to
165 ±15 N•m (120 ±12 lbf ft). For proper sideshift Always wear the proper protective equipment
operation, make sure there is including eye protection and petroleum-resistant
0.76 to 1.52 mm (0.03 to 0.06 in.) clearance gloves when handling hydraulic oil. Thoroughly
between bottom of hooks and outer frame. See B wash oil from exposed areas of skin as soon as
in Figure 9. possible.
The hydraulic oil is hot at normal operating
4. Connect hydraulic lines, as tagged during temperatures. Be careful when draining the oil.
removal, to sideshift cylinder. Never check for leaks by putting hands on
hydraulic lines or components under pressure.
5. Install backrest and capscrews on sideshift Hydraulic oil under pressure can be injected into
carriage. Tighten capscrews to the skin.
195 N•m (144 lbf ft).
6. Install forks. See Fork Replacement.

CAUTION
INTEGRAL SIDESHIFT CARRIAGE, LIFT
TRUCKS MANUFACTURED DECEMBER, system.
2016 THROUGH LATE JUNE, 2018
NOTE: Tag hydraulic lines and fittings prior to
Remove disconnecting to aid in connecting during installation.
1. Lower carriage completely and remove forks. See 4. Disconnect hydraulic lines from sideshift cylinder.
Fork Replacement for removal procedures. Put caps and plugs on open lines and cylinder
ports. See Figure 11.
2. Remove four capscrews, washers, nuts, and load
backrest from carriage. See Figure 6.
13
1. HYDRAULIC HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

2. INTEGRAL SIDESHIFT HYDRAULIC HOSES 4. INTEGRAL SIDESHIFT CARRIAGE
Figure 11. Integral Sideshift Carriage Hydraulic Hose Connections
5. Remove four capscrews and washers securing 6. Use a crane, with a capacity of 38 kg (84 lb), to lift
lower mounting hooks to outer frame. See outer frame away from inner frame (see
Figure 12. Figure 13). Lay outer frame flat on a pallet or
workbench.
14
1. LUBE FITTING 10. LOAD ROLLERS

2. OUTER FRAME 11. SHIM
3. CAPSCREW 12. SPACER
4. WASHER 13. FORK REMOVAL NOTCH
5. ANCHOR PIN 14. INTEGRAL SIDESHIFT CYLINDER
7. LOWER MOUNTING HOOK 16. CHAIN PIN
8. UPPER BEARINGS 17. CHAIN ANCHOR
9. SNAP RING
Figure 12. Integral Sideshift Carriage Component Parts
15
Clean and Inspect
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect function
of the mast. Consult your Yale lift truck dealer for
1. Clean and inspect the carriage bars for damage

and smoothness. Ensure the carriage bars are
parallel and the ends are flush. If carriage bars
have any protruding welds or damaged notches,
repair by grinding, filing, or welding.
2. Clean the bearing areas. Inspect the sideshift

bearings for wear as follows:
a. If either upper bearing is worn to less than

bearings by driving the upper bearings from
Figure 13. Remove Outer Frame the inner frame. See Assemble section for
procedures to replace upper bearings and
Disassemble Figure 14.
1. Remove the upper and lower bearings from the b. If either lower bearing is worn to less than
inner frame. See Figure 12. 2.5 mm (0.1 in.) thickness, replace both lower
bearings by prying the lower bearings from the
2. If damaged, remove lube fittings from outer inner frame. See Assemble section for
frame. See Figure 12. procedures to replace lower bearings and
Figure 14.
3. Disassemble sideshift cylinder. See Cylinder
Repair (Mast S/N B551, B555, B559)
16
A. MINIMUM THICKNESS, 2.5 mm (0.1 in.)

2. CARRIAGE BARS
*Bold arrows indicate which side to apply grease.
3. Inspect sideshift cylinder. See Cylinder Repair 3. Apply a 1 mm (0.040 in.) layer of multipurpose
(Mast S/N B551, B555, B559) 2100YRM1440 for grease to upper and lower bearing surfaces.
procedures. Install the upper and lower bearings onto inner
frame:
4. Inspect load rollers for wear and damage. If load
rollers must be replaced, make a note of the a. To install new upper bearing, align the pins on
location and number of the shims to ensure the bottom side of bearing to notches on top
correct installation. carriage bar and slide into place on top
Assemble
1. Assemble sideshift cylinder. See Cylinder Repair pins on backside of lower bearing to holes on
(Mast S/N B551, B555, B559) 2100YRM1440 for lower carriage bar and tap bearing into place
procedures. on lower carriage bar using a rubber or brass
hammer. See Figure 14.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 12.
Install
NOTE: Use a wood block or a plastic hammer to fully 1. Use a crane, with a capacity of 38 kg (84 lb), and
seat the upper bearings onto the inner frame. Proper install outer frame onto inner frame.
lower hook clearance requires the upper bearings be
fully seated.
17
2. Install lower mounting hook using four capscrews

3. Relieve hydraulic pressure to the sideshift
and washers. Tighten capscrews to
cylinder by moving sideshift lever in both
150 to 180 N•m (108 to 132 lbf ft). See Figure 12.
directions several times.
3. Connect hydraulic lines, as noted during removal,
to sideshift cylinder. See Figure 11.
WARNING
4. Install load backrest onto integral sideshift Always wear the proper protective equipment
carriage. Tighten capscrews to including eye protection and petroleum-resistant
195 N•m (144 lbf ft). See Figure 6 gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
5. Install forks. See Fork Replacement section for possible.
procedures. The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the oil.
INTEGRAL SIDESHIFT CARRIAGE, LIFT Never check for leaks by putting hands on
TRUCKS MANUFACTURED LATE JUNE, hydraulic lines or components under pressure.
2018 AND AFTER Hydraulic oil under pressure can be injected into
the skin.
Remove
1. Lower carriage completely and remove forks. See
Fork Replacement for removal procedures. CAUTION
2. Remove four capscrews, washers, nuts, and load contaminants when servicing the hydraulic
backrest from carriage. See Figure 6. system.
NOTE: Tag hydraulic lines and fittings prior to

WARNING disconnecting to aid in connecting during installation.
Before disconnecting the hydraulic hoses, relieve 4. Disconnect hydraulic lines from sideshift cylinder.
the pressure in the hydraulic system. Serious Put caps and plugs on open lines and cylinder
injury can occur if pressure is not relieved from ports. See Figure 15.
hydraulic system prior to disconnecting hydraulic
hoses.
18
1. HYDRAULIC HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

2. INTEGRAL SIDESHIFT HYDRAULIC HOSES 4. INTEGRAL SIDESHIFT CARRIAGE
Figure 15. Integral Sideshift Carriage Hydraulic Hose Connections
5. Remove four capscrews and washers securing 6. Use a crane, with a capacity of 38 kg (84 lb), to lift
lower mounting hooks to outer frame. See outer frame away from inner frame (see
Figure 16. Figure 17). Lay outer frame flat on a pallet or
workbench.
19
1. LUBE FITTING 10. LOAD ROLLERS

2. OUTER FRAME 11. SHIM
3. CAPSCREW 12. SPACER
4. WASHER 13. FORK REMOVAL NOTCH
5. ANCHOR PIN 14. INTEGRAL SIDESHIFT CYLINDER
7. LOWER MOUNTING HOOK 16. CHAIN PIN
8. UPPER BEARINGS 17. CHAIN ANCHOR
9. SNAP RING
Figure 16. Integral Sideshift Carriage Component Parts
20
Clean and Inspect
WARNING
1. Clean and inspect the carriage bars for damage

and smoothness. Ensure the carriage bars are
parallel and the ends are flush. If carriage bars
have any protruding welds or damaged notches,
repair by grinding, filing, or welding.
2. Clean the bearing areas. Inspect the sideshift

bearings for wear as follows:
a. If either upper bearing is worn to less than

bearings by driving the upper bearings from
Figure 17. Remove Outer Frame the inner frame. See Assemble section for
procedures to replace upper bearings and
Disassemble Figure 18.
1. Remove the upper and lower bearings from the b. If either lower bearing is worn to less than
inner frame. See Figure 16. 2.5 mm (0.1 in.) thickness, replace both lower
bearings by prying the lower bearings from the
2. If damaged, remove lube fittings from outer inner frame. See Assemble section for
frame. See Figure 16. procedures to replace lower bearings and
Figure 18.
3. Disassemble sideshift cylinder. See Cylinder
21
A. MINIMUM THICKNESS, 2.5 mm (0.1 in.)

2. CARRIAGE BARS
*Bold arrows indicate which side to apply grease.
3. Inspect sideshift cylinder. See Cylinder Repair 3. Apply a 1 mm (0.040 in.) layer of multipurpose
(Mast S/N B551, B555, B559) 2100YRM1440 grease to upper and lower bearing surfaces.
for procedures. Install the upper and lower bearings onto inner
frame:
4. Inspect load rollers for wear and damage. If load
rollers must be replaced, make a note of the a. To install new upper bearing, align the pins on
location and number of the shims to ensure the bottom side of bearing to notches on top
correct installation. carriage bar and slide into place on top
Assemble
1. Assemble sideshift cylinder. See Cylinder Repair pins on backside of lower bearing to holes on
(Mast S/N B551, B555, B559) 2100YRM1440 lower carriage bar and tap bearing into place
for procedures. on lower carriage bar using a rubber or brass
hammer. See Figure 18.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 16.
Install
NOTE: Use a wood block or a plastic hammer to fully 1. Use a crane, with a capacity of 38 kg (84 lb), and
seat the upper bearings onto the inner frame. Proper install outer frame onto inner frame.
lower hook clearance requires the upper bearings be
fully seated.
22
2. Install lower mounting hook using four capscrews

and washers. Tighten capscrews to
150 to 180 N•m (108 to 132 lbf ft). See Figure 16.
3. Connect hydraulic lines, as noted during removal,

to sideshift cylinder. See Figure 15.
4. Install load backrest onto integral sideshift

carriage. Tighten capscrews to
195 N•m (144 lbf ft). See Figure 6.
5. Install forks. See Fork Replacement section for

procedures.
1. OUTER FORK CARRIER
FORK POSITIONER, LIFT TRUCKS 2. CAPSCREW
MANUFACTURED BEFORE DECEMBER, 3. SPACER BAR*
2016 4. INNER FORK CARRIER
*Spacer bar used on 977 mm (38.5 in.) and
NOTE: This section covers lift trucks equipped with an 1067 mm (42 in.) class II carriages.
integral sideshift carriage, manufactured before
December, 2016 and equipped with a fork positioner. Figure 19. Fork Carrier Spacer Bar
NOTE: The fork positioner can be removed from the
integral sideshift carriage with the integral sideshift Remove
carriage on or off the mast. In the steps below, the fork
positioner is removed with the integral sideshift CAUTION
carriage on the mast. If integral sideshift carriage must Remove fork latch pins if adding a fork positioner
be removed from mast first, go to Integral Sideshift attachment (see Figure 2). Damage to forks and
Carriage, Lift Trucks Manufactured Prior To December, other carriage components can occur if fork latch
2016. pins are not removed prior to using attachment.
NOTE: Depending on size and configuration of forks
installed on lift truck, there may be a spacer bar 1. Lower carriage and remove four capscrews from
between inner and outer fork carriers. See Figure 19. inner fork carriers. Slide inner fork carriers down
cylinder shell to remove forks. See Figure 20.
23
1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME
Figure 20. Fork Removal
WARNING WARNING
DO NOT try to remove a fork without a lifting Before disconnecting the hydraulic hoses, relieve
device. Each hook fork for these lift trucks can the pressure in the hydraulic system. Serious
weigh 45 to 115 kg (99 to 254 lb) injury can occur if pressure is not relieved from
hydraulic system prior to disconnecting hydraulic
2. Slide fork to fork removal notch in bottom bar of hoses.
carriage. See Figure 20. Lower fork onto blocks
so bottom hook of fork moves through fork
removal notch. Lower carriage further so top hook
of fork is disengaged from the top carriage bar.
Move carriage away from fork or use a lifting
device to move fork away from carriage.
3. Remove four capscrews and load backrest from

24
WARNING CAUTION
Always wear the proper protective equipment DO NOT bend tube assemblies during removal.
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly NOTE: Note placement of fork positioner cylinders
wash oil from exposed areas of skin as soon as and tag all hydraulic hoses, lines, and fittings prior to
possible. removal to aid in installation.
The hydraulic oil is hot at normal operating 4. Disconnect and cap tube assemblies (8,
temperatures. Be careful when draining the oil. Figure 21) from header hoses.
Never check for leaks by putting hands on
Hydraulic oil under pressure can be injected into
the skin.
CAUTION
system.
25
NOTE: BACK (DRIVER'S) VIEW SHOWN. THREE STAGE FFL INTEGRAL SIDESHIFT CARRIAGE SHOWN.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 6. OUTER FRAME

2. FORK POSITIONER HYDRAULIC HOSE 7. FORK CARRIER
(CLOSE) 8. TUBE ASSEMBLY
3. INTEGRAL SIDESHIFT CARRIAGE HYDRAULIC 9. RELIEF TUBE ASSEMBLY
HOSES 10. HOSE GUIDE
4. MANIFOLD
5. FORK POSITIONER CYLINDER
Figure 21. Hydraulic Connections, Fork Positioner Cylinder
5. Remove lower hooks and bracket weldments. 6. Install lifting eye in hole (see Figure 22) on
See Figure 22 and Figure 24 integral sideshift carriage and use lifting device to
lift outer frame up to disconnect relief tube
assembly and hydraulic hoses (open and close)
from fork positioner. See Figure 22.
26
NOTE: RIGHT INTEGRAL SIDESHIFT CARRIAGE BAR REMOVED FOR CLARITY. THREE STAGE FFL INTE-
GRAL SIDESHIFT CARRIAGE SHOWN. SOME COMPONENTS OMITTED FOR CLARITY.
NOTE: FRONT VIEW SHOWN.
1. CAPSCREW AND LOCK WASHER 5. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY

2. SHIM 6. LOWER HOOK
3. FORK POSITIONER CYLINDER 7. TAPPED HOLE FOR LIFT EYE
4. FORK CARRIER
Figure 22. Fork Positioner Cylinder Removal
NOTE: Make note of shims used to aid in reassembly. Install

7. Remove capscrews, lock washers, and shims 1. Place fork positioner cylinders onto integral
from integral sideshift carriage. See Figure 22. sideshift carriage. Hand tighten capscrew and
Remove fork positioner from outer frame. lockwasher on one side. See Figure 22. Add
shims as follows:
Clean and Inspect
NOTE: Maximum number of shims per side is five.
See the section Cylinder Repair (Mast S/N B551,
The maximum difference in number of shims per side
B555, B559) 2100YRM1440 for cleaning and
is two.
inspection procedures.
a. Measure gap at opposite side and determine
Disassemble and Assemble the number of shims required.
To disassemble and assemble the fork positioner NOTE: The maximum gap allowed before tightening
cylinders, see the section Cylinder Repair (Mast S/N capscrews is 0.50 mm (.020 in.).
B551, B555, B559) 2100YRM1440 for procedures.
b. Install equal amount of shims on both sides of
the fork positioner assembly.
27
2. Finish installing fork positioner assembly to 7. Assemble bracket weldment to lower hook and
integral sideshift carriage by tightening both hand tighten. Assemble lower hook on retainer
capscrews and lockwashers to 65 N•m (50 lbf ft). plate and tighten capscrews to
See Figure 22. 165 N•m (122 lbf ft). See Figure 24.
3. Connect fork positioner hydraulic hoses to fork 8. Position bracket weldment over fork positioner
positioner manifold. Tighten to hydraulic hoses (see Figure 21) and adjust so
21 N•m (186 lbf in). See Figure 21. that bracket weldment makes contract with fork
positioner hoses and tighten capscrew to
4. Thread fork positioner hydraulic hoses through 8 N•m (71 lbf in). See Figure 24.
hose guides.
5. Assemble outer frame with fork positioner to inner

frame. Using a lifting device, position outer frame
at approximately the same height of the inner
frame and approximately 150 mm (6 in.) away.
From the rear of the outer frame, connect fork
positioner hydraulic tubes to header hoses and
hand tighten. See Figure 21.
6. Assemble outer frame onto inner frame. Position

fork positioner hydraulic tubes so they are in line
with inner frame retainer plates. See Figure 23.
1. BRACKET WELDMENT
2. RETAINER PLATE
3. WASHER
4. LOWER HOOK
5. CAPSCREW (LOWER HOOK)
6. CAPSCREW (BRACKET WELDMENT)
Figure 24. Bracket Weldment and Lower Hook

Assembly
9. Tighten fork positioner hydraulic tubes to header

hoses to 42 N•m (31 lbf ft).
Fork Positioner Hydraulic Hose

Adjustment
1. RETAINER PLATE 1. To adjust the fork positioner hydraulic hoses, hold
2. INNER FRAME the large hex nut and rotate the small hex nut
towards the load face of the carriage (towards the
Figure 23. Inner Frame Retainer Plates
forks). See Figure 25.
28
2. The fork positioner hoses are correctly adjusted 3. Move fork positioner and check to ensure fork
when the fork positioner hydraulic hoses stay carriers clear fork positioner relief tubes through
entirely within the integral sideshift carriage and complete fork carrier cycle. See Figure 21.
do not contact the mast channels under all
conditions.
NOTE: BACK (DRIVER'S) VIEW SHOWN. THREE STAGE FFL INTEGRAL SIDESHIFT CARRIAGE SHOWN.
HOSE BRACKET AND GUIDES OMITTED FOR CLARITY.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. LARGE HEX NUT

2. FORK POSITIONER HYDRAULIC HOSE 6. TUBE ASSEMBLY
(CLOSE) 7. RELIEF TUBE ASSEMBLY
3. MANIFOLD 8. INTEGRAL SIDESHIFT HYDRAULIC HOSES
4. SMALL HEX NUT
Figure 25. Fork Positioner Hydraulic Hose Adjustment
4. Install backrest and capscrews on sideshift

carriage. Tighten capscrews to CAUTION
WARNING removed prior to using attachment.
DO NOT try to install a fork without a lifting device.
Each hook fork for these lift trucks can weigh 5. Install forks to outer fork carriers. Secure inner
45 to 115 kg (99 to 254 lb) fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to
29
6. To adjust the fork positioner cylinders, See Remove

2100YRM1440 for procedures. 1. Lower carriage and remove four capscrews from
inner fork carriers. Slide inner fork carriers down
cylinder shell to remove forks. See Figure 27.
FORK POSITIONER, LIFT TRUCKS
MANUFACTURED DECEMBER, 2016 AND
AFTER WARNING
NOTE: This section covers lift trucks equipped with an DO NOT try to remove a fork without a lifting
integral sideshift carriage, manufactured after device. Each hook fork for these lift trucks can
December, 2016 and equipped with a fork positioner. weigh 45 to 115 kg (99 to 254 lb).
NOTE: The fork positioner can be removed from the 2. Slide fork to fork removal notch in bottom bar of
integral sideshift carriage with the integral sideshift carriage. See Figure 27. Lower fork onto blocks
carriage on or off the mast. In the steps below, the fork so bottom hook of fork moves through fork
positioner is removed with the integral sideshift removal notch. Lower carriage further so top hook
carriage on the mast. If integral sideshift carriage must of fork is disengaged from top carriage bar. Move
be removed from mast first, go to Integral Sideshift carriage away from fork or use a lifting device to
Carriage, Lift Trucks Manufactured December, 2016 move fork away from carriage.
Through Late June, 2018.
NOTE: Depending on size and configuration of forks
installed on lift truck, there may be a spacer bar
between inner and outer fork carriers. See Figure 26.
1. OUTER FORK CARRIER

2. CAPSCREW
3. SPACER BAR*
4. INNER FORK CARRIER
*Spacer bar used on 907 mm (35.7 in.),
977 mm (38.5 in.), and 1067 mm (42 in.) class II
carriages.
Figure 26. Fork Carrier Spacer Bar
30
1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME
Figure 27. Fork Removal
3. Remove four capscrews and load backrest from

carriage. See Figure 6. WARNING
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the oil.
WARNING
Before disconnecting the hydraulic hoses, relieve Never check for leaks by putting hands on
the pressure in the hydraulic system. Serious hydraulic lines or components under pressure.
injury can occur if pressure is not relieved from Hydraulic oil under pressure can be injected into
hydraulic system prior to disconnecting hydraulic the skin.
hoses.
CAUTION
WARNING Protect the hydraulic system from dirt and
Always wear the proper protective equipment contaminants when servicing the hydraulic
including eye protection and petroleum-resistant system.
wash oil from exposed areas of skin as soon as
possible. CAUTION
DO NOT bend tube assemblies during removal.
NOTE: Tag all hydraulic hoses, lines, and fittings prior

to removal to aid in installation.
31
4. Disconnect and cap tube assemblies (8, NOTE: Make note of shims used to aid in reassembly.
Figure 28) from header hoses.
8. Remove capscrews, lockwashers, and shims
from integral sideshift carriage. See Figure 29.
5. Remove capscrews and washers and remove
lower hooks from retainer plates on inner frame.
9. Remove fork positioner from outer frame.
See Figure 29.
For procedures to repair the fork positioner
6. Install lifting eye in hole (7, Figure 29) on outer cylinder, see Cylinder Repair (Mast S/N B551,
frame of integral sideshift carriage. Use a lifting B555, B559) 2100YRM1440.
device, with a capacity of 49 kg (108 lb), to lift
outer frame with fork positioner attached.
7. Disconnect relief tube assembly and hydraulic

hoses (open and close) from fork positioner. See
Figure 28.
NOTE: BACK (DRIVER'S) VIEW SHOWN.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 6. FORK CARRIER

2. FORK POSITIONER HYDRAULIC HOSE 7. RELIEF TUBE ASSEMBLY
(CLOSE) 8. TUBE ASSEMBLY
3. INTEGRAL SIDESHIFT CARRIAGE HYDRAULIC 9. HOSE GUIDE
HOSES 10. MANIFOLD
4. FORK POSITIONER CYLINDER
5. OUTER FRAME
Figure 28. Hydraulic Connections, Fork Positioner Cylinder
32
NOTE: FRONT VIEW SHOWN.
1. CAPSCREW AND LOCKWASHER 5. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY

2. SHIMS 6. LOWER HOOK
3. FORK POSITIONER CYLINDER 7. TAPPED HOLE FOR LIFT EYE
4. FORK CARRIER
Figure 29. Fork Positioner Cylinder Removal
Disassemble and Assemble side is two. The maximum gap allowed before
tightening capscrews is 0.50 mm (.020 in.).
See Cylinder Repair (Mast S/N B551, B555, B559)
2100YRM1440 to disassemble and assemble the fork a. Measure gap at opposite side and determine
positioner cylinders. the number of shims required.
Clean and Inspect b. Install shims on both sides of the fork

positioner assembly.
See Cylinder Repair (Mast S/N B551, B555, B559)
2100YRM1440 for cleaning and inspection 2. Install second lockwasher and capscrew. Tighten
procedures. both capscrews to 65 N•m (50 lbf ft). See
Figure 29.
Install
3. Connect fork positioner hydraulic hoses to fork
1. Place fork positioner cylinders onto outer frame.
positioner manifold. Tighten hoses to
Install lockwasher and capscrew on one side and
21 N•m (186 lbf in). See Figure 28.
hand tighten capscrew. See Figure 29. Add shims
as follows: 4. Thread fork positioner hydraulic hoses through
hose guides. See Figure 28.
NOTE: The maximum number of shims per side is
five. The maximum difference in number of shims per
33
5. Install lifting eye and use a lifting device, with a Fork Positioner Hydraulic Hose
capacity of 62 kg (136 lb), to install outer frame, Adjustment
with fork positioner attached, onto inner frame.
1. To adjust the fork positioner hydraulic hoses, hold
6. Using a lifting device, position outer frame at the the large hex nut and rotate the small hex nut
same height of inner frame and 150 mm (6 in.) towards the load face of the carriage (towards the
away. forks). See Figure 31.
7. From rear of outer frame, connect fork positioner 2. Fork positioner hoses are correctly adjusted when
hydraulic tubes to header hoses and hand fork positioner hydraulic hoses stay entirely within
tighten. See Figure 28. the integral sideshift carriage and do not contact
mast channels under all conditions.
8. Position fork positioner hydraulic tubes so they
are in line with retainer plates on inner frame. 3. Move fork positioner and check to ensure fork
carriers clear fork positioner relief tubes through
9. Using a washer and capscrew, install lower hook complete fork carrier cycle. See Figure 31.
to retainer plates and tighten capscrews to
165 N•m (122 lbf ft). See Figure 30. 4. Install load backrest to sideshift carriage. Tighten
capscrews to 195 N•m (144 lbf ft). See Figure 6.
10. Tighten fork positioner hydraulic tubes to header
hoses to 42 N•m (31 lbf ft).
WARNING
DO NOT try to install a fork without a lifting device.
Each hook fork for these lift trucks can weigh
45 to 115 kg (99 to 254 lb)
CAUTION
removed prior to using attachment.
5. Install forks to outer fork carriers. Secure inner

fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to
6. Adjust fork positioner cylinders. See Cylinder

1. RETAINER PLATES
2. OUTER FRAME (FORK BAR)
3. INNER FRAME
Figure 30. Retainer Plates and Inner and Outer

Frame
34
4000 YRM 1441 Mast Repair
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. LARGE HEX NUT

2. FORK POSITIONER HYDRAULIC HOSE 6. TUBE ASSEMBLY
(CLOSE) 7. RELIEF TUBE ASSEMBLY
3. MANIFOLD 8. INTEGRAL SIDESHIFT HYDRAULIC HOSES
4. SMALL HEX NUT
Figure 31. Fork Positioner Hydraulic Hoses Adjustment
Mast Repair
REMOVE NOTE: If mast needs to be disassembled, remove
forks and carriage. See sections Fork Replacement
and Carriages Repair. If only lift, tilt and free-lift
WARNING cylinders need to be removed for repair, the mast does
The mast is heavy. The mast can weigh not need to be removed from lift truck. See section
approximately 907 kg (2000 lb). Make sure all Cylinder Repair (Mast S/N B551, B555, B559)
lifting devices (hoists, cables, chains, slings, etc.) 2100YRM1440.
are suitable and of adequate capacity to lift the
NOTE: The length of lift chains must be checked
mast.
before mast is removed. See section Lift Chains
Adjustment.
CAUTION NOTE: Crane capacity must be at least

Make sure all the mast weldments are fastened 907 kg (2000. lb).
together. Make sure the safety chains will not
damage the sheaves, tubing, or other parts of the
mast.
35
Mast Repair 4000 YRM 1441
1. Fully lower all of the mast weldments. Tilt mast 4. Remove free-lift cylinder for lift trucks equipped
fully forward. Connect a crane to top of mast with a two or three-stage FFL mast. See Cylinder
using chains to support mast in an upright Repair (Mast S/N B551, B555, B559)
position when tilt cylinders are disconnected. See 2100YRM1440 for procedures.
Safety Procedures When Working Near Mast.
NOTE: Allow mast to tilt forward enough to gain
NOTE: Before disconnecting any hydraulic hoses, be access to mast mount capscrews.
sure to tag each hose with a letter: A and B for three
5. Disconnect lower mast mounts from lift truck by
function mast and A, B, C, and D for four function
removing capscrews that hold mast pivot pins to
mast, to aid in reconnecting when installing mast onto
mounts on drive axle. See Figure 32 and
lift truck. See Header Hose Arrangement.
Figure 33.
2. Tag and disconnect hydraulic hoses from mast.
3. Remove tilt and main lift cylinders. See Cylinder

36
1. OUTER MAST 3. GREASE FITTING

2. BUSHING 4. PIVOT PIN
Figure 32. Mast Mounts, Pivot Pin Connections
37
1. DRIVE AXLE Figure 34. Mast Pivot Pin

2. HANGER MOUNTS
b. Check that pins fit snug in outer mast. If pins
Figure 33. Mast Mounts, Drive Axle can be moved up and down a minimum of
4 mm (0.20 in.), replace bushings in outer mast
and/or mast pivot pins as required. See
WARNING Figure 34.
The mast is heavy. The mast can weigh
approximately 907 kg (2000 lb). Make sure all TWO-STAGE LFL AND TWO-STAGE FFL
lifting devices (hoists, cables, chains, slings, etc.) MASTS, DISASSEMBLE
mast.
WARNING
6. Use a crane to lift mast assembly from lift truck. The mast weldments can slide when the mast is
Position mast across wooden beams on the floor moved. A weldment that slides can cause injury.
with carriage side up.
NOTE: Note shim arrangement and load roller
7. Check mast and mounting flanges for wear or location during removal to help aid in assembly
damage: process.
a. Remove mast pivot pins from the outer mast. 1. Slide inner mast from bottom of outer mast
approximately 30 cm (12 in.). Remove strip
bearings and load rollers from top of outer mast.
See Figure 35. Remove load rollers from bottom
of inner mast. See Figure 37 and Figure 38.
38
NOTE: When replacing outer mast, copy part number

and date code information from old channel and stamp
that information on new channel with a letter R at the
end to indicate that it has been replaced.
907 kg (2000 lb).
2. Slide inner mast halfway out of the top of outer
mast. Connect a crane to center of inner mast.
See Figure 36. Slide inner mast out of outer mast
until the mast stub shafts of inner mast are in
notches of outer channels. Remove inner mast
from outer mast.
1. STRIP BEARINGS
2. SHIMS
3. TOP OF OUTER MAST
4. O-RINGS
Figure 35. Strip Bearings
WARNING
approximately 907 kg (2000 lb). Make sure all Figure 36. Inner Mast
lifting devices (hoists, cables, chains, slings, etc.)
mast.
39
Figure 37. Two-Stage, Limited Free-Lift (LFL) Mast
40
1. SNAP RING 14. MAIN LIFT CYLINDERS

2. SHIM(S) 15. SPRING
3. LOAD ROLLER 16. O-RING
4. INNER MAST 17. FITTING
5. CHAIN SHEAVE ASSEMBLY 18. HOSE
6. BEARING 19. LOWERING CONTROL VALVE ASSEMBLY
7. CHAIN SHEAVE 20. CAPSCREW
8. PIN 21. SPACER
9. COTTER PIN 22. BEARING STRIP
10. CHAIN ANCHOR 23. OUTER MAST
11. WASHER 24. STUBSHAFT
12. NUT 25. LOCKNUT
13. LIFT CHAIN
41
Figure 38. Two-Stage, Full Free-Lift (FFL) Mast
42
1. SNAP RING 13. O-RING

2. SHIM(S) 14. FITTING
3. LOAD ROLLER 15. HOSE
4. INNER MAST 16. LOWERING CONTROL VALVE ASSEMBLY
5. FREE-LIFT CYLINDER 17. CAPSCREW
6. CROSSHEAD 18. SPACER
7. FREE-LIFT CHAIN 19. BEARING STRIP
8. WASHER 20. OUTER MAST
9. NUT 21. STUBSHAFT
10. MAST MOUNTS 22. LOCKNUT
11. MAIN LIFT CYLINDERS 23. BRACKET
12. SPRING
3. Using a brass drift, remove tilt rod bushing from

outer mast. Discard tilt rod bushing. See WARNING
Figure 39. The weldments can slide when the mast is moved.
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.
NOTE: Note shim arrangement and load roller

location during removal to aid in assembly process.
3. Remove strip bearings at top of intermediate
mast. Remove load rollers at bottom of inner mast
and top of intermediate mast. See Figure 40.
WARNING
approximately 907 kg (2000 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.)
mast.

907 kg (2000 lb).
1. TILT ROD BUSHING
4. Slide inner mast halfway out of top of
Figure 39. Tilt Rod Bushing Location intermediate mast. Connect a crane to center of
inner mast. See Figure 36. Slide inner mast out of
4. Remove lowering control valve from outer mast. intermediate mast until stub shafts are in notches
See Figure 37 and Figure 38. of intermediate mast. Remove inner mast from
intermediate mast.
5. Remove and disassemble chain sheaves as
necessary for cleaning and repair. NOTE: Note shim arrangement and load roller
location during removal to aid in assembly process.
THREE-STAGE FFL MAST, DISASSEMBLE
5. Slide intermediate mast from bottom of outer
1. Remove pins for lift chains at chain anchors on mast approximately 30 cm (12 in.). Remove strip
inner mast. bearings at top of outer mast. Remove snap rings
and load rollers from both weldments. See
2. Disconnect and remove lift chains between outer Figure 40.
mast and inner mast. Slide inner mast from
bottom of intermediate mast approximately
30 cm (12 in.).
43
Figure 40. Three-Stage, Full Free-Lift (FFL) Mast
44
1. OUTER MAST 18. FITTING

2. LOAD ROLLER 19. HOSE
3. SHIM 20. LOWERING CONTROL VALVE
4. SNAP RING 21. CAPSCREW
5. STUBSHAFT 22. CLAMP
6. O-RING 23. TUBE
7. SHIM 24. SPACER
8. BEARING STRIP 25. LOCK NUT
9. CHAIN 26. INTERMEDIATE MAST
10. COTTER PIN 27. BEARING
11. PIN 28. CHAIN SHEAVE ASSEMBLY
12. CHAIN ANCHOR 29. CHAIN SHEAVE
13. WASHER 30. INNER MAST
14. NUT 31. CHAIN GUARD
15. FREE-LIFT CYLINDER 32. CROSSHEAD
16. MAIN LIFT CYLINDER 33. BRACKET
17. SPRING 34. VALVE ASSEMBLY (FLOW LIMITING)
1. Inspect chain sheaves and load rollers for wear or

WARNING damage.
approximately 907 kg (2000 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.) WARNING
are suitable and of adequate capacity to lift the Cleaning solvents may be flammable and toxic and
mast. can cause severe skin irritation. When using
cleaning solvents, always follow the solvent
NOTE: Crane capacity must be at least manufacturer's recommended safety precautions.
907 kg (2000 lb).
Compressed air can move particles so that they
6. Slide intermediate mast halfway out of top of cause injury to the user or to other personnel.
outer mast. Connect a crane to center of Make sure that the path of the compressed air is
intermediate mast. See Figure 36. Slide away from all personnel. Wear protective goggles
intermediate mast out of outer mast until stub or a face shield to prevent injury to the eyes.
shafts are in notches of outer mast. Remove
intermediate mast from outer mast. 2. Clean the lift chains by soaking in solvent for 30
minutes to remove all dirt and grease. Hang lift
7. Using a brass drift, remove tilt rod bushing from chains up and remove solvent using compressed
outer mast. Discard tilt rod bushing. See air. The lift chains must be installed in the mast
Figure 39. and the mast must be installed on the lift truck
before they can be checked for correct length.
8. Remove lowering control valve from outer mast. Lubricate chains by soaking them in SAE 30W
See Figure 40. engine oil for 30 minutes. Hang chains over a drip
pan for one hour to remove excess oil.
9. Disassemble chain sheaves as necessary for
repair and cleaning. Remove the hydraulic lines
and fittings from weldments as necessary. WARNING
Never replace only the worn section of a chain.
CLEAN AND INSPECT Replace the complete chain. Never replace only
one chain of a chain pair. Replace both chains.
CAUTION
NOTE: The chains must be inspected in the area of
DO NOT use steam to clean lift chains, sheaves, or
chain that passes over the chain sheave during the
load rollers. The bearings in the sheaves and load
first portion of a lift. Those links will show maximum
rollers are sealed and lubricated.
wear.
45
3. Inspect the lift chains for wear or damage. A lift

chain becomes longer when it is worn. If a chain WARNING
is 3% longer than a new lift chain, the lift chain Be careful when cleaning with steam. Steam can
must be replaced. cause serious burns. Wear protective clothing,
gloves, and eye protection. Never expose your
4. If a chain scale is available, check the lift chain as skin to steam.
shown in Figure 41. If a chain scale is not
available, measure 20 links of the lift chain. Cleaning solvents may be flammable and toxic and
Compare the measurement with the lengths given can cause severe skin irritation. When using
in Figure 41. cleaning solvents, always follow the solvent
manufacturer's recommended safety precautions.
6. Clean the mast weldments with steam or solvent.
WARNING
7. Inspect sliding surfaces for wear or damage.

Inspect load roller contact surfaces for wear or
damage. Inspect all welds for cracks.
TWO-STAGE LFL AND TWO-STAGE FFL

MAST, ASSEMBLE
WARNING
NOTE: THE INSTRUCTIONS FOR MEASURING approximately 907 kg (2000 lb). Make sure all
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR lifting devices (hoists, cables, chains, slings, etc.)
SCALE (YALE PART NO. 580037684). are suitable and of adequate capacity to lift the
mast.
1. CHAIN WEAR SCALE
NOTE: The shims for the load rollers keep mast
Figure 41. Lift Chains Check
weldments parallel and provide correct clearance.
During assembly, shim arrangement will be
Pitch Wear Limit The approximately the same as before disassembly. Check
Total length of
maximum clearance and adjust shims for wear or for changes
20 links (pitch)
length of 20 caused by repairs. The strip bearings are also
of new chain
links adjusted by using shims. See section Carriage
12.7 mm 254.0 mm 261.6 mm Adjustments for adjustment procedures.
(0.5 in.)15.9 mm (10.0 in.)317.5 (10.3 in.)327.0 NOTE: Crane capacity must be at least
(0.6 in.)19.1 mm mm mm 907 kg (2000 lb).
(0.8 in.)25.4 mm (12.5 in.)381.0 (12.9 in.)392.4
(1.0 in.) mm mm 1. Connect a crane to center of the inner mast. See
(15.0 in.)508.0 (15.5 in.)523.3 Figure 42. Fit stub shafts through notches in outer
mm (20.0 in.) mm (20.6 in.) mast. Slide inner mast into outer mast so stub
shafts are seen at top and bottom of weldments.
5. Inspect chain anchors, pins, and cotter pins for See Figure 37 and Figure 38.
damage. Replace if damaged.
46
Figure 42. Inner Mast
2. Install strip bearings and shims on the outer mast.

See Figure 43. Apply chassis lube to bearing 1. TILT ROD BUSHING
surface. Check clearance of strip bearings as Figure 44. Tilt Rod Bushing Location
described in section Carriage Adjustments.
6. On two-stage LFL mast, install chain sheaves at
inner mast. Be sure to install snap rings that hold
chain sheave to shaft for correct position.
7. Connect lift chains to chain anchors at main lift

cylinder mounts. Attach wires between ends of lift
chains and crossmember to control lift chains
during mast installation.
THREE-STAGE FFL MAST, ASSEMBLE

NOTE: The shims for the load rollers keep mast
weldments parallel and provide correct clearance.
approximately the same as before disassembly. Check
clearance and adjust shims for wear or for changes
Figure 43. Strip Bearings caused by repairs. The strip bearings are also
adjusted by using shims. See section Carriage
3. Install load rollers and shims on both weldments. Adjustments for adjustment procedures.
Check clearance of load rollers as described in NOTE: Crane capacity must be at least
section Carriage Adjustments. 907 kg (2000 lb).
4. Install housing for lowering control valve on outer 1. Put outer mast on the floor with carriage side up.
mast. Tighten nuts for lowering control valve to See Figure 40. Connect a crane to center of
18 N•m (13 lbf in). Install lowering control valve in intermediate mast. See Figure 42. Fit lower stub
housing. Connect hydraulic lines and fittings shafts of intermediate mast into notches in the top
between housing and main lift cylinders. of outer mast. Slide intermediate mast into outer
mast so stub shafts are seen at top and bottom of
5. Install new tilt rod bushing into outer mast. See both weldments.
Figure 44.
NOTE: The load rollers must be in place before strip
bearing can be shimmed.
47
2. Install strip bearings and shims on channels of NOTE: The load rollers must be in place before
outer mast. See Figure 43. Apply chassis lube to bearing strips can be shimmed.
bearing surfaces. Check clearance of strip
8. Install strip bearings and shims on the channels
bearings as described in section Carriage
of the intermediate mast. Apply grease to bearing
Adjustments.
surfaces. Install load rollers and shims on
intermediate and inner masts. Before doing the
3. Install load rollers and shims on outer mast and at
next step, adjust inner mast as described in
bottom of intermediate mast.
section Carriage Adjustments.
4. Install housing for lowering control valve on outer
9. Connect main lift chains to chain anchors at main
mast. Tighten nuts for the lowering control valve
lift cylinder mounts. Put lift chains over chain
to 18 N•m (13 lbf in). Install lowering control valve
sheaves and connect them to anchors at bottom
in housing. Connect hydraulic lines and fittings
of inner mast.
between housing and main lift cylinders.
10. Connect free-lift chains to chain anchors at
5. Install new tilt rod bushing into outer mast. See
crossmember. Attach a wire between the end of
Figure 44.
lift chain and bottom of mast to control lift chain
6. Install chain sheaves at intermediate mast. Be during mast installation.
sure to install snap rings that hold chain sheave
to shaft for the correct position. MAST, INSTALL
1. Lubricate lower mast mounting surface to prepare
NOTE: Crane capacity must be at least for installation.
907 kg (2000 lb).
7. Connect a crane to center of inner mast. Slide 2. Apply an even coat of grease to pivot pins and
inner mast into intermediate mast so stub shafts install them into mounts at bottom of outer mast.
are seen at top and bottom of both. See Figure 45.
NOTE: Use multipurpose grease #2 with 2 to 4%

Molybdenum Disulfide for normal operations.
48
1. OUTER MAST 3. GREASE FITTING

2. BUSHING 4. PIVOT PIN
Figure 45. Mast Mounts, Pivot Pin Connections
NOTE: Crane capacity must be at least 4. Using a crane, position mast so pivot pins seat
907 kg (2000 lb). into hanger mounts on drive axle. Install
capscrews that hold mast pivot pins to drive axle
3. Connect crane to top of mast using chains. Make
hangers. Tighten capscrews to
sure all mast uprights are fastened together.
270 N•m (199 lbf ft). Refer to Figure 45 and
Make sure chains will not damage sheaves,
Figure 46.
tubing, or other parts of mast.
49
load backrest and any attachment if lift truck is

equipped with one.
8. If lift truck is equipped with a three-stage FFL
mast, adjust chain anchors on main lift cylinders
until tops of inner and outer mast are at the same
level within ±1.5 mm (0.06 in.). See Figure 40.
9. Raise mast without a load to its full height and

check for side kicking. Mast side kicking is when
the mast moves either to the right or left as it is
being raised. If the mast is side kicking, see Mast
Adjustments section for procedures to correct it.
NOTE: The load rollers and sheaves have sealed

bearings and do not need additional lubrication.
10. Lubricate sliding surfaces and load roller surfaces
1. DRIVE AXLE along full length of channels as shown in
2. HANGER MOUNTS
Figure 47. Apply lubricant only to surfaces
Figure 46. Mast Mounts, Drive Axle indicated.
5. Install tilt cylinders and main lift cylinders. If lift

truck is equipped with two or three-stage FFL
mast, install free-lift cylinder. See Cylinder
6. Install carriage as described in section .
WARNING
Never check for leaks by putting hands on
the skin.
7. Check tilt cylinder adjustment as described in

2100YRM1440. Operate mast and check for
leaks and correct operation. Check lift chains as A. LOWER LOAD ROLLERS
described in section . B. UPPER LOAD ROLLERS
NOTE: Before checking for mast side kicking and 1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
adjusting chain anchors on main lift cylinders for lift 3. LOAD ROLLER
trucks equipped with a three-stage FFL mast, the mast
must be fully assembled to include the carriage, forks, Figure 47. Lubricate Mast
50
4000 YRM 1441 Header Hose Arrangement
Header Hose Arrangement

roll clamps. These auxiliary functions require header
WARNING hoses for their operation.
Always wear the proper protective equipment
including eye protection and petroleum-resistant
TWO-STAGE LFL
wash oil from exposed areas of skin as soon as WARNING
possible. Before working on or near the mast, see Safety
Never check for leaks by putting hands on Procedures When Working Near Mast in this
hydraulic lines or components under pressure. section.
the skin. NOTE: This procedure is for the four-function option.
The three-function option will have hoses A and B
Before installing header hoses, make sure you know only.
the lift height of the mast. The tension on the header NOTE: The lift chains and carriage height must be
hoses is adjusted according to lift height. Lift height is correctly adjusted before the header hoses can be
on the Nameplate of the lift truck and on the right-hand adjusted. See section Lift Chains Adjustment for
side of outer mast. procedures.
Some lift trucks are equipped with auxiliary hydraulic 1. Mark each hose with a single letter: A, B, C, and
functions that are fastened to the carriage. Examples D. See Figure 48.
of these auxiliary functions are sideshift carriages or
51
Header Hose Arrangement 4000 YRM 1441
Figure 48. Header Hose Alignment for Two-Stage Limited Free-Lift Mast
52

NOTE: SOME COMPONENTS OMITTED FOR CLARITY.
A. HOSE A C. HOSE C
B. HOSE B D. HOSE D
2. Dimension E is determined by the height of the

outer mast channel from the ground and the
length of the outer mast channel. See dimensions
Y and Z in Figure 49. To determine E, see Table 2
and Table 3.
Table 2. Standard Two-Stage LFL Hose Dimensions, Lift Truck Models ERC030-040VA
Channel Length
Lift Height Dimension "E"
(Reference)
mm in. mm mm in.
3192 125.7 2040 2258 89.0
Table 3. Standard Two-Stage LFL Hose Dimensions, Lift Truck Models ERC16-20VA
Channel Length
Lift Height Dimension "E"
(Reference)
mm in. mm mm in.
3392 133.5 2140 2357 92.7
3792 149.3 2340 2554 100.5
4292 169.0 2590 2899 114.1
3. Clamp end of hose (smaller fitting), that attaches 5. Attach hoses to carriage brackets with clamps.
to carriage in a vise (DO NOT clamp on threads), See Figure 50.
and pull on other end until hose is straight. DO
NOT apply enough force to stretch the hose. See 6. Place hoses at the location of the hose sheave.
Figure 49. The sheave(s) and stub shafts must be
assembled, and hose(s) must be routed onto
NOTE: This mark will be used to pretension the sheave(s) before hose(s) are attached to mast.
header hoses during installation. Refer to Figure 50. Tighten hose clamp hardware
(12) to 8 N•m (71 lbf in) and sheave assembly
4. Place a mark on all hoses at dimension E (all
capscrews (13) to 66 N•m (49 lbf ft).
measurements are made from carriage end of
hose [the smaller fitting]).
53
1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE
Figure 49. Header Hose Measurement for Two-Stage Limited Free-Lift Mast
54
Figure 50. Header Hoses for Two-Stage Limited Free-Lift Mast
55
A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. HOSE 10. NUT

2. CAPSCREW 11. BRACKET
3. CLAMP 12. CAPSCREW
4. NUT 13. CAPSCREW
5. BRACKET 14. LOCKWASHER
6. CLAMP 15. STUB SHAFT
7. CLAMP 16. SHEAVE
8. CLAMP 17. SPACER
9. CAPSCREW 18. WASHER
7. Put clamps (8) over hoses and attach clamps to 907.2 kg (2000 lb) to raise carriage high enough to
upper brackets. DO NOT tighten hardware. install a safety chain. See Figure 51.
8. Align mark E at bottom of clamps. Tighten
NOTE: To make the alignment of dimension E easier,
hardware to 8 N•m (71 lbf in). Refer to Figure 50.
use a crane with a capacity of at least
1. HOOK 2. SHACKLE
Figure 51. Chaining the Carriage (LFL)
9. Connect header hoses to cowl hoses. 11. With no load on forks, check header hose
adjustment by operating mast through full lift
10. Use rubber clamps and hose clamps to attach cycle two times. When properly adjusted, hoses
hoses to main lift cylinders. DO NOT allow hoses will not be so tight that they compress when they
to stretch or fold while tilting mast fully forward pass over the sheaves nor will they be so loose
and backward. that they touch the load backrest or any
56
crossmember that is next to a sheave. If NOTE: The lift chains and carriage height must be
necessary, repeat until hoses are properly correctly adjusted before header hoses can be
adjusted. See Table 2 and Table 3. adjusted. See section Lift Chains Adjustment for
procedures.
TWO-STAGE FFL 1. Mark each hose with a single letter: A, B, C, and
D. See Figure 55.
WARNING
2. Dimensions E and G are determined by the
Before working on or near the mast, see Safety
height of outer mast channel from the ground and
Procedures When Working Near Mast in this
the length of outer mast channel. See dimensions
section.
Y and Z in Figure 52. See Table 4, Table 5,
NOTE: This procedure is for the four-function option. Table 6, and Table 7 for dimensions E and G.
only.
57
Figure 52. Header Hose Measurement for Two-Stage Full Free-Lift Mast,
58
1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE
Table 4. Standard Two-Stage FFL Hose Dimensions, Three Function Mast, Lift Truck Models
ERC030-040VA
Channel Length
Lift Height Dimension "E" Dimension "G"
(Reference)
mm in. mm mm in. mm in.
3178 125.1 1990 1255 49.4 3142 123.7
3478 136.9 2140 1329 52.3 3441 135.5
Table 5. Standard Two-Stage FFL Hose Dimensions, Four Function Mast, Lift Truck Models ERC030-040VA
Channel Length
(Reference)
3178 125.1 1990 1255 49.4 3024 119.1
3478 136.9 2140 1329 52.3 3323 131.0
Table 6. Standard Two-Stage FFL Hose Dimensions, Three Function Mast, Lift Truck Models ERC16-20VA
Channel Length
(Reference)
3378 133.0 2090 1305 51.4 3341 131.5
Table 7. Standard Two-Stage FFL Hose Dimensions, Four Function Mast, Lift Truck Models ERC16-20VA
Channel Length
(Reference)
3378 133.0 2090 1305 51.4 3223 127.0
3. Clamp end of hose (smaller fitting) that attaches 5. Attach hoses to carriage bracket with clamps.
to carriage in a vise (DO NOT clamp on threads),
and pull on other end until hose is straight. DO 6. Route header hose A and C over bottom right-
NOT apply enough force to stretch hose. See and left-hand free-lift hose sheaves. Then route
Figure 52. header hose B and D over top right- and left-hand
free-lift hose sheaves. See Figure 54 and
NOTE: These marks will be used to pretension the Figure 55.
header hoses during installation.
7. Put clamps over header hoses and attach clamps
4. Place a mark on all hoses at dimension E and G
to free-lift bracket. DO NOT tighten hardware.
(all measurements are made from the carriage
end of hose [the smaller fitting]).
59
NOTE: To make the alignment of dimension E easier, 8. Align mark E at bottom of clamp. Tighten
use a crane with a capacity at least 907.2 kg (2000 lb) hardware to 8 N•m (71 lbf in).
to raise carriage high enough to install a safety chain.
See Figure 53.
1. HOOK 2. SHACKLE
Figure 53. Chaining the Carriage (LFL)
9. Apply a spray lubricant on the hoses in the area 10. Connect header hoses C and D to cowl hoses.
that will contact channels. Make sure hoses are Connect header hoses A and B to tubes. See
properly aligned in channels. Put clamps over Figure 54 and Figure 55.
hoses and attach clamps to channels. Tighten
hardware to 8 N•m (71 lbf in).
60
Figure 54. Header Hoses for Two-Stage Full Free-Lift Mast
61

NOTE: FOUR-FUNCTION MAST SHOWN.
A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. ALIGN MARK G AT TOP OF THIS CLAMP.
1. CLAMP 9. STUBSHAFT
2. TUBE 10. NUT
3. RUBBER CLAMP 11. STRAP CLAMP
4. CAPSCREW 12. CHANNEL
5. BRACKET 13. HOSE
6. LOCKWASHER 14. CAP
7. WASHER 15. HOSE SHEAVE
8. SPACER
11. Use rubber clamps and strap clamps to attach 13. With no load on forks, check header hose
hoses to main lift cylinders. DO NOT allow cowl adjustment by operating mast through full lift
hoses to stretch or fold while tilting mast fully cycle two times. When properly adjusted, hoses
forward and backward. will not be so tight that they compress when they
pass over sheaves nor will they be so loose that
12. With no load on forks, operate mast through full they touch load backrest or any crossmember
lift cycle two times. With mast at full lift height, that is next to a sheave. See Figure 55.
attach clamp at bottom of hose loop on third
and/or fourth function hoses. This action allows
hoses to fit properly in hose channel.
62
NOTE: SOME COMPONENTS OMITTED FOR CLARITY.
A. HOSE A C. HOSE C
B. HOSE B D. HOSE D
Figure 55. Header Hose Alignment for Two-Stage Full Free-Lift Mast,
63
THREE-STAGE FFL NOTE: The lift chains and carriage height must be
correctly adjusted before header hoses can be
adjusted. See section Lift Chains Adjustment for
WARNING procedures.
Before working on or near the mast, see Safety
1. Mark each hose with a single letter: A, B, C, or D.
See Figure 56.
section.
NOTE: This procedure is for the four-function option.

only.
64
Figure 56. Header Hose Alignment for Three-Stage Full Free-Lift Mast (Sheet 1 of 3)
65
66
A. HOSE A F. ALIGN G ON HOSES B AND C AT BOTTOM OF

B. HOSE B THIS CLAMP. ALIGN G ON HOSES A AND D AT
C. HOSE C BOTTOM OF THIS CLAMP.
D. HOSE D G. MAIN LIFT CYLINDER (LH)
E. FRONT VIEW H. MAIN LIFT CYLINDER (RH)
I. FREE-LIFT CYLINDER
1. HOSE GUIDE 4. NUT

2. CAPSCREW 5. HOSE CLAMP
3. WASHER
2. Dimensions E and G are determined by the

height of outer mast channel from the ground and
the length of outer mast channel. See dimension
Y and Z in Figure 57. See Table 8 and Table 9 for
dimensions E and G.
67
1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE
Figure 57. Header Hose Measurement for Three-Stage Full Free-Lift Mast
68
Table 8. Standard Three-Stage FFL Hose Dimensions, Three and Four Function Mast, Lift Truck Models
ERC030-040VA
Channel Length
(Reference)
4560 179.5 1940 1292 51.0 3699 145.6
4710 185.4 1990 1316 52.0 3797 149.5

4860 191.3 2040 1341 52.7 3895 153.3
5010 197.2 2140 1390 54.7 4091 161.1
5460 215.0 2290 1463 57.5 4385 172.6
Table 9. Standard Three-Stage FFL Hose Dimensions, Three and Four Function Mast, Lift Truck Models
ERC16-20VA
Channel Length
(Reference)
4860 191.3 2040 1341 52.7 3895 153.3
5160 203.1 2190 1414 55.7 4189 165.0
5460 215.0 2290 1463 57.5 4385 172.6
3. Clamp the end of the hose (smaller fitting) that 907.2 kg (2000 lb) to raise the carriage high enough to
attaches to the carriage in a vise (DO NOT clamp attach a safety chain. See Figure 53.
on threads), and pull on the other end until hose
7. Align the mark for dimension E at the bottom of
is straight. DO NOT apply enough force to stretch
the clamp to create proper hose tension. Tighten
hose.
hardware to 8 N•m (71 lbf in). Install hose guards.
Tighten capscrews that mount guards to
NOTE: These marks will be used to pretension the
18 N•m (13 lbf ft).
header hose during installation.
4. Place a mark on all hoses at dimensions E and G 8. Position hoses at hose sheave. The hose sheave
(all measurements are made from carriage end of and stub shaft must be installed on the hose
the hose [smaller fitting]). See Figure 57, Table 8, before they are attached to the mast. Tighten
and Table 9. hardware to 66 N•m (49 lbf ft).
5. Attach hoses to carriage bracket with clamps. 9. Put clamps over hoses and attach clamps to the
Apply spray lubricant to the surface of hose guide upper brackets. DO NOT tighten the hardware.
that contacts the hoses.
NOTE: To make the alignment of dimension G easier,
6. Route header hose B and C over left- and right- use a crane to raise the inner channel high enough to
hand free-lift hose sheaves. Then route headers install a safety chain.
A and D over top left- and right-hand free-lift hose
10. Align mark G on hoses A and D at bottom edge of
sheaves. See Figure 56.
clamp to create proper tension. Align mark G on
hoses B and C at top edge of clamp to create
NOTE: To make the alignment of dimension E easier,
proper tension. Tighten hardware to
use a crane with a capacity of at least
8 N•m (71 lbf in). See Figure 56, .
69
11. Install clamps. See Figure 58.
70
Figure 58. Header Hoses for Three-Stage Full Free-Lift (FFL) Mast,
71
Lift Chains Adjustment 4000 YRM 1441
1. LOCK NUT 8. LOCKWASHER

2. HOSE SHEAVE 9. CLAMP
3. SPACER 10. HOSE
4. WASHER 11. NUT
5. CAPSCREW 12. HOSE GUIDE
6. STUBSHAFT 13. CAP
7. BRACKETS 14. FREE-LIFT CYLINDER BRACKET
12. Connect header hoses to cowl hoses. 5. Cycle mast a few times to ensure proper tracking
of hoses.
13. Use rubber clamps and strap clamps to attach
hoses to main lift cylinders. Make sure hoses do 6. Secure hose assemblies to main lift cylinders with
not stretch or fold while tilting mast fully forward hose clamp and screw clamp.
and backward.
NOTE: If hose tension between carriage and clamp at
the free-lift bracket is correct, go to Step 7.
14. With no load on forks, check header hose
adjustment by operating mast through the full lift If hose tension between carriage and clamp at
cycle two times. When properly adjusted, hoses free-lift bracket is incorrect, loosen clamps and
will not be so tight that they compress when they pull (if hoses are loose) or push (if hoses are
pass over sheaves nor will they be so loose that tight) on the hoses so they move
they touch load backrest or any crossmember 15.0 mm (0.6 in.) side to side. Tighten hardware
that is next to a sheave. If necessary, repeat until to 8 N•m (71 lbf in).
hoses are properly adjusted.
NOTE: If hose tension between clamp at upper
ADJUSTMENT bracket and clamp at free-lift bracket is correct, go to
Step 8.
When properly adjusted, hoses will not be so tight that
they compress when they pass over sheaves, nor will 7. If tension of hoses is incorrect, loosen clamps and
they be so loose that they touch load backrest or any pull hoses down (if too loose) or push hoses up (if
crossmember that is next to a sheave. too tight) so they can move 15.0 mm (0.6 in.) side
to side. Re-tighten hardware to 8 N•m (71 lbf in).
1. Cap off hoses when attachments have been
removed. 8. With no load on the forks, check header hose
adjustment by operating mast through full lift
2. Check that hoses and cables are routed properly. cycle two times. When properly adjusted, hoses
will not be so tight that they compress when they
3. Slowly raise free-lift and main cylinders to take up pass over sheaves nor will they be so loose that
slack in lift chains. they touch load backrest or any crossmember
that is next to a sheave. If necessary, repeat until
4. Tighten strap clamps at bracket weldment. hoses are properly adjusted.
Lift Chains Adjustment

Never allow anyone under a raised carriage. DO
WARNING NOT put any part of your body in or through the lift
mechanism unless all parts of the mast are
When working on or near the mast, see Safety
completely lowered and the engine is STOPPED.
section. Never check for leaks by putting hands on
During test procedures for the hydraulic system,
fasten the load to the carriage with chains to
the skin.
prevent it from falling. Keep all personnel away
from the lift truck during the tests. When lift chains are correctly adjusted:
72
4000 YRM 1441 Lift Chains Adjustment
• The tension will be the same on each chain of

the chain set. Check tension by pushing on both
chains at the same time.
• The chain length will be correct.
• The chains must travel freely through the
complete cycle.
NOTE: When the lift chain adjustments are complete,

make sure the threads on the nuts of the chain
anchors are completely engaged. Inspect the torque of
the prevailing torque nut (locknut) used to adjust the
chain anchor with every lift chain adjustment. After
carriage and or mast section(s) are adjusted for proper
ground clearance, prevent the carriage and or mast
section(s) from fully lowering (see Safety Procedures
When Working Near Mast). With slack chain(s), check
locknut torque. If 2.5 N•m (22.1 lbf in) for 1/2-20,
4.5 N•m (39.8 lbf in) for 5/8-18 nuts, 1. MAST
6.0 N•m (53.1 lbf in) for 3/4-16 of torque cannot be 2. CARRIAGE
reached; replace locknut. The chain anchors, after 3. FORK
4. HEEL OF FORK IS
adjustment, must be able to move on their mountings. 12.0 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) ABOVE
NOTE: When chain adjustments are complete, make FLOOR LEVEL
sure threads on nuts of chain anchors are completely
Figure 59. Lift Chain Adjustment, Hook or Pin-Type
engaged. Make sure chain anchors are not adjusted
Forks
too tight. The chain anchors must be able to move on
their mounting.
1. When adjusting lift chains on forklift trucks
equipped with either pin or hook-type forks
installed, go to Step 2. If forklift truck is normally
equipped with a hook-type carriage and has an
attachment without forks, go to Step 3.
NOTE: Prior to performing adjustment procedures,

make sure forklift truck is parked on a level surface
and mast is in the vertical position.
2. Adjust chain anchors that support the carriage,
until bottom of fork heel is
12.0 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above
floor level. See Figure 59.
3. Adjust chain anchors that support the carriage,

until bottom of lower carriage bar is above floor
level as shown in Table 10. Adjust chain anchors
1. MAST
that support the carriage, until bottom of the lower 2. CARRIAGE
carriage bar is 3. DISTANCE FROM FLOOR TO LOWER
88.5 +3.0/−6.0 mm (3.50 +0.12/−0.24 in.) above CARRIAGE BAR
floor level. See Figure 60.
Figure 60. Lift Chain Adjustment, Hook-Type
Table 10. Hook-Type Carriage Chain Adjustment Carriage
Class II 88.5 +3.0/−6.0 mm (3.50

+0.12/−0.24 in.)
73
Carriage Adjustments 4000 YRM 1441
Carriage Adjustments
1. Install load rollers on carriage. Install shims for 5. Check lateral movement of carriage (see
load rollers onto stubshaft in the same sequence Figure 61):
as when disassembled. On carriages equipped
with six load rollers, there are no shims under top a. Fully lower carriage to ground.
load rollers.
b. Place hand or small pry bar between top of
2. Use a lifting device to raise carriage. Find the carriage side plate and inner channel flange.
point of tightest fit between carriage load rollers
and inner mast channels. c. Move carriage back and forth and check
movement.
3. Remove carriage from mast. Adjust shim
arrangement for each roller for clearance d. Carriage lateral movement must not be greater
between roller and inner channel. Repeat Step 1 than 2.5 mm (0.10 in.).
and Step 2 until there is zero clearance at the
point of tightest fit. e. If carriage lateral movement is greater than
2.5 mm (0.10 in.), add or remove shims and
4. Keep shim arrangement on each side of carriage repeat Step a through Step d until correct
approximately equal. The carriage must be movement is achieved.
centered within inner mast to within
+1.50 mm (0.06 in.).
74
4000 YRM 1441 Carriage Adjustments
A. TOP VIEW C. CARRIAGE FRONT VIEW

B. MAST FRONT VIEW
1. CHANNEL 8. EQUAL SPACE ±1.5 mm (0.060 in.)

2. LOAD ROLLER 9. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
3. STUB SHAFT 10. PUT SPACER ON OUTSIDE OF TOP LOAD
4. SNAP RING ROLLER, UNDER SNAP RING
5. SHIMS 11. SHIM FOR ZERO CLEARANCE AT POINT OF
6. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.) TIGHTEST FIT
7. ZERO CLEARANCE AT POINT OF TIGHTEST 12. CARRIAGE LATERAL MOVEMENT
FIT 2.5 mm (0.10 in.)
13. CHECK CARRIAGE LATERAL MOVEMENT HERE
Figure 61. Carriage Adjustment
6. After adjustment, lubricate channels with a thin

CAUTION layer of grease. Adjust hydraulic hoses and make
Too much grease will cause the rollers to slide and sure connections are correct, if carriage is
wear flat areas on the rollers and introduce equipped with hydraulic attachments.
contamination into and on mast channels.
75
Mast Adjustments 4000 YRM 1441
Mast Adjustments
LOAD ROLLER ADJUSTMENT 2. Perform the following steps to adjust the mast
load rollers:
NOTE: Shims are installed on both sides of load
rollers. DO NOT add or remove shims from stub a. Use a crowbar to move mast uprights from
shafts. To change position of the roller on the stub side to side to measure movement. Measure
shaft, move shims from one side of load roller to the movement in a minimum of three different
other. positions of each mast upright.
approximately the same as before disassembly. Check b. Separate mast uprights and change shim
clearance and adjust shims after repairs have been arrangements as required. Assemble uprights.
completed. Slide upright all the way to the top and bottom
to find the tightest fit.
1. The load rollers control alignment of mast
uprights. See Figure 61. The alignment conditions c. Repeat Step a and Step b until there is zero
are given on a list below with the most important clearance at the point of the tightest fit.
condition first.
d. Measure distance between channels of mast
a. The mast uprights must be parallel to each uprights on top and bottom. Change shims to
other. keep distance equal between top and bottom
so mast uprights are parallel. Also make sure
b. Use shims to adjust load rollers so there is the mast uprights are parallel within
zero clearance between load roller and 1.5 mm (0.060 in.).
channel at point of tightest fit.
3. Adjust strip bearings. See Figure 62. Insert shims
c. The number of shims under a load roller must under strip bearing. Adjust clearance until there is
be approximately the same as the stub shaft in less than 0.8 mm (0.030 in.) at the tightest fit. See
the opposite side of the upright. This ensures Figure 61.
the uprights will be approximately in the center.
1. STRIP BEARING 4. SHIMS

2. LOAD ROLLER 5. O-RING
3. MAST UPRIGHT
Figure 62. Strip Bearings Arrangement
76
4000 YRM 1441 Mast Adjustments
MAST SIDE KICKING ADJUSTMENT

To adjust the mast for side kicking, do the following:
1. Place lift truck on a level surface and apply

parking brake.
2. Raise mast and visually inspect it as it reaches its

full height.
3. If mast is moving to the left, shims will need to

either be added or removed from the top of right
main lift cylinder. If mast moves to the right, shims
will need to either be added or removed from the
top of left main lift cylinder. See Figure 38 and
Figure 40 for shim location on main lift cylinders.
4. If shims are to be added, use the smallest shim

size available on the cylinder being adjusted. See
Parts Manual for shim sizes and part numbers.
5. Raise the mast again and visually inspect it to

ensure that it is no longer side kicking. If side
kicking is still present, repeat Step 3 and Step 4.
77
4000 YRM 1441 6/19 (10/17)(11/16)(9/14)(2/14)(8/13)

Mast Repair (S/N B551, B555, AND B559) : Maintenance

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Maintenance

MAST REPAIR (S/N

PART NO. 550025859 4000 YRM 1441

©2019 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

ERC16-20VA (ERC030-040VA) [A969]

Safety Procedures When Working Near Mast

WARNING 1. Put mast in vertical position.

Figure 1. Safety Chaining the Mast

Legend for Figure 1.

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

1. OUTER MAST 5. FREE-LIFT CYLINDER

1. LOAD BACKREST 6. SPRING

Figure 2. Carriage and Forks

Never repair damaged forks by heating or welding.

1. Inspect forks for cracks and wear. Check that fork

2. Replace any damaged or broken parts that are

Table 1. Fork Tip Alignment (Continued)

Figure 4. Fork Wear Check

4. Check alignment of fork tips. Differences in height

WARNING Figure 7. Standard Carriage

NOTE: Crane capacity must be at least

2. If carriage bars have any protruding welds or WARNING

5. Remove sideshift cylinder from inner frame. See

NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 13. PIN

Figure 8. Integral Sideshift Carriage

b. Remove lower bearings from lower carriage

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

Figure 9. Lower Mounting Hooks Wear Limit and

A. MINIMUM THICKNESS 2.5 mm (0.1 in.)

1. LOWER BEARINGS 3. UPPER BEARINGS

Figure 10. Upper and Lower Bearings

NOTE: Use a wood block or a plastic hammer to fully WARNING

4. Repair sideshift cylinder as indicated in section

3. Install lower mounting hooks and four capscrews

6. Install forks. See Fork Replacement.

1. HYDRAULIC HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

Figure 11. Integral Sideshift Carriage Hydraulic Hose Connections

1. LUBE FITTING 10. LOAD ROLLERS

Figure 12. Integral Sideshift Carriage Component Parts

Clean and Inspect

1. Clean and inspect the carriage bars for damage

2. Clean the bearing areas. Inspect the sideshift

a. If either upper bearing is worn to less than

A. MINIMUM THICKNESS, 2.5 mm (0.1 in.)

1. LOWER BEARINGS 3. UPPER BEARINGS

Figure 14. Upper and Lower Bearings

2. Install lower mounting hook using four capscrews

NOTE: Tag hydraulic lines and fittings prior to

1. HYDRAULIC HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

Figure 15. Integral Sideshift Carriage Hydraulic Hose Connections

1. LUBE FITTING 10. LOAD ROLLERS

Figure 16. Integral Sideshift Carriage Component Parts

Clean and Inspect

1. Clean and inspect the carriage bars for damage

2. Clean the bearing areas. Inspect the sideshift

a. If either upper bearing is worn to less than