Maintenance

MAST REPAIR (S/N

C661, C662, C663,
C665)
2, 3, AND 4-STAGE HEAVY DUTY
MASTS
ERP16-20VF (ERP30-40VF) [A955];
ERP15-20VT (ERP030-040VT) [G807];
ESC030-40AC [B883];ESC030-40AD [C883]

PART NO. 524333799 4000 YRM 1405

 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 .......................................................................................................... 2
Fork Replacement .................................................................................................................................................... 7
Remove .................................................................................................................................................................7
Install .....................................................................................................................................................................9
Checks .................................................................................................................................................................. 9
Carriages Repair .....................................................................................................................................................10
Standard Carriage ...............................................................................................................................................10
Remove ...........................................................................................................................................................10
Clean and Inspect ........................................................................................................................................... 14
Install ...............................................................................................................................................................14
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 ................................................ 15
Remove ...........................................................................................................................................................15
Disassemble ....................................................................................................................................................18
Clean and Inspect ........................................................................................................................................... 18
Assemble ........................................................................................................................................................ 19
Install ...............................................................................................................................................................20
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 .................... 20
Remove ...........................................................................................................................................................20
Disassemble ....................................................................................................................................................23
Clean and Inspect ........................................................................................................................................... 23
Assemble ........................................................................................................................................................ 24
Install ...............................................................................................................................................................25
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 .............................................................. 25
Remove ...........................................................................................................................................................25
Disassemble ....................................................................................................................................................28
Clean and Inspect ........................................................................................................................................... 28
Assemble ........................................................................................................................................................ 29
Install ...............................................................................................................................................................30
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 ..................................................................30
Remove ...........................................................................................................................................................30
Clean and Inspect ........................................................................................................................................... 34
Disassemble and Assemble ............................................................................................................................34
Install ...............................................................................................................................................................34
Fork Positioner Hydraulic Hose Adjustment ................................................................................................35
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 ....................... 37
Remove ...........................................................................................................................................................37
Clean and Inspect ........................................................................................................................................... 40
Disassemble and Assemble ............................................................................................................................40
Install ...............................................................................................................................................................40
Fork Positioner Hydraulic Hose Adjustment ....................................................................................................41
Fork Positioner Carriage, Lift Trucks Manufactured June, 2018 and After ......................................................... 42
Remove ...........................................................................................................................................................43
Clean and Inspect ........................................................................................................................................... 46
Disassemble and Assemble ............................................................................................................................46
Install ...............................................................................................................................................................46
Fork Positioner Hydraulic Hose Adjustment ....................................................................................................47
Two-Stage Mast With Limited Free-Lift Repair ....................................................................................................... 48
Remove ...............................................................................................................................................................48
Disassemble ....................................................................................................................................................... 60
Clean and Inspect ............................................................................................................................................... 62
Assemble ............................................................................................................................................................ 65

©2019 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Install ...................................................................................................................................................................66
Header Hose Installation and Adjustment ...........................................................................................................68
Install ...............................................................................................................................................................68
Adjust .............................................................................................................................................................. 76
Two-Stage Mast With Full Free-Lift Repair .............................................................................................................76
Remove ...............................................................................................................................................................77
Disassemble ....................................................................................................................................................... 87
Clean and Inspect ............................................................................................................................................... 92
Assemble ............................................................................................................................................................ 95
Install ...................................................................................................................................................................96
Header Hose Installation and Adjustment ...........................................................................................................97
Install ...............................................................................................................................................................97
Adjust ............................................................................................................................................................ 106
Three-Stage Mast With Full Free-Lift Repair ........................................................................................................ 107
Remove .............................................................................................................................................................107
Disassemble ......................................................................................................................................................118
Clean and Inspect ............................................................................................................................................. 125
Assemble .......................................................................................................................................................... 127
Install .................................................................................................................................................................129
Header Hose Installation and Adjustment .........................................................................................................130
Install .............................................................................................................................................................130
Adjust ............................................................................................................................................................ 139
Four-Stage Mast With Full Free-Lift Repair .......................................................................................................... 139
Remove .............................................................................................................................................................139
Disassemble ..................................................................................................................................................... 144
Clean and Inspect ............................................................................................................................................. 149
Assemble .......................................................................................................................................................... 150
Install .................................................................................................................................................................151
Header Hose Installation and Adjustment .........................................................................................................153
Lift Chains Adjustment ..........................................................................................................................................158
Carriage Adjustments ........................................................................................................................................... 159
Tilt Cylinders Adjustment ...................................................................................................................................... 160
Mast Adjustments ................................................................................................................................................. 160
Load Roller, Adjust ............................................................................................................................................160
Mast Side Kicking, Adjust ................................................................................................................................. 162

This section is for the following models:

ERP16-20VF (ERP30-40VF) [A955];

ERP15-20VT (ERP030-040VT) [G807];
(ESC030-40AC) [B883];
(ESC030-40AD) [C883]

ii
4000 YRM 1405 General

General
a new hose that is the correct replacement for the
WARNING hose you are inspecting.
Before working on or near the mast, see Safety This section has the repair procedures for the Two-
Procedures When Working Near Mast section in Stage, Limited Free-Lift (LFL) with serial number
this YRM . C661; Two-Stage, Full Free-Lift (FFL) with serial
number C663, Three-Stage, Full Free-Lift (FFL) with
NOTE: Hoses have a service life that is determined serial number C662, and Four-Stage, Full Free-Lift
by application and time. Install a new hose if the hose (FFL) with serial number C665, Heavy Duty mast. The
is leaking, worn through, or damaged. A hose has mast serial number is located on the right side of the
been damaged if the hose cover is cracked, exposing outer mast. Other information about the mast can also
the braiding, or if the hose has been kinked or be found in this area. See Figure 1.
crushed, or if the hose is no longer flexible. Install a Procedures for adjusting the carriage, lift chains, mast,
new hose if the hose has been tensioned beyond the and tilt cylinders are located at the end of this manual.
adjustment range. If necessary, make a comparison to

1
General 4000 YRM 1405

NOTE: MAST AND SERIAL NUMBER SHOWN ARE NOT COVERED IN THIS MANUAL. ART USED FOR IL-
LUSTRATIVE PURPOSES. INFORMATION SHOWN IS FOUND IN SAME POSITION ON ALL MASTS COV-
ERED IN THIS MANUAL.

1. MAST SERIAL NUMBER 4. MAST LIFT HEIGHT (IN MILLIMETERS)

2. MANUFACTURING PLANT 5. MAST ASSEMBLY PART NUMBER
3. PRODUCTION SEQUENCE

Figure 1. Mast Serial Number Location

2
4000 YRM 1405 Safety Procedures When Working Near Mast

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:

1. Put mast in vertical position.

WARNING
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. On
the mast or carriage unless all parts are the four-stage mast, it is the first intermediate
completely lowered or a safety chain is mast. See Figure 2 Figure 3 or Figure 4 .
installed. Also make sure that the power is
OFF and the key is removed. Put a DO NOT 3. Use a 3/8-inch minimum safety chain with a hook
OPERATE tag in the operator's to fasten the crossmembers together so the
compartment. Disconnect the battery and movable member cannot lower. Put hook on back
put a tag or lock on the battery connector. side of mast. Make sure hook is completely
• Be careful of the forks. When the mast is engaged with a link in the chain. Make sure safety
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
time. Use a ladder or personnel lift to work 4. Lower mast until there is tension in safety chain
on the mast. and free-lift cylinder (full free-lift models) is
• Mast repairs require disassembly and completely retracted.
removal of parts and can require removal of
the mast or carriage. Follow the repair NOTE: Apply the parking brake. After lowering or
procedures in this section. restraining the mast, shut off the power, and remove
WHEN WORKING NEAR THE MAST ALWAYS: key. Put a DO NOT OPERATE tag in the operator's
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
push the lift/lower control lever forward until 5. Install another safety chain (9.5 mm (3/8 in.)
there is no movement in the mast. Make sure minimum) between the top or bottom bar of the
that all parts of the mast that move are fully carriage (item 6, Figure 2) (item 6, Figure 3) and
lowered. a crossmember on the outer mast as a secondary
safety device. Install a DO NOT REMOVE tag on
OR the safety chain(s).

3
Safety Procedures When Working Near Mast 4000 YRM 1405

Figure 2. Safety Chaining the Mast (Sit-Down Lift Trucks)

4
4000 YRM 1405 Safety Procedures When Working Near Mast

Legend for Figure 2.

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

B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST

1. OUTER MAST 5. FREE-LIFT CYLINDER

2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST

5
Safety Procedures When Working Near Mast 4000 YRM 1405

Figure 3. Safety Chaining the Mast (Sit-Down Lift Trucks)

6
4000 YRM 1405 Fork Replacement

Legend for Figure 3.

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

NOTE: TWO-STAGE MASTS SHOWN. FOR THREE-STAGE MAST, ALIGN THE CROSSMEMBER OF INTER-
MEDIATE WELDMENT ALONG WITH INNER AND OUTER WELDMENTS WHEN CHAINING THE MAST.

A. LIMITED FREE-LIFT MAST B. FULL FREE-LIFT MAST

1. SAFETY CHAIN AND HOOK 4. CARRIAGE (TOP BAR)

2. MAST CROSSMEMBERS ALIGNED 5. FREE-LIFT CYLINDER
3. INNER WELDMENT 6. OUTER WELDMENT

Figure 4. Safety Chaining the Mast (Stand-Up Lift Trucks)

Fork Replacement
REMOVE
If lift truck is equipped with a fork positioner, see WARNING
Carriages Repair for procedures to remove the forks. 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).

7
Fork Replacement 4000 YRM 1405

A fork can be removed from the carriage for See Figure 6. Lower carriage further so top hook of
replacement of the fork or other maintenance. Slide fork is disengaged from top carriage bar. Move
fork to the fork removal notch in bottom bar of the carriage away from fork or use a lifting device to move
carriage. See Figure 5. Lower fork onto blocks so the fork away from carriage.
bottom hook of fork moves through fork removal notch.

1. LOAD BACKREST 6. WEDGE

2. CARRIAGE 7. WASHER
3. FORKS 8. SPRING
4. FORK 9. PIN
5. KNOB 10. FORK REMOVAL NOTCH

Figure 5. Carriage and Forks

8
4000 YRM 1405 Fork Replacement

2. Replace any damaged or broken parts that are

used to keep forks locked in position.

3. Inspect fork wear. Ensure heel wear is not more

than 10% of original thickness. If fork wear is
more than 10%, fork must be replaced or rerated.
Perform fork wear inspection using a BOL256N1
caliper ruler Yale P/N 550088603 , as follows.
See Figure 8.

a. Determine the normal thickness of the "N" of

the fork using the scale or ruler portion of the
caliper ruler. Measurement has to be done on
the fork shank using the caliper ruler.

b. Position the caliper at the end of the heel

internal radius (item A, Figure 7) with the
opening corresponding to the measure
thickness of the fork shank in above (e.g. N
1. CARRIAGE BARS 1.75 use N 1.75 opening). This is typically the
2. HOOK FORK section of the fork where wear is the greatest.
3. BLOCKS Note that the opening distance has been
reduced by 10% from the nominal thickness.
Figure 6. Hook Fork Removal
c. If the fork enters the opening, it is mandatory to
INSTALL replace it. DANGER OF BREAKING.
If lift truck is equipped with a fork positioner, see Furthermore, a 10% reduction in fork blade
Carriages Repair for procedures to install the forks. thickness results in 20% reduction in operating
capacity.
Move the fork and carriage so the top hook on the fork
can engage the upper carriage bar. See Figure 6. Table 1. Fork Tip Alignment, Lift Truck Models
Raise the carriage to move the lower hook through the ERP16-20VF (ERP030-040VF) (A955) and
fork removal notch. Slide the fork on the carriage so ERP15-20VT (ERP030-040VT) (G807)
both upper and lower hooks engage the carriage bars.
Engage the latch pin with a notch in the upper carriage Fork Tip Alignment Specifications
bar.
Standard Fork Lengths Maximum Fork Tip
Difference1
CHECKS
mm (in.) mm (in.)
WARNING 914 (36) 27 (1.08)
DO NOT try to correct fork tip alignment by 1000 (39) 30 (1.17)
bending the forks or adding shims. Replace bent 1067 (42) 32 (1.26)
forks.
1100 (43) 33 (1.29)
Never repair damaged forks by heating or welding.
Forks are made of tempered steel using special 1200 (47) 36 (1.42)
procedures. Always replace damaged forks as a 1219 (48) 37 (1.44)
complete set.
1Differenceof alignment between fork tips must be no
1. Inspect the forks for cracks and wear. Check the more than 3% of the total fork length.
alignment of the fork tips as shown in Table 1 and
Table 2. Check that the bottom of the fork is not
worn (item A, Figure 7).

9
Carriages Repair 4000 YRM 1405

Table 2. Fork Tip Alignment, Lift Truck Models

ESC030-040AC (B883) and ESC030-040AD (C883)
Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip
Difference1
mm (in.) mm (in.)
914 (36) 27 (1.08)
1067 (42) 32 (1.26)
1219 (48) 37 (1.46)
1Difference of alignment between fork tips must be no
more than 3% of the total fork length.

Figure 8. Fork Wear Check

A. HEEL OF FORK (MUST BE 90% OF DIMENSION

B)
B. ORIGINAL FORK THICKNESS (DIMENSION B)

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS
3. MAXIMUM ANGLE 93°
4. FORK REMOVAL NOTCH
5. CARRIAGE

Figure 7. Fork Check

Carriages Repair
STANDARD CARRIAGE Remove
NOTE: The four-stage FFL mast covered in this 1. Remove the forks. See Fork Replacement for
section is used only on lift truck models procedures.
ERP030-040VT (G807), ESC030-40AC (B883), and
ESC030-40AD (C883). 2. Remove four socket head capscrews, washers,
nuts, and load backrest. See Figure 9.

10
4000 YRM 1405 Carriages Repair

1. SOCKET HEAD CAPSCREW

2. WASHER
3. NUT
4. CARRIAGE
5. LOAD BACKREST

Figure 9. Load Backrest Removal

3. Connect a lifting device to the carriage. Lift the

carriage so that the lift chains become loose.

WARNING
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
prevent the lift chains from falling and causing an
injury or damage.

4. Remove the chain pin from each chain anchor at

the carriage. See Figure 10 and Figure 11.
Disconnect the lift chains from the carriage. Use
wire to connect the ends of the lift chains to a part
of the mast. Make sure the chains can move
freely when the inner mast is raised.
NOTE: THREE-STAGE FFL CARRIAGE SHOWN.
LOAD BACK REST MOUNTED THE SAME WAY ON
TWO-STAGE FFL AND TWO-STAGE LFL CARRIAG-
ES. MOUNTING OF LOAD BACK REST IS SIMILAR
ON FOUR-STAGE FFL MAST.

11
Carriages Repair 4000 YRM 1405

NOTE: THREE-STAGE FFL CARRIAGE SHOWN. TWO-STAGE LFL, AND TWO-STAGE FFL CARRIAGES ARE
SIMILAR.

1. SNAP RING 6. LOAD ROLLER

2. ANCHOR PIN 7. SHIM
3. COTTER PIN 8. STUBSHAFT
4. CARRIAGE 9. CHAIN PIN
5. SPACER 10. CHAIN ANCHOR

Figure 10. Standard Carriage, Three-Stage FFL Mast

12
4000 YRM 1405 Carriages Repair

1. LOAD ROLLER MOUNT 9. CAPSCREW

2. SHIM 10. CHAIN ANCHOR
3. LOAD ROLLER 11. ANCHOR PIN
4. SHIM 12. COTTER PIN
5. RETAINING CAP 13. JAM NUTS
6. CAPSCREW 14. THIN JAM NUT
7. THRUST ROLLER 15. THICK JAM NUT
8. LOCKWASHER

Figure 11. Standard Carriage, Four-Stage FFL Mast

inner or intermediate mast. See the section

WARNING Cylinder Repair (Mast S/N A270-72, A551,
To help prevent possible injury, make sure the A555, A559, A626, A627, A751-52, B551, B555,
carriage is stable and will not fall over when the B586-91, B749-54, C661-63, C665, D507-09,
inner mast is raised above the load rollers of the D515, D562-64, E509, E564) 2100YRM1382.
carriage. Connect a crane [the capacity of the crane must
be at least 681 kg (1501 lb), for two and three-
5. Use the lift cylinders to raise the inner or stage mast and 1100 kg (2385 lb) for four-stage
intermediate mast. If the hydraulic system cannot mast] to the top of the inner mast. Carefully raise
be used, disconnect the lift cylinders from the the inner mast until it is above the load rollers of

13
Carriages Repair 4000 YRM 1405

the carriage. Install safety chains to secure the 3. If the carriage bars have any protruding welds or
mast in its extended position and disconnect the damaged notches, repair by grinding, filing, or
crane. See Safety Procedures When Working welding.
Near Mast.
4. Clean and inspect the chain anchors and chain
6. Move lift truck away from the carriage. anchor pins. See Figure 10 and Figure 11. Check
Completely lower the inner mast. chain anchors and anchor pins for wear and
serviceability. Discard worn or unserviceable
Clean and Inspect chain anchors and chain anchor pins. Discard
cotter pins.
1. If load rollers must be replaced (see Figure 10
and Figure 11), make a note of the location and
number of the shims. Install the shims, load
Install
rollers, and snap rings. See Carriage Adjustments 1. Connect a crane [the capacity of the crane must
for correct adjustment of the load rollers. be at least 681 kg (1501 lb), for two and three-
stage mast and 1100 kg (2385 lb) for four-stage
mast] to the top of the inner mast. Carefully raise
WARNING the inner mast until it is above the load rollers of
Compressed air can move particles so that they the carriage. Install safety chains to secure the
cause injury to the user or to other personnel. mast in its extended position and disconnect the
Make sure that the path of the compressed air is crane. See Safety Procedures When Working
away from all personnel. Wear protective goggles Near Mast.
or a face shield to prevent injury to the eyes.
2. Move the lift truck toward the carriage until the
inner mast is aligned with the carriage rollers. If
the inner mast has been raised and secured
WARNING using a crane and safety chains, connect the
Cleaning solvents can be flammable and toxic, and crane, raise the inner mast, and remove the
can cause skin irritation. When using cleaning safety chains. Carefully lower the inner mast until
solvents, always follow the recommendations of it engages all of the load rollers. Disconnect the
the manufacturer. crane, if attached, and reconnect the lift cylinders.
See the section Cylinder Repair (Mast S/N
A270-72, A551, A555, A559, A626, A627,
CAUTION A751-52, B551, B555, B586-91, B749-54,
DO NOT use cleaning solvent, compressed air, or C661-63, C665, D507-09, D515, D562-64, E509,
steam to clean lift chain sheaves or load rollers. E564) 2100YRM1382.
The bearings in the lift chain sheaves and load
rollers are sealed and lubricated. Cleaning solvent, 3. Check the clearance of the load rollers. See
compressed air, and steam can damage the load Carriage Adjustments in this section.
roller bearings.
NOTE: Use new cotter pins each time the chain pins
2. Clean any oil, grease, dirt, and other debris from are removed.
the carriage frame. Use a cleaning solvent and
4. Connect the lift chains to the chain anchors at the
compressed air to dry.
carriage. Install new cotter pins in the chain pins.
Adjust the lift chains as described in Carriage
Adjustments in this section.
WARNING
Improper welding procedures can damage the 5. Install the load backrest on the carriage (see
structure of the mast or cause incorrect function Figure 9). Tighten the socket head capscrews to
of the mast. Consult Resident Service Engineering 195 N•m (144 lbf ft).
through the Contact Management System before
welding on the mast. 6. Install the forks. See Fork Replacement.

14
4000 YRM 1405 Carriages Repair

INTEGRAL SIDESHIFT CARRIAGE, LIFT NOTE: Tag hydraulic lines and fittings prior to
TRUCKS MANUFACTURED PRIOR TO disconnecting to aid in connecting during installation.
DECEMBER, 2016 4. Disconnect hydraulic lines from sideshift cylinder.
NOTE: The four-stage FFL mast covered in this Put caps and plugs on open lines and cylinder
section is used only on lift truck models ports. Figure 12.
ERP030-040VT (G807), ESC030-40AC (B883), and
ESC030-40AD (C883) .

Remove
1. Lower the carriage completely. Remove the forks.
See Fork Replacement for removal procedures.

2. Remove the four capscrews, washers, nuts and

load backrest from carriage. See Figure 9.

WARNING
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious
injury can occur if pressure is not relieved from
hydraulic system prior to disconnecting hydraulic
NOTE: THREE-STAGE FFL CARRIAGE SHOWN.
hoses.
HYDRAULIC CONNECTIONS FOR TWO-STAGE LFL
3. Relieve hydraulic pressure to the sideshift AND TWO- AND FOUR-STAGE FFL IS SIMILAR.
cylinder by moving sideshift lever in both
1. HYDRAULIC FITTINGS
directions several times. 2. HYDRAULIC HOSES
3. INTEGRAL SIDESHIFT CYLINDER

WARNING Figure 12. Integral Sideshift Hydraulic Hose

Always wear the proper protective equipment Connections
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly NOTE: Perform Step 5 for lift trucks equipped with
wash oil from exposed areas of skin as soon as two and three-stage FFL mast and two-stage LFL
possible. masts.

The hydraulic oil is hot at normal operating 5. Remove four capscrews and washers securing
temperatures. Be careful when draining the oil. lower mounting hooks to outer frame. See
Figure 13.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
the skin.

CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.

15
Carriages Repair 4000 YRM 1405

NOTE: TWO-STAGE LFL CARRIAGE SHOWN. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY FOR TWO
AND THREE-STAGE FFL IS SIMILAR.

1. CAPSCREW 12. SNAP RING

2. WASHER 13. COTTER PIN
3. FORK REMOVAL NOTCH 14. CHAIN ANCHOR
4. OUTER FRAME 15. CHAIN ANCHOR MOUNTING BRACKET
5. LOWER HOOK 16. INNER FRAME
6. LUBE FITTING 17. STUBSHAFT
7. LOWER BEARING 18. SHIMS
8. HAIRPIN 19. LOAD ROLLER
9. CLEVIS PIN 20. SIDESHIFT CYLINDER
10. PIN 21. SPACER
11. UPPER BEARING

Figure 13. Integral Sideshift Carriage, Two and Three-Stage FFL Mast and Two-Stage LFL Mast

NOTE: Perform Step 6 for lift trucks equipped with 6. Remove capscrews and lower retainers from
four-stage FFL mast. bottom of outer frame. See Figure 14.

16
4000 YRM 1405 Carriages Repair

1. OUTER FRAME 9. O-RING

2. LUBE FITTING 10. WIPER
3. LOWER RETAINER 11. SEAL
4. CAPSCREW 12. LOWER BEARING
5. UPPER BEARING 13. HYDRAULIC FITTING
6. CYLINDER ROD 14. CYLINDER BLOCK
7. INNER FRAME 15. LOAD ROLLER STUBSHAFT
8. GLAND

Figure 14. Integral Sideshift Carriage, Four-Stage FFL Mast

WARNING
On integral sideshift carriage for four-stage FFL
mast, the cylinder rod should be pushed in
cylinder block before removing outer frame from
inner frame to avoid injury to personnel.

7. Use a crane with a capacity of at least

40 kg (90 lb) for two-stage LFL and two- and
three-stage FFL mast, and 48 kg (106 lb) for four-
stage FFL mast, to lift outer frame away from the
inner frame (see Figure 15). Lay the outer frame
flat on a pallet or workbench.

17
Carriages Repair 4000 YRM 1405

NOTE: OUTER FRAME FOR INTEGRAL SIDESHIFT

CARRIAGE USED ON TWO AND THREE-STAGE
FFL MAST AND TWO-STAGE LFL MASTS SHOWN.
REMOVAL OF OUTER FRAME ON FOUR-STAGE
FFL MAST THE SAME. 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.)
1. OUTER FRAME MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
2. LIFTING HOOK
3. LIFTING DEVICE Figure 16. Lower Mounting Hooks Wear Limit and
Clearance Adjustment, Two and Three-Stage FFL
Figure 15. Remove Outer Frame
Mast and Two-Stage LFL Mast
Disassemble
1. Remove the upper and lower bearings from the WARNING
inner frame. See Figure 13 and Figure 14. Improper welding procedures can damage the
structure of the mast or cause incorrect function
2. If damaged, remove lube fittings from outer of the mast. Consult your Yale lift truck dealer for
frame. more information before welding on the mast.
3. Remove and disassemble the integral sideshift 2. Clean and inspect the carriage bars for damage
cylinder. See the section Cylinder Repair (Mast and smoothness. Ensure the carriage bars are
S/N A270-72, A551, A555, A559, A626, A627, parallel and the ends are flush. If carriage bars
A751-52, B551, B555, B586-91, B749-54, have any protruding welds or damaged notches,
C661-63, C665, D507-09, D515, D562-64, E509, repair by grinding, filing, or welding.
E564) 2100YRM1382 for procedures.
3. Clean the bearing areas. Inspect the sideshift
Clean and Inspect bearings for wear as follows:
NOTE: Perform Step 1 on lift trucks equipped with two
a. If either upper bearing is worn to less than
and three-stage FFL mast and two-stage LFL mast.
2.5 mm (0.1 in.) thickness, replace upper
1. Inspect the lower mounting hooks for wear. bearings by driving the upper bearings from
Replace the hooks if they are worn beyond the the inner frame. See Figure 17.
wear limit. The wear limit clearance range is
0.76 mm (0.03 in.) minimum and b. If either lower bearing is worn to less than
1.52 mm (0.06 in.) maximum. See A in Figure 16. 2.5 mm (0.1 in.) thickness, replace lower
bearings by prying the lower bearings from the
inner frame. See Figure 17.

18
4000 YRM 1405 Carriages Repair

NOTE: INTEGRAL SIDESHIFT CARRIAGE FOR TWO AND THREE-STAGE FFL MAST AND TWO-STAGE LFL
MAST SHOWN. MEASUREMENT OF BEARINGS AND MINIMUM THICKNESS OF BEARINGS IS THE SAME
ON FOUR-STAGE FFL MAST. ON FOUR-STAGE FFL MAST, GREASE IS APPLIED ON SAME SIDE OF LOW-
ER BEARINGS AS SHOWN IN FIGURE 17. ALSO, SEE FIGURE 14.

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 17. Upper and Lower Bearings

Assemble
WARNING 1. Assemble and install the integral sideshift
Cleaning solvents can be flammable and toxic, and cylinder. See the section Cylinder Repair (Mast
can cause skin irritation. When using cleaning S/N A270-72, A551, A555, A559, A626, A627,
solvents, always follow the recommendations of A751-52, B551, B555, B586-91, B749-54,
the manufacturer. C661-63, C665, D507-09, D515, D562-64, E509,
E564) 2100YRM1382 for procedures.
4. Inspect the sideshift cylinder. See the section
Cylinder Repair (Mast S/N A270-72, A551, 2. If lube fittings were removed, install new lube
A555, A559, A626, A627, A751-52, B551, B555, fittings into outer frame. See Figure 13 and
B586-91, B749-54, C661-63, C665, D507-09, Figure 14.
D515, D562-64, E509, E564) 2100YRM1382 for
procedures. NOTE: Use a wood block or a plastic hammer to fully
seat the upper bearings onto the inner frame. Proper
5. Inspect load rollers for wear and damage (see lower hook clearance requires the upper bearings be
Figure 13 and Figure 14). If load rollers must be fully seated.
replaced, make a note of the location and number
of the shims to ensure correct installation. See
Carriage Adjustments.

19
Carriages Repair 4000 YRM 1405

3. Apply a 1 mm (0.040 in.) layer of multipurpose INTEGRAL SIDESHIFT CARRIAGE, LIFT

grease to upper and lower bearing surfaces. TRUCKS MANUFACTURED DECEMBER,
Install the upper and lower bearings onto the
inner frame.
2016 THROUGH LATE JUNE, 2018
This section covers lift truck models ERP030-040VT
a. To install new upper bearing, align the pins on (G807), ESC030-40AD (C883), and ERP030-040VF
the bottom side of bearing to notches on top (A955) manufactured between December, 2016 and
carriage bar and slide into place on top late June, 2018 and equipped with three-stage FFL
carriage. See Figure 17. mast with S/N C662.

b. To install new lower bearing, align the circular Remove

pins on backside of lower bearing to holes on
lower carriage bar and tap bearing into place 1. Lower carriage completely and remove forks. See
on lower carriage bar using a rubber or brass Fork Replacement for removal procedures.
hammer. See Figure 17.
2. Remove four capscrews, washers, nuts, and load
Install backrest from carriage. See Figure 9.

1. Use a crane with a capacity of at least

40 kg (90 lb) for two-stage LFL and two- and WARNING
three-stage FFL mast, and 48 kg (106 lb) for four- Before disconnecting the hydraulic hoses, relieve
stage FFL mast, to install the outer frame onto the pressure in the hydraulic system. Serious
inner frame. See Figure 15. injury can occur if pressure is not relieved from
hydraulic system prior to disconnecting hydraulic
NOTE: Perform Step 2 for lift trucks equipped with hoses.
two and three-stage FFL mast and two-stage LFL
mast. 3. Relieve hydraulic pressure to the sideshift
2. Install the lower mounting hooks using four cylinder by moving sideshift lever in both
capscrews and washers. Tighten to directions several times.
165 ±15 N•m (120 ±12 lbf ft). For proper sideshift
operation, make sure there is
0.76 to 1.52 mm (0.03 to 0.06 in.) clearance WARNING
between the bottom of the hooks and the outer Always wear the proper protective equipment
frame. See B in Figure 16. including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
NOTE: Perform Step 3 for lift trucks equipped with wash oil from exposed areas of skin as soon as
four-stage FFL mast. possible.
3. Apply Loctite™ 243 to capscrew holes on bottom The hydraulic oil is hot at normal operating
of outer frame. Install lower retainers to bottom of temperatures. Be careful when draining the oil.
outer frame using capscrews. See Figure 14. Never check for leaks by putting hands on
Tighten capscrews to 60 N•m (44 lbf ft). hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
4. Connect the hydraulic lines, as noted during the skin.
removal, to the sideshift cylinder.

5. Install load backrest onto sideshift carriage. See

Figure 9. Tighten the capscrews to CAUTION
195 N•m (144 lbf ft). Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
6. Install the forks. See Fork Replacement section system.
for the procedures.
NOTE: Tag hydraulic lines and fittings prior to
disconnecting to aid in connecting during installation.

20
4000 YRM 1405 Carriages Repair

4. Disconnect hydraulic lines from sideshift cylinder.

Put caps and plugs on open lines and cylinder
ports. See Figure 18.

1. HYDRAULIC HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

2. INTEGRAL SIDESHIFT HYDRAULIC HOSES

Figure 18. Integral Sideshift Carriage Hydraulic Hose Connections

5. Remove four capscrews and washers securing 6. Use a crane, with a capacity of 40 kg (90 lb), to lift
lower mounting hooks to outer frame. See outer frame away from inner frame (see
Figure 19. Figure 20). Lay outer frame flat on a pallet or
workbench.

21
Carriages Repair 4000 YRM 1405

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
6. LOWER BEARING 15. COTTER PIN
7. LOWER MOUNTING HOOK 16. CHAIN PIN
8. UPPER BEARINGS 17. CHAIN ANCHOR
9. SNAP RING

Figure 19. Integral Sideshift Carriage Component Parts

22
4000 YRM 1405 Carriages Repair

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
more information before welding on the mast.

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

2.5 mm (0.1 in.) thickness, replace both upper
bearings by driving the upper bearings from
Figure 20. Remove Outer Frame the inner frame. See Assemble section for
procedures to replace upper bearings and
Disassemble Figure 21.

1. Remove the upper and lower bearings from the b. If either lower bearing is worn to less than
inner frame. See Figure 19. 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 19. procedures to replace lower bearings and
Figure 21.
3. Disassemble sideshift cylinder. See Cylinder
Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100YRM1382 for
procedures.

23
Carriages Repair 4000 YRM 1405

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 21. Upper and Lower Bearings

3. Inspect sideshift cylinder. See Cylinder Repair NOTE: Use a wood block or a plastic hammer to fully
(Mast S/N A270-72, A551, A555, A559, A626, seat the upper bearings onto the inner frame. Proper
A627, A751-52, B551, B555, B586-91, B749-54, lower hook clearance requires the upper bearings be
C661-63, C665, D507-09, D515, D562-64, E509, fully seated.
E564) 2100YRM1382 for procedures.
3. Apply a 1 mm (0.040 in.) layer of multipurpose
grease to upper and lower bearing surfaces.
4. Inspect load rollers for wear and damage (see
Install the upper and lower bearings onto inner
Figure 19). If load rollers must be replaced, make
frame:
a note of the location and number of the shims to
ensure correct installation. See Carriage
a. To install new upper bearing, align the pins on
Adjustments
the bottom side of bearing to notches on top
carriage bar and slide into place on top
Assemble carriage. See Figure 21.
1. Assemble sideshift cylinder. See Cylinder Repair
(Mast S/N A270-72, A551, A555, A559, A626, b. To install new lower bearing, align the circular
A627, A751-52, B551, B555, B586-91, B749-54, pins on backside of lower bearing to holes on
C661-63, C665, D507-09, D515, D562-64, E509, lower carriage bar and tap bearing into place
E564) 2100YRM1382 on lower carriage bar using a rubber or brass
hammer. See Figure 21.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 19.

24
4000 YRM 1405 Carriages Repair

Install 3. Relieve hydraulic pressure to the sideshift

1. Use a crane, with a capacity of 40 kg (90 lb), and cylinder by moving sideshift lever in both
install outer frame onto inner frame. See directions several times.
Figure 20.

2. Install lower mounting hook using four capscrews WARNING

and washers. Tighten capscrews to Always wear the proper protective equipment
150 to 180 N•m (108 to 132 lbf ft). See Figure 19. including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
3. Connect hydraulic lines, as noted during removal, wash oil from exposed areas of skin as soon as
to sideshift cylinder. See Figure 18. possible.

4. Install load backrest onto integral sideshift The hydraulic oil is hot at normal operating
carriage. Tighten capscrews to temperatures. Be careful when draining the oil.
195 N•m (144 lbf ft). Never check for leaks by putting hands on
hydraulic lines or components under pressure.
5. Install forks. See Fork Replacement section for Hydraulic oil under pressure can be injected into
procedures. the skin.

INTEGRAL SIDESHIFT CARRIAGE, LIFT

TRUCKS MANUFACTURED LATE JUNE, CAUTION
2018 Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
This section covers lift truck models ERP030-040VT system.
(G807), ESC030-40AD (C883), and ERP030-040VF
(A955) manufactured Late June, 2018 and after NOTE: Tag hydraulic lines and fittings prior to
equipped with three-stage FFL mast with S/N C662. disconnecting to aid in connecting during installation.
4. Disconnect hydraulic lines from sideshift cylinder.
Remove Put caps and plugs on open lines and cylinder
1. Lower carriage completely and remove forks. See ports. See Figure 22.
Fork Replacement for removal procedures.

2. Remove four capscrews, washers, nuts, and load

backrest from carriage. See Figure 9.

WARNING
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious
injury can occur if pressure is not relieved from
hydraulic system prior to disconnecting hydraulic
hoses.

25
Carriages Repair 4000 YRM 1405

1. HYDRAULIC HOSE FITTINGS 3. INTEGRAL SIDESHIFT CYLINDER

2. INTEGRAL SIDESHIFT HYDRAULIC HOSES

Figure 22. Integral Sideshift Carriage Hydraulic Hose Connections

5. Remove four capscrews and washers securing 6. Use a crane, with a capacity of 40 kg (90 lb), to lift
lower mounting hooks to outer frame. See outer frame away from inner frame (see
Figure 23. Figure 24). Lay outer frame flat on a pallet or
workbench.

26
4000 YRM 1405 Carriages Repair

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
6. LOWER BEARING 15. COTTER PIN
7. LOWER MOUNTING HOOK 16. CHAIN PIN
8. UPPER BEARINGS 17. CHAIN ANCHOR
9. SNAP RING

Figure 23. Integral Sideshift Carriage Component Parts

27
Carriages Repair 4000 YRM 1405

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
more information before welding on the mast.

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

2.5 mm (0.1 in.) thickness, replace both upper
bearings by driving the upper bearings from
Figure 24. Remove Outer Frame the inner frame. See Assemblesection for
procedures to replace upper bearings and
Disassemble Figure 25.

1. Remove the upper and lower bearings from the b. If either lower bearing is worn to less than
inner frame. See Figure 25. 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 23. procedures to replace lower bearings and
Figure 25.
3. Disassemble sideshift cylinder. See Cylinder
Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100YRM1382 for
procedures.

28
4000 YRM 1405 Carriages Repair

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 25. Upper and Lower Bearings

3. Inspect sideshift cylinder. See Cylinder Repair NOTE: Use a wood block or a plastic hammer to fully
(Mast S/N A270-72, A551, A555, A559, A626, seat the upper bearings onto the inner frame. Proper
A627, A751-52, B551, B555, B586-91, B749-54, lower hook clearance requires the upper bearings be
C661-63, C665, D507-09, D515, D562-64, E509, fully seated.
E564) 2100YRM1382 for procedures.
3. Apply a 1 mm (0.040 in.) layer of multipurpose
grease to upper and lower bearing surfaces.
4. Inspect load rollers for wear and damage (see
Install the upper and lower bearings onto inner
Figure 23). If load rollers must be replaced, make
frame:
a note of the location and number of the shims to
ensure correct installation. See Carriage
a. To install new upper bearing, align the pins on
Adjustments.
the bottom side of bearing to notches on top
carriage bar and slide into place on top
Assemble carriage. See Figure 25.
1. Assemble sideshift cylinder. See Cylinder Repair
(Mast S/N A270-72, A551, A555, A559, A626, b. To install new lower bearing, align the circular
A627, A751-52, B551, B555, B586-91, B749-54, pins on backside of lower bearing to holes on
C661-63, C665, D507-09, D515, D562-64, E509, lower carriage bar and tap bearing into place
E564) 2100YRM1382 . on lower carriage bar using a rubber or brass
hammer. See Figure 25.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 23.

29
Carriages Repair 4000 YRM 1405

Install
1. Use a crane, with a capacity of 40 kg (90 lb), and
install outer frame onto inner frame. See
Figure 24.

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 23.

3. Connect hydraulic lines, as noted during removal,

to sideshift cylinder. See Figure 23.

4. Install load backrest onto integral sideshift

carriage. Tighten capscrews to
195 N•m (144 lbf ft). 1. OUTER FORK CARRIER
2. CAPSCREW
3. SPACER BAR*
5. Install forks. See Fork Replacement section for 4. INNER FORK CARRIER
procedures. *Spacer bar used on 977 mm (38.5 in.) and
1067 mm (42 in.) class II carriages.
FORK POSITIONER, LIFT TRUCKS
MANUFACTURED PRIOR TO DECEMBER, Figure 26. Fork Carrier Spacer Bar
2016
Remove
NOTE: The fork positioner can be removed from the
integral sideshift carriage with the integral sideshift
carriage on or off the mast. In the steps below, the fork CAUTION
positioner is removed with the integral sideshift Remove fork latch pins if adding a fork positioner
carriage on the mast. If integral sideshift carriage must attachment. Damage to forks and other carriage
be removed from mast first, go to Integral Sideshift components can occur if fork latch pins are not
Carriage, Lift Trucks Manufactured Prior To December, removed prior to using attachment.
2016.
1. Lower carriage and remove four capscrews from
NOTE: Depending on size and configuration of forks inner fork carriers. Slide inner fork carriers down
installed on lift truck, there may be a spacer bar cylinder shell to remove forks. See Figure 27.
between inner and outer fork carriers. See Figure 26.

30
4000 YRM 1405 Carriages Repair

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

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 27. 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 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

carriage. See Figure 9.

31
Carriages Repair 4000 YRM 1405

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 28) from header hoses.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
the skin.

CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.

32
4000 YRM 1405 Carriages Repair

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 28. Hydraulic Connections, Fork Positioner Cylinder

5. Remove lower hooks and bracket weldments. 6. Install lifting eye in hole (7, Figure 29) on integral
See Figure 29 and Figure 31. 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 29.

33
Carriages Repair 4000 YRM 1405

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 29. Fork Positioner Cylinder Removal

NOTE: Make note of shims used to aid in reassembly. D515, D562-64, E509, E564) 2100YRM1382 for
procedures.
7. Remove capscrews, lock washers, and shims
from integral sideshift carriage. See Figure 29.
Remove fork positioner from outer frame. Install
1. Place fork positioner cylinders onto outer frame.
Clean and Inspect Hand tighten capscrew and lockwasher on one
side. See Figure 29. Add shims as follows:
See Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555,
NOTE: Maximum number of shims per side is five.
B586-91, B749-54, C661-63, C665, D507-09, D515,
The maximum difference in number of shims per side
D562-64, E509, E564) 2100YRM1382 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 Cylinder Repair (Mast S/N A270-72, capscrews is 0.50 mm (.020 in.).
A551, A555, A559, A626, A627, A751-52, B551,
B555, B586-91, B749-54, C661-63, C665, D507-09, b. Install equal amount of shims on both sides of
the fork positioner assembly.

34
4000 YRM 1405 Carriages Repair

2. Finish installing fork positioner assembly to outer 7. Assemble bracket weldment to lower hook and
frame by tightening both capscrews and hand tighten. Assemble lower hook on retainer
lockwashers to 65 N•m (50 lbf ft). See Figure 29. plate and tighten capscrews to
165 N•m (122 lbf ft). See Figure 31.
3. Connect fork positioner hydraulic hoses to fork
positioner manifold. Tighten to 8. Position bracket weldment over fork positioner
21 N•m (186 lbf in). See Figure 28. hydraulic hoses (see Figure 28) and adjust so
that bracket weldment makes contract with fork
4. Thread fork positioner hydraulic hoses through positioner hoses and tighten capscrew to
hose guides. 8 N•m (71 lbf in). See Figure 31.

5. Assemble outer frame with fork positioner to inner

frame. Using a lifting device, position outer frame
at approximately the same height of inner frame
and approximately 150 mm (6 in.) away. From
rear of outer frame, connect fork positioner
hydraulic tubes to header hoses and hand
tighten. See Figure 28.

6. Assemble outer frame onto inner frame. Position

fork positioner hydraulic tubes so they are in line
with inner frame retainer plates. See Figure 30.

1. BRACKET WELDMENT
2. RETAINER PLATE
3. WASHER
4. LOWER HOOK
5. CAPSCREW (LOWER HOOK)
6. CAPSCREW (BRACKET WELDMENT)

Figure 31. 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

1. RETAINER PLATE Adjustment
2. INNER FRAME 1. To adjust the fork positioner hydraulic hoses, hold
the large hex nut and rotate the small hex nut
Figure 30. Inner Frame Retainer Plates
towards the load face of the carriage (towards the
forks). See Figure 32.

35
Carriages Repair 4000 YRM 1405

2. Fork positioner hoses are correctly adjusted when 4. Install backrest and capscrews on sideshift
fork positioner hydraulic hoses stay entirely within carriage. Tighten capscrews to
the integral sideshift carriage and do not contact 195 N•m (144 lbf ft). See Figure 9.
mast channels under all conditions.

3. Move fork positioner and check to ensure fork

carriers clear fork positioner relief tubes through
complete fork carrier cycle. See Figure 28.

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 32. Fork Positioner Hydraulic Hose Adjustment

WARNING CAUTION
DO NOT try to install a fork without a lifting device. Remove fork latch pins if adding a fork positioner
Each hook fork for these lift trucks can weigh attachment. Damage to forks and other carriage
45 to 115 kg (99 to 254 lb). components can occur if fork latch pins are not
removed prior to using attachment.

36
4000 YRM 1405 Carriages Repair

5. Install forks to outer fork carriers. Secure inner

fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to
35 N•m (25 lbf ft). See Figure 27.

6. To adjust the fork positioner cylinders, See

Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555,
B586-91, B749-54, C661-63, C665, D507-09,
D515, D562-64, E509, E564) 2100YRM1382 for
procedures.

FORK POSITIONER CARRIAGE, LIFT

TRUCKS MANUFACTURED DECEMBER, 1. OUTER FORK CARRIER
2016 THROUGH LATE JUNE, 2018 2. CAPSCREW
3. SPACER BAR*
This section covers lift truck models ERP030-040VT 4. INNER FORK CARRIER
(G807), ESC030-40AD (C883), and ERP030-040VF *Spacer bar used on 977 mm (38.5 in.) and
(A955) manufactured between December, 2016 and 1067 mm (42 in.) class II carriages.
late June, 2018 and equipped with three-stage FFL
mast with S/N C662. Figure 33. Fork Carrier Spacer Bar
NOTE: The fork positioner can be removed from the Remove
integral sideshift carriage with integral sideshift
carriage on or off the mast. In the steps below, the fork 1. Lower carriage and remove four capscrews from
positioner is removed with integral sideshift carriage inner fork carriers. Slide inner fork carriers down
on the mast. If integral sideshift carriage must be cylinder shell to remove forks. See Figure 34.
removed from mast first, go to Integral Sideshift
Carriage, Lift Trucks Manufactured December, 2016
Through Late June, 2018 for procedures. WARNING
NOTE: Depending on size and configuration of forks DO NOT try to remove a fork without a lifting
installed on lift truck, there may be a spacer bar device. Each hook fork for these lift trucks can
between inner and outer fork carriers. See Figure 33. weigh 45 to 115 kg (99 to 254 lb).

2. Slide fork to fork removal notch in bottom bar of

carriage. See Figure 34. 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 top carriage bar. Move
carriage away from fork or use a lifting device to
move fork away from carriage.

37
Carriages Repair 4000 YRM 1405

1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME

Figure 34. Fork Removal

3. Remove four capscrews, washers, nuts, and load

backrest from carriage. See Figure 9. 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.
gloves when handling hydraulic oil. Thoroughly
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.

38
4000 YRM 1405 Carriages Repair

4. Disconnect and cap tube assemblies (8, NOTE: Make note of shims used to aid in reassembly.
Figure 35) from header hoses.
8. Remove capscrews, lockwashers, and shims
from integral sideshift carriage. See Figure 36.
5. Remove capscrews and washers and remove
lower hooks from retainer plates on inner frame.
9. Remove fork positioner from outer frame.
See Figure 36.
For procedures to repair the fork positioner
6. Install lifting eye in hole (7, Figure 36) on outer cylinder, see Cylinder Repair (Mast S/N
frame of integral sideshift carriage. Use a lifting A270-72, A551, A555, A559, A626, A627,
device, with a capacity of 62 kg (136 lb), to lift A751-52, B551, B555, B586-91, B749-54,
outer frame with fork positioner attached. C661-63, C665, D507-09, D515, D562-64, E509,
E564) 2100YRM1382 for procedures.
7. Disconnect relief tube assembly and hydraulic
hoses (open and close) from fork positioner. See
Figure 35.

NOTE: BACK (DRIVER'S) VIEW 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. INTEGRAL SIDESHIFT CYLINDER

Figure 35. Hydraulic Connections, Fork Positioner Cylinder

39
Carriages Repair 4000 YRM 1405

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 36. Fork Positioner Cylinder Removal

Clean and Inspect NOTE: The maximum number of shims per side is
five. The maximum difference in number of shims per
See Cylinder Repair (Mast S/N A270-72, A551, side is two. The maximum gap allowed before
A555, A559, A626, A627, A751-52, B551, B555, tightening capscrews is 0.50 mm (.020 in.).
B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100YRM1382 for cleaning and a. Measure gap at opposite side and determine
inspection procedures. the number of shims required.

Disassemble and Assemble b. Install shims on both sides of the fork

positioner assembly.
See Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, 2. Install second lockwasher and capscrew. Tighten
B586-91, B749-54, C661-63, C665, D507-09, D515, both capscrews to 65 N•m (50 lbf ft). See
D562-64, E509, E564) 2100YRM1382 to disassemble Figure 36.
and assemble the fork positioner cylinders.
3. Connect fork positioner hydraulic hoses to fork
Install positioner manifold. Tighten hoses to
21 N•m (186 lbf in). See Figure 35.
1. Place fork positioner cylinders onto outer frame.
Install lockwasher and capscrew on one side and 4. Thread fork positioner hydraulic hoses through
hand tighten capscrew. See Figure 36. Add shims hose guides. See Figure 35.
as follows:

40
4000 YRM 1405 Carriages Repair

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 38.

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 35. 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. See 3. Move fork positioner and check to ensure fork
Figure 37. carriers clear fork positioner relief tubes through
complete fork carrier cycle. See Figure 35.
9. Using a washer and capscrew, install lower hook
to retainer plates and tighten capscrews to 4. Install load backrest to sideshift carriage. Tighten
165 N•m (122 lbf ft). See Figure 36. capscrews to 195 N•m (144 lbf ft). See Figure 9.

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
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.

5. Install forks to outer fork carriers. Secure inner

fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to
35 N•m (25 lbf ft). See Figure 34.

6. Adjust fork positioner cylinders. See Cylinder

Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515,
1. RETAINER PLATES D562-64, E509, E564) 2100YRM1382 for
2. OUTER FRAME (FORK BAR) procedures.
3. INNER FRAME

Figure 37. Retainer Plates and Inner and Outer

Frame

41
Carriages Repair 4000 YRM 1405

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 38. Fork Positioner Hydraulic Hoses Adjustment

FORK POSITIONER CARRIAGE, LIFT

TRUCKS MANUFACTURED JUNE, 2018
AND AFTER
This section covers lift truck models ERP030-040VT
(G807), ESC030-40AD (C883), and ERP030-040VF
(A955) manufactured June, 2018 and after and
equipped with three-stage FFL mast with S/N C662.
NOTE: The fork positioner can be removed from the
integral sideshift carriage with integral sideshift
carriage on or off the mast. In the steps below, the fork
positioner is removed with integral sideshift carriage
on the mast. If integral sideshift carriage must be
removed from mast first, go to Integral Sideshift 1. OUTER FORK CARRIER
Carriage, Lift Trucks Manufactured Late June, 2018 for 2. CAPSCREW
3. SPACER BAR*
procedures. 4. INNER FORK CARRIER
NOTE: Depending on size and configuration of forks *Spacer bar used on 977 mm (38.5 in.) and
installed on lift truck, there may be a spacer bar 1067 mm (42 in.) class II carriages.
between inner and outer fork carriers. See Figure 39.
Figure 39. Fork Carrier Spacer Bar

42
4000 YRM 1405 Carriages Repair

Remove 2. Slide fork to fork removal notch in bottom bar of

1. Lower carriage and remove four capscrews from carriage. See Figure 40. Lower fork onto blocks
inner fork carriers. Slide inner fork carriers down so bottom hook of fork moves through fork
cylinder shell to remove forks. See Figure 40. removal notch. Lower carriage further so top hook
of fork is disengaged from top carriage bar. Move
carriage away from fork or use a lifting device to
WARNING move fork away from carriage.
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).

1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME

Figure 40. Fork Removal

3. Remove four capscrews, washers, nuts, and load

backrest from carriage. See Figure 9. WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resistant
WARNING
gloves when handling hydraulic oil. Thoroughly
Before disconnecting the hydraulic hoses, relieve wash oil from exposed areas of skin as soon as
the pressure in the hydraulic system. Serious possible.
injury can occur if pressure is not relieved from
hydraulic system prior to disconnecting hydraulic
hoses.

43
Carriages Repair 4000 YRM 1405

5. Remove capscrews and washers and remove

WARNING lower hooks from retainer plates on inner frame.
See Figure 42.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the oil. 6. Install lifting eye in hole (7, Figure 42) on outer
Never check for leaks by putting hands on frame of integral sideshift carriage. Use a lifting
hydraulic lines or components under pressure. device, with a capacity of 62 kg (136 lb), to lift
Hydraulic oil under pressure can be injected into outer frame with fork positioner attached.
the skin.
7. Disconnect relief tube assembly and hydraulic
hoses (open and close) from fork positioner. See
CAUTION Figure 41.
Protect the hydraulic system from dirt and
NOTE: Make note of shims used to aid in reassembly.
contaminants when servicing the hydraulic
system. 8. Remove capscrews, lockwashers, and shims
from integral sideshift carriage. See Figure 42.

9. Remove fork positioner from outer frame.

CAUTION
DO NOT bend tube assemblies during removal. For procedures to repair the fork positioner
cylinder, see Cylinder Repair (Mast S/N
NOTE: Tag all hydraulic hoses, lines, and fittings prior A270-72, A551, A555, A559, A626, A627,
to removal to aid in installation. A751-52, B551, B555, B586-91, B749-54,
4. Disconnect and cap tube assemblies (8, C661-63, C665, D507-09, D515, D562-64, E509,
Figure 41) from header hoses. E564) 2100YRM1382 .

44
4000 YRM 1405 Carriages Repair

NOTE: BACK (DRIVER'S) VIEW 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. INTEGRAL SIDESHIFT CYLINDER

Figure 41. Hydraulic Connections, Fork Positioner Cylinder

45
Carriages Repair 4000 YRM 1405

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 42. Fork Positioner Cylinder Removal

Clean and Inspect NOTE: The maximum number of shims per side is
five. The maximum difference in number of shims per
See Cylinder Repair (Mast S/N A270-72, A551, side is two. The maximum gap allowed before
A555, A559, A626, A627, A751-52, B551, B555, tightening capscrews is 0.50 mm (.020 in.).
B586-91, B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100YRM1382 for cleaning a. Measure gap at opposite side and determine
and inspection procedures. the number of shims required.

Disassemble and Assemble b. Install shims on both sides of the fork

positioner assembly.
See Cylinder Repair (Mast S/N A270-72, A551,
A555, A559, A626, A627, A751-52, B551, B555, 2. Install second lockwasher and capscrew. Tighten
B586-91, B749-54, C661-63, C665, D507-09, D515, both capscrews to 65 N•m (50 lbf ft). See
D562-64, E509, E564) 2100YRM1382 to disassemble Figure 42.
and assemble the fork positioner cylinders.
3. Connect fork positioner hydraulic hoses to fork
Install positioner manifold. Tighten hoses to
21 N•m (186 lbf in). See Figure 41.
1. Place fork positioner cylinders onto outer frame.
Install lockwasher and capscrew on one side and 4. Thread fork positioner hydraulic hoses through
hand tighten capscrew. See Figure 42. Add shims hose guides. See Figure 41.
as follows:

46
4000 YRM 1405 Carriages Repair

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 44.

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 41. 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. See 3. Move fork positioner and check to ensure fork
Figure 41. carriers clear fork positioner relief tubes through
complete fork carrier cycle. See Figure 41.
9. Using a washer and capscrew, install lower hook
to retainer plates and tighten capscrews to 4. Install load backrest to sideshift carriage. Tighten
165 N•m (122 lbf ft). See Figure 42. capscrews to 195 N•m (144 lbf ft). See Figure 9.

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
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.

5. Install forks to outer fork carriers. Secure inner

fork carriers to outer fork carriers using four
capscrews. Tighten capscrews to
35 N•m (25 lbf ft). See Figure 40.

6. Adjust fork positioner cylinders. See Cylinder

Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515,
1. RETAINER PLATES D562-64, E509, E564) 2100YRM1382 for
2. OUTER FRAME (FORK BAR) procedures.
3. INNER FRAME

Figure 43. Retainer Plates and Inner and Outer

Frame

47
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

1. LARGE HEX NUT 4. FORK POSITIONER HYDRAULIC HOSE (CLOSE)

2. SMALL HEX NUT 5. RELIEF TUBE ASSEMBLY
3. FORK POSITIONER HYDRAULIC HOSE (OPEN)

Figure 44. Fork Positioner Hydraulic Hoses Adjustment

Two-Stage Mast With Limited Free-Lift Repair

REMOVE NOTE: If the mast needs to be disassembled, remove
the forks and carriage. See the sections Fork
Replacement and Carriages Repair for procedures. If
WARNING only the main lift cylinders or tilt cylinders need to be
The mast is heavy. The mast can weigh repaired, the mast does not need to be removed from
approximately 907 kg (2000 lb). Make sure all the lift truck. See the section Cylinder Repair (Mast
lifting devices (hoists, cables, chains, slings, etc.) S/N A270-72, A551, A555, A559, A626, A627,
are suitable and of adequate capacity to lift the A751-52, B551, B555, B586-91, B749-54, C661-63,
mast. Serious injury can occur if the mast falls. C665, D507-09, D515, D562-64, E509, E564)
2100YRM1382 for procedures. For header hose
installation and adjustment, see the section Header
CAUTION Hose Installation and Adjustment.
Make sure all the mast weldments are fastened
together. Make sure the safety chains will not
damage the sheaves, tubing, or other parts of the
mast.

48
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

1. Fully lower all mast weldments. Tilt the mast fully

forward. Connect a crane or lifting device, with a
capacity of at least 907 kg (2000 lb), to all top CAUTION
crossmembers of the mast weldments using Disposal of lubricants and fluids must meet local
chains to support the mast in an upright position environmental regulations.
when the tilt cylinders are disconnected. See the
section Safety Procedures When Working Near 2. Position a drip pan with a capacity of
Mast. 21 liter (22.5 qt) under the area of the hydraulic
fittings.

3. ERP16-20VF (ERP30-40VF) (A955) and

WARNING
ERP15-20VT (ERP030-040VT) (G807) Models
Hydraulic oil is hot after system operation and can
Only - Remove the floor mat. Lift the floor plate
cause burns. DO NOT disconnect any hydraulic
up enough to disconnect the electrical connectors
hoses until the oil in the system has cooled.
from the accelerator pedal or Foot Directional
Completely lower forks to relieve hydraulic Control pedal, and remove floor plate with
pressure before disconnecting any hoses. accelerator pedal or Foot Directional Control still
attached. See Figure 45.

CAUTION
Protect the hydraulic system from dirt and
contaminants when disconnecting hydraulic hoses
from the mast. If hydraulic system becomes
contaminated, damage to hydraulic system can
occur.

49
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

Figure 45. Floor Plate and Accelerator Pedal, Remove

50
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 45.

NOTE: FLOOR MAT REMOVED FOR CLARITY. STANDARD ACCELERATOR PEDAL IS SHOWN. PROCE-
DURES TO REMOVE FLOOR PLATE WITH A FOOT DIRECTIONAL CONTROL PEDAL ARE THE SAME.
MODELS ERP16-20VF (ERP30-40VF) (A955) AND ERP15-20VT (ERP030-040VT) (G807) ONLY.

A. TOP VIEW B. BOTTOM VIEW

1. CAPSCREW 5. ACCELERATOR PEDAL MOUNTING PLATE

2. ACCELERATOR PEDAL 6. ACCELERATOR PEDAL POSITION SENSOR
3. FLOOR PLATE 7. ELECTRICAL CONNECTORS
4. PEDAL BASE 8. NUTS

4. ESC030-40AC (B883) and ESC030-40AD function mast and A, B, C, and D for four function
(C883) Models Only - Remove the hydraulic mast, to aid in reconnecting when installing the mast
compartment cover from the lift truck to access onto the lift truck. See Figure 48.
the mast hose connections.
5. Before loosening or removing hose clamps from
lower crossmember, mark hoses using a paint
NOTE: Perform Step 5 and Step 6 for lift truck models
pen or other permanent marking device. The
ERP15-20VT (ERP030-040VT) (G807) and
marks are used to reinstall hoses in the correct
ERP16-20VF (ERP30-40VF) (A955) manufactured
position. See Figure 46.
before February, 2016 and for lift truck models
ESC030-40AC (B883) and ESC030-40AD (C883) .
6. Loosen hose clamp, located just below the brake
NOTE: Before disconnecting any hydraulic hoses, be pedal, so that hoses are able to move within the
sure to tag each hose with a letter: A and B for three clamp without stretching. See Figure 46.

51
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

A. MARK HOSES HERE TO ENSURE HOSES ARE IN SAME POSITION WHEN TIGHTENING CLAMP.

1. HOSE CLAMP (LOWER CROSSMEMBER) 3. LEFT MAIN LIFT CYLINDER

2. CAPSCREW 4. RIGHT MAIN LIFT CYLINDER

Figure 46. Hose Marking, For Lift Truck Models Manufactured Before February, 2016 And For Lift Truck
Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ESC030-40AC (B883)
and ESC030-40AD (C883)

52
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

NOTE: Perform Step 7 for lift truck models

8. Remove the capscrew, special washer,
ERP15-20VT (G807) and ERP16-20VF (A955)
lockwasher external tooth, and rod end pin from
manufactured after February, 2016.
the tilt cylinder rod ends on the outer mast.
7. Tag and disconnect hydraulic hoses from mast. Remove tilt cylinder rod ends from outer mast.
See Figure 49. See Figure 47.

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

53
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

NOTE: MAST FOR LIFT TRUCK MODELS ERP15-20VT (ERP030-040VT) (G807) AND ERP16-20VF
(ERP30-40VF) (A955) MANUFACTURED BEFORE FEBRUARY, 2016 AND FOR LIFT TRUCK MODELS
ESC030-40AC (B883) AND ESC030-40AD (C883) SHOWN. TILT CYLINDER MOUNTING FOR LIFT TRUCK
MODELS ERP15-20VT (G807) AND ERP16-20VF (A955) MANUFACTURED AFTER FEBRUARY, 2016 IS SIMI-
LAR.

1. TILT CYLINDER ROD END 5. CAPSCREW

2. TILT CYLINDER SHELL 6. GREASE FITTING
3. SPECIAL WASHER 7. ROD END PIN
4. LOCK WASHER EXTERNAL TOOTH

Figure 47. Tilt Cylinder Mounting

54
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

9. Use lifting device and tilt the mast forward until

there is enough space for access to the third and
fourth function (if equipped) hose clamp and main
lift supply hose connections.

10. Disconnect the third and fourth (if equipped)

function hoses.
See Figure 48 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 49 for lift truck models
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016

NOTE: Perform Step 11 for lift truck models

ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955) manufactured
before February, 2016 and for lift truck models
ESC030-40AC (B883) and ESC030-40AD (C883) .
11. Remove the hose clamps from the lower
crossmember. See Figure 46.

12. Disconnect the main lift supply hose.

See Figure 48 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 49 for lift truck models
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016
Figure 48. Mast Hydraulic Hose Removal, Lift
Truck Models Manufactured Before February, 2016
And For Lift Truck Models ERP15-20VT
(ERP030-040VT) (G807) and ERP16-20VF
(ERP30-40VF) (A955) ESC030-40AC (B883) and
ESC030-40AD (C883)

55
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

Legend for Figure 48.

NOTE: BACK VIEW OF MAST SHOWN.

A. HEADER HOSE
B. HEADER HOSE
C. HEADER HOSE
D. HEADER HOSE

1. FOURTH FUNCTION HOSE

2. LIFT CHAIN
3. CHAIN ANCHOR
4. THIRD FUNCTION HOSES
5. MAIN LIFT SUPPLY HOSE
6. LOWERING CONTROL VALVE
7. HOSE CONNECTIONS

NOTE: BACK VIEW OF MAST SHOWN.

A. HEADER HOSE
B. HEADER HOSE
C. HEADER HOSE
D. HEADER HOSE

1. FOURTH FUNCTION HOSE

2. LIFT CHAIN
3. CHAIN ANCHOR
4. THIRD FUNCTION HOSES
5. MAIN LIFT SUPPLY HOSE
6. LOWERING CONTROL VALVE
7. HOSE CONNECTIONS

Figure 49. Mast Hydraulic Hose Removal, Lift

Truck Models Manufactured After February, 2016
ERP15-20VT (G807) and ERP16-20VF (A955)

13. Move disconnected mast hoses underneath the

mast.

14. Use the lifting device and move mast back into
vertical position.

56
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

Figure 50. Two-Stage, Limited Free-Lift (LFL) Mast, Lift Truck Models Manufactured Before February, 2016
And For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF)
(A955) ESC030-40AC (B883) and ESC030-40AD (C883)

57
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

Legend for Figure 50.

A. HOSE SHEAVE ASSEMBLY B. CHAIN SHEAVE ASSEMBLY

1. SNAP RING 14. OUTER MAST

2. SHIM 15. CHAIN ANCHOR
3. LOAD ROLLER 16. COTTER PIN
4. INNER MAST 17. CHAIN ANCHOR PIN
5. LOWERING CONTROL VALVE 18. O-RING
6. LOWERING CONTROL VALVE MOUNTING 19. STRIP BEARING
BRACKET 20. CHAIN SHEAVE
7. LOWERING CONTROL VALVE HOUSING 21. BEARING
8. SPRING AND LOWERING CONTROL VALVE 22. LEFT MAIN LIFT CYLINDER
WASHER 23. HOSE GUARD
9. RIGHT MAIN LIFT CYLINDER 24. STUBSHAFT
10. NUT 25. HOSE SHEAVE
11. WASHER 26. SPECIAL WASHER
12. SPACER
13. CAPSCREW

58
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

Figure 51. Two-Stage, Limited Free-Lift (LFL) Mast, Lift Truck Models Manufactured After February, 2016
ERP15-20VT (G807) and ERP16-20VF (A955)

59
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

Legend for Figure 51.

A. HOSE SHEAVE ASSEMBLY B. CHAIN SHEAVE ASSEMBLY

1. SNAP RING 14. OUTER MAST

2. SHIM 15. CHAIN ANCHOR
3. LOAD ROLLER 16. COTTER PIN
4. INNER MAST 17. CHAIN ANCHOR PIN
5. LOWERING CONTROL VALVE 18. O-RING
6. LOWERING CONTROL VALVE MOUNTING 19. STRIP BEARING
BRACKET 20. CHAIN SHEAVE
7. LOWERING CONTROL VALVE HOUSING 21. BEARING
8. SPRING AND LOWERING CONTROL VALVE 22. LEFT MAIN LIFT CYLINDER
WASHER 23. HOSE GUARD
9. RIGHT MAIN LIFT CYLINDER 24. STUBSHAFT
10. NUT 25. HOSE SHEAVE
11. WASHER 26. SPECIAL WASHER
12. SPACER
13. CAPSCREW

NOTE: Make a note of each shim arrangement. The NOTE: When placing mast on wooden beams, do not
shim arrangement will be approximately the same lay mast with main lift cylinders resting on wooden
during assembly. beams.
15. Remove the bolts that hold the retainer caps to 16. Use lifting device or crane to lift mast assembly
the mast mount stubshafts. Remove the shims from lift truck. Position the outer mast across
and bushings. See Figure 52. wooden beams on the floor with the carriage side
up.

DISASSEMBLE

WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the oil.

CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
1. RETAINER CAP
2. BOLTS NOTE: If only the lift cylinders need to be removed
3. SHIM and repaired, see Cylinder Repair (Mast S/N
4. BUSHING A270-72, A551, A555, A559, A626, A627, A751-52,
5. MAST MOUNTING STUBSHAFT B551, B555, B586-91, B749-54, C661-63, C665,
6. GREASE FITTING D507-09, D515, D562-64, E509, E564) 2100YRM1382
for procedures. For header hose installation and
Figure 52. Mast Mounting
adjustment, see the section Header Hose Installation
and Adjustment.

60
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

1. Clean the area around the hydraulic fittings for 4. Slide the inner mast weldment from the outer
the lift cylinders. Remove the cylinder restraint mast weldment approximately 30 cm (12 in.) to
brackets at the top of the outer mast. Disconnect disengage the main lift cylinders from the inner
the fittings at the lift cylinders and put caps on the mast weldment. Remove the main lift cylinders
open lines. from the outer mast weldment.
See Figure 50 for lift truck models
5. Remove the lowering control valve housing for
• ERP15-20VT (ERP030-040VT) (G807) and the lowering control valve from the outer mast.
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016 NOTE: Make a note of each shim arrangement on
• ESC030-40AC (B883) and ESC030-40AD load rollers. The shim arrangement will be
(C883) approximately the same during assembly.
See Figure 51 for lift truck models 6. Remove the snap rings, shims, and load rollers
• ERP15-20VT (G807) and ERP16-20VF (A955) from the bottom of the inner mast.
manufactured after February, 2016

2. Remove the header hoses. WARNING

Be careful when removing or installing snap rings
on the load rollers. These snap rings can come
WARNING loose during removal or installation with enough
Be careful when removing or installing snap rings. force to cause an injury. Always use the correct
These snap rings can come loose during removal snap ring pliers and wear eye and face protection
or installation with enough force to cause an when removing and installing snap rings onto load
injury. Always use the correct snap ring pliers, and rollers.
wear eye and face protection during removal or
installation. 7. Remove snap rings, shims, and load rollers from
top of outer mast.
3. Remove the capscrew, washers, spacer, and nut See Figure 50 for lift truck models
at the mount near the top of each main lift
cylinder. Remove the snap rings, washers, and • ERP15-20VT (ERP030-040VT) (G807) and
shims from the top of each main lift cylinder. ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
Disconnect the main lift chains at the chain
anchors. • ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 50 for lift truck models
See Figure 51 for lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955) • ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured before February, 2016 manufactured after February, 2016
• ESC030-40AC (B883) and ESC030-40AD 8. Remove strip bearings from top of outer mast.
(C883)
See Figure 53.
See Figure 51 for lift truck models
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016

WARNING
The mast weldments can slide when the mast is
moved. A weldment that slides can cause serious
injury.

61
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

Figure 54. Mast Disassembly

10. Remove the hose and chain sheaves from inner

mast and disassemble them as necessary for
1. STRIP BEARING cleaning and repair.
2. SHIMS See Figure 50 for lift truck models
3. TOP OF OUTER MAST
4. O-RING • ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
Figure 53. Strip Bearings manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
WARNING
See Figure 51 for lift truck models
The mast is heavy and can weigh approximately
907 kg (2000 lb). Make sure all lifting devices • ERP15-20VT (G807) and ERP16-20VF (A955)
(hoists, cables, chains, slings, etc.) are suitable manufactured after February, 2016
and of adequate capacity to lift the mast.
CLEAN AND INSPECT
NOTE: If the outer mast is being replaced, copy the
part number and date code information from the old
CAUTION
channel and stamp that information on the channel of
the new outer mast with the letter R at the end to DO NOT use steam or high-pressure water to clean
indicate that it has been replaced. the load rollers or the lift chains. Steam and high-
pressure water can remove the lubrication from
9. Slide the inner mast weldment halfway out of the the bearings in the load rollers. Water in the
top of the outer mast weldment. Connect a crane bearings of the sheaves and the link pins of chains
[the capacity of the crane must be at least can also shorten the service life of these parts.
907 kg (2000 lb)] to the center of the inner mast
weldment. See Figure 54. Slide the inner mast 1. Inspect chain sheaves and load rollers for wear or
weldment out of the outer mast weldment until the damage. DO NOT use steam to clean lift chain
mast stub shafts of the inner mast weldment are sheaves or load rollers. The bearings in the
in the notches of the outer channels. Remove the sheaves and load rollers are sealed and
inner mast weldment from the outer mast lubricated.
weldment.

62
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

NOTE: The chains must be inspected in the area of

WARNING chain that passes over the chain sheave during the
Cleaning solvents may be flammable and toxic and first portion of a lift. These links will show maximum
can cause severe skin irritation. When using wear.
commercial cleaning solvents, always comply with
3. Inspect the lift chains for wear and damage. A lift
solvent manufacturer's recommended safety
chain becomes longer when it is worn. If a chain
precautions.
is 3% longer than a new lift chain, the lift chain
must be replaced.

WARNING 4. If a chain scale is available (Yale Part No.

Compressed air can move particles so that they 580037684) , check lift chains as shown in
cause injury to the user or to other personnel. Figure 55. If a chain scale is not available
Make sure that the path of the compressed air is measure 20 links of chain. Measure from the
away from all personnel. Wear protective goggles center of a pin to the center of another pin 20
or a face shield to prevent injury to the eyes. pitches away. Compare the length with the chart
in Figure 55. Replace chain if the length of 20
2. Clean the lift chains by soaking in solvent for 30 links of the worn section is more than the
minutes to remove all dirt and grease. Hang lift maximum wear limit.
chains up and remove solvent using compressed
air.

WARNING
Never replace only the worn section of a chain.
Replace the complete chain. Never replace only
one chain of a chain pair. Replace both chains.
Damage to the lift truck and serious injury can
occur if lift chains are not replaced correctly.

63
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE
(YALE PART NO. 580037684) .

Pitch
Total length of 20 links (pitch) of Wear Limit The maximum length
new chain of 20 links

12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE

Figure 55. Lift Chains Check

5. Lubricate lift chains by soaking them in SAE 30

engine oil for 30 minutes. Hang chains over a drip WARNING
pan for one hour to remove excess oil.
Steam can cause serious burns. Wear protective
6. Inspect chain anchors, pins, and cotter pins for clothing, gloves, and eye protection. Never expose
damage. Replace if damaged. your skin to steam.

7. Clean the mast weldments with steam or solvent.

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

64
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

2. Connect a lifting device to the center of inner

WARNING mast (see Figure 54). Fit the stub shafts through
Improper welding procedures can damage the notches in the outer mast. Slide inner mast into
structure of the mast or cause incorrect function the outer mast so stub shafts are seen at the top
of the mast which can result in serious injury to and bottom of the weldments.
personnel. Consult your Yale lift truck dealer for See Figure 50 for lift truck models
more information before welding on the mast.
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
8. Inspect the sliding surfaces for wear or damage.
manufactured before February, 2016
Inspect the load roller contact surfaces for wear
or damage. Inspect all welds for cracks. • ESC030-40AC (B883) and ESC030-40AD
(C883)
9. Remove the bushings and shims from the stub See Figure 51 for lift truck models
shafts. See Figure 52. Inspect the bushings,
• ERP15-20VT (G807) and ERP16-20VF (A955)
shims and retainer caps for wear or damage. See manufactured after February, 2016
the Parts Manual if any part needs to be
replaced. NOTE: The shims for the load rollers keep the
weldments parallel and provide correct clearance.
ASSEMBLE During assembly, the location of the shims will be
NOTE: When the mast has header hoses installed, approximately the same as they were before
see the procedures in the section Header Hose disassembly. Check clearance and adjust shims for
Installation and Adjustment. wear or changes because of repairs. Strip bearings
are also adjusted by using shims.
1. Install snap rings, chain sheave and bearing onto
stubshaft on top of inner mast. Apply thin coat of 3. Install the strip bearings, O-rings, and the shims
multipurpose grease with 2 to 4% molybdenum to top of outer mast. (see Figure 53.) Apply thin
disulfide to hose sheave stubshafts. coat of multipurpose grease with 2 to 4%
molybdenum disulfide to bearing surface. Check
Install special washers, spacer, hose sheave, the clearance of the strip bearings as described in
stubshaft weldment, washer, and capscrew. Mast Adjustments.
Tighten capscrew to 66 N•m (49 lbf ft).
See Figure 50 for lift truck models 4. Install the load rollers, snap rings, and shims on
both top of outer mast and bottom of inner mast.
• ERP15-20VT (ERP030-040VT) (G807) and
Check the clearance of the load rollers and strip
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016 bearings as described in Mast Adjustments.

• ESC030-40AC (B883) and ESC030-40AD 5. Install lowering control valve and lowering control
(C883) valve housing to the outer mast. Tighten nut to
See Figure 51 for lift truck models 18 N•m (159 lbf in).
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016 6. To install the main lift cylinders, push the inner
mast to engage the rods of the lift cylinders.
Install shims, washers, and snap rings to top of
WARNING main lift cylinders.
The mast is heavy. The mast can weigh 7. Install the capscrew, washers, spacer, and nut at
approximately 907 kg (2000 lb). Make sure all the mount near the top of each main lift cylinder.
lifting devices (hoists, cables, chains, slings, etc.) Tighten capscrew to 40 N•m (29.5 lbf ft). Install
are suitable and of adequate capacity to lift the the snap rings, washers, and shims from the top
mast. of each main lift cylinder. Connect the main lift
chains at the chain anchors.
See Figure 50 for lift truck models

65
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

• ERP15-20VT (ERP030-040VT) (G807) and See Figure 48 for the following lift truck models
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016 • ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
• ESC030-40AC (B883) and ESC030-40AD manufactured before February, 2016
(C883)
• ESC030-40AC (B883) and ESC030-40AD
See Figure 51 for lift truck models (C883)
• ERP15-20VT (G807) and ERP16-20VF (A955) See Figure 49 for lift truck models
manufactured after February, 2016
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016
INSTALL
1. Lubricate the bushings with chassis lube and NOTE: Perform Step 6 for lift truck models
install them onto the stub shafts at the bottom of ERP15-20VT (ERP030-040VT) (G807) and
the outer mast weldment. See Figure 52. ERP16-20VF (ERP30-40VF) (A955) manufactured
before February, 2016 and for lift truck models
ESC030-40AC (B883) and ESC030-40AD (C883) .
WARNING 6. Install hose clamps to lower crossmember. Be
The mast is heavy. The mast can weigh sure to match clamps to marks on hoses made
approximately 907 kg (2000 lb). Make sure all during removal. See Figure 46. Tighten clamp
lifting devices (hoists, cables, chains, slings, etc.) socket head capscrews to 11 N•m (97 lbf in).
are suitable and of adequate capacity to lift the
mast. Serious injury can occur if the mast falls.
WARNING
2. Connect a lifting device to the top of the mast Use a pry bar, NOT your fingers, to align the tilt
using chains. Make sure all mast uprights are cylinder clevises with the outer mast. The tilt
fastened together. Make sure chains will not cylinder or mast can shift and cause serious
damaged chain sheaves, tubing, or other parts of injury.
the mast.
7. Apply multipurpose grease with 2 to 4%
3. Use the lifting device and install the mast into the molybdenum disulfide to rod end pin and connect
transmission housing mounts. Apply Loctite™ tilt cylinders to mast using rod end pin, capscrew,
#242 adhesive sealant to bolt threads. Install the special washer, and lockwasher external tooth.
bolts, shims and retainer caps. Tighten the bolts Tighten capscrews to 38 N•m (28 lbf ft). See
in a diametric pattern to 24 N•m (212 lbf in). Figure 47.
NOTE: Use lifting device and tilt mast forward until 8. ERP16-20VF (ERP30-40VF) (A955) and
there is enough space for access to the third, fourth ERP15-20VT (ERP030-040VT) (G807) Models
and main lift supply hose connections. Only - Connect the accelerator pedal or Foot
4. Connect the main lift supply hose. Directional Control pedal, and install floor plate
and floor mat. See Figure 45.
See Figure 48 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and 9. ESC030-40AC (B883) and ESC030-40AD
ERP16-20VF (ERP30-40VF) (A955) (C883) Models Only - Install the hydraulic
manufactured before February, 2016 compartment cover to the lift truck as removed.
• ESC030-40AC (B883) and ESC030-40AD
(C883) 10. Install the carriage as described in Carriages
Repair and install the forks as shown in the
See Figure 49 for lift truck models
section Fork Replacement.
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016

5. Connect the third and fourth (if equipped) function

hoses.

66
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

11. Check the tilt cylinder adjustment. See the service

manual Cylinder Repair (Mast S/N A270-72,
A551, A555, A559, A626, A627, A751-52, B551,
B555, B586-91, B749-54, C661-63, C665,
D507-09, D515, D562-64, E509, E564)
2100YRM1382 for procedures. Operate the mast
and check for leaks and check to ensure mast is
operating correctly. Check lift chains as described
in the section Lift Chains Adjustment.

NOTE: Before checking for mast side kicking, the

mast must be fully assembled to include the carriage,
forks, load backrest and any attachments if the lift
truck is equipped with one. A. UPPER LOAD ROLLERS
12. Raise the mast, without a load to its full height B. LOWER LOAD ROLLERS
and check for side kicking. Mast side kicking is
where the mast, without a load, moves either to 1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
the right or left as it is being raised. If the mast is 3. LOAD ROLLER
side kicking, see the Mast Adjustments section for
procedures to correct mast side kicking. Figure 56. Mast Lubrication

13. Lubricate the sliding surfaces and load roller

surfaces along the full length of the channels as
shown in Figure 56. Apply lubricant only to
surfaces indicated in Figure 56.

67
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

HEADER HOSE INSTALLATION AND Before installing the header hoses, make sure you
ADJUSTMENT know the lift height of the mast. The tension on the
header hoses is adjusted according to lift height. The
Install lift height is on the Nameplate of the lift truck and on
the right side of the outer mast.
WARNING NOTE: This procedure is for the four-function option.
Always wear the proper protective equipment The three-function option will have hoses A and B
including eye protection and petroleum-resistant only.
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as NOTE: The carriage height must be correct before the
possible. header hoses can be adjusted. See Lift Chains
Adjustment for the carriage adjustment procedure.
1. Mark each hose with a single letter: A, B, C, and
WARNING D.
Never check for leaks by putting hands on See Figure 57 for the following lift truck models
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into • ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
the skin.
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
WARNING
See Figure 58 for lift truck models
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this • ERP15-20VT (G807) and ERP16-20VF (A955)
section. manufactured after February, 2016

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

68
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

Figure 57. Header Hose Alignment for Two-Stage Limited Free-Lift Mast, For Lift Truck Models
Manufactured Before February, 2016 And For Lift Truck Models .ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955) ESC030-40AC (B883) and ESC030-40AD (C883)

69
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

Legend for Figure 57.

NOTE: REAR VIEW SHOWN. PARTS OF THE MAST AND CARRIAGE OMITTED FOR CLARITY.

A. HOSE C. HOSE
B. HOSE D. HOSE

NOTE: REAR VIEW SHOWN. PARTS OF THE MAST AND CARRIAGE OMITTED FOR CLARITY.

A. HOSE C. HOSE
B. HOSE D. HOSE

Figure 58. Header Hose Alignment for Two-Stage Limited Free-Lift Mast, For Lift Truck Models
Manufactured After February, 2016ERP15-20VT (G807) and ERP16-20VF (A955)

70
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

2. Clamp the end of the hose (the smaller fitting) outer mast channel. This mark will be used to
that attaches to the carriage in a vise (DO NOT pretension the header hoses during installation. See
clamp on the threads), and pull on the other end Figure 59 and Table 3.
until the hose is straight. DO NOT apply enough
3. Place a mark on all the hoses at dimension E. All
force to stretch the hose. See Figure 59.
measurements are made from the carriage end of
the hose (the smaller fitting). See Figure 60.
NOTE: Dimension E is determined by the height of
outer mast channel from the ground and the length of

71
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE

Figure 59. Header Hose Measurement for Two-Stage Limited Free-Lift Mast

72
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

Table 3. Two-Stage Limited Free-Lift (LFL) Hose Dimensions

Channel Length
Lift Height Dimension "E"
(Reference)
mm in. mm mm in.
2992 117.8 1890 2160 85.0
3192 125.7 1990 2258 89.0
3392 133.5 2090 2357 92.8
3892 153.2 2440 2702 106.4
4392 172.9 2690 2948 116.1
4892 192.6 3040 3293 129.6

4. Lift carriage off the ground approximately 6. Install hoses to the carriage brackets with the
76 mm (3 in.). Place blocks under carriage for clamps and tighten capscrews to
support. 18 N•m (13 lbf ft). See Figure 60.

5. Install carriage brackets to carriage. Tighten

capscrews to 18 N•m (13 lbf ft). See Figure 60.

73
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

Figure 60. Header Hoses for Two-Stage Limited Free-Lift Mast

74
4000 YRM 1405 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 60.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP

1. SPECIAL WASHER 9. NUT

2. SPACER 10. HOSE BRACKET
3. HOSE SHEAVE 11. CLAMP
4. STUBSHAFT 12. HOSES
5. LOCKWASHER 13. CARRIAGE
6. CAPSCREW 14. CARRIAGE BRACKET
7. BAR 15. CARRIAGE BRACKET MOUNTING CAPSCREW
8. SOCKET HEAD CAPSCREWS

7. Apply a thin coat of multipurpose grease with 9. Put the clamps over the hoses and attach the
molybdenum disulfide to hose sheave stubshafts clamps to the upper brackets. DO NOT tighten
before installing hose sheaves. Place the hoses the hardware.
at the location of the hose sheave.
NOTE: To make the alignment of dimension E easier,
8. The sheave(s) and stub shafts must be use a crane with a capacity of at least
assembled, and the hose(s) must be routed onto 907.2 kg (2000 lb) to raise the carriage high enough to
the sheave(s) before the hose(s) are attached to install a safety chain. See Figure 61.
the mast. Tighten the hose clamp hardware to
10. Align mark E at the bottom of the clamps. Tighten
8 N•m (71 lbf in) and the sheave assembly
the hardware to 8 N•m (71 lbf in). Refer to
capscrews to 66 N•m (49 lbf ft). See Figure 60.
Figure 60.
Install clamps to main lift cylinders. Tighten
capscrews and nuts to 25 N•m (221 lbf in).

75
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1405

1. HOOK 2. SHACKLE

Figure 61. Chaining the Carriage (LFL)

11. Connect the header hoses to the truck hoses. 4. Tighten strap clamps at the bracket weldment.

12. Use the rubber clamps and hose clamps to attach 5. Cycle the mast a few times to ensure proper
the hoses to the main lift cylinders and just below tracking of hoses.
the middle crossmember on the outer mast. DO
NOT allow the hoses to stretch or fold while tilting 6. Secure hose assemblies to main lift cylinders with
the mast fully forward and backward. hose clamp and screw clamp.

13. With no load on the forks, check the header hose 7. If the tension of the hoses is incorrect, loosen the
adjustment by operating the mast through the full clamps and pull the hoses down (if too loose) or
lift cycle two times. push the hoses up (if too tight), half the width of
the clamp 15.0 mm (0.6 in.). Re-tighten the
Adjust hardware to 8 N•m (71 lbf in).
When properly adjusted, the hoses will not be so tight 8. With no load on the forks, check the header hose
that they compress when they pass over the sheaves, adjustment by operating the mast through the full
nor will they be so loose that they touch the load lift cycle two times. When properly adjusted, the
backrest or any crossmember that is next to a sheave. hoses will not be so tight that they compress
when they pass over the sheaves nor will they be
1. Cap off hoses when attachments have been so loose that they touch the load backrest or any
removed. crossmember that is next to a sheave. If
necessary, repeat until the hoses are properly
2. Check that hoses and cables are routed properly.
adjusted.
3. Slowly raise the main cylinders to take up slack in
the lift chains.

76
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Two-Stage Mast With Full Free-Lift Repair

REMOVE
WARNING
Hydraulic oil is hot after system operation and can
WARNING
cause burns. DO NOT disconnect any hydraulic
The mast is heavy. The mast can weigh hoses until the oil in the system has cooled.
approximately 907 kg (2000 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.) Completely lower forks to relieve hydraulic
are suitable and of adequate capacity to lift the pressure before disconnecting any hoses.
mast. Serious injury can occur if the mast falls.

CAUTION
CAUTION Protect the hydraulic system from dirt and
Make sure all the mast weldments are fastened contaminants when disconnecting hydraulic hoses
together. Make sure the safety chains will not from the mast. If hydraulic system becomes
damage the sheaves, tubing, or other parts of the contaminated, damage to hydraulic system can
mast. occur.

NOTE: If the mast needs to be disassembled, remove

the forks and carriage. See the sections Fork CAUTION
Replacement and Carriages Repair for procedures. If Disposal of lubricants and fluids must meet local
only the main lift cylinders, tilt cylinders, or free-lift environmental regulations.
cylinder needs to be repaired, the mast does not need
to be removed from the lift truck. See the section 2. Position a drip pan with a capacity of
Cylinder Repair (Mast S/N A270-72, A551, A555, 21 liter (22.5 qt) under the area of the hydraulic
A559, A626, A627, A751-52, B551, B555, B586-91, fittings.
B749-54, C661-63, C665, D507-09, D515, D562-64,
E509, E564) 2100YRM1382 for procedures. For 3. ERP16-20VF (ERP30-40VF) (A955) and
header hose installation and adjustment, see the ERP15-20VT (ERP030-040VT) (G807) Models
section Header Hose Installation and Adjustment. Only - Remove the floor mat. Lift the floor plate
up enough to disconnect the electrical connectors
1. Fully lower all mast weldments. Tilt the mast fully
from the accelerator pedal or Foot Directional
forward. Connect a crane with a capacity of at
Control pedal, and remove floor plate with
least 907 kg (2000 lb) to all top crossmembers of
accelerator pedal or Foot Directional Control still
the mast weldments using chains to support the
attached. See Figure 62.
mast in an upright position when the tilt cylinders
are disconnected. See the section Safety
Procedures When Working Near Mast.

77
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 62. Floor Plate and Accelerator Pedal, Remove

78
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 62.

NOTE: FLOOR MAT REMOVED FOR CLARITY. STANDARD ACCELERATOR PEDAL IS SHOWN. PROCE-
DURES TO REMOVE FLOOR PLATE WITH A FOOT DIRECTIONAL CONTROL PEDAL ARE THE SAME.
MODELS ERP16-20VF (ERP30-40VF) (A955) AND ERP15-20VT (ERP030-040VT) (G807) ONLY.

A. TOP VIEW B. BOTTOM VIEW

1. CAPSCREW 5. ACCELERATOR PEDAL MOUNTING PLATE

2. ACCELERATOR PEDAL 6. ACCELERATOR PEDAL POSITION SENSOR
3. FLOOR PLATE 7. ELECTRICAL CONNECTORS
4. PEDAL BASE 8. NUTS

4. ESC030-40AC (B883) and ESC030-40AD 6. Loosen hose clamp, located just below the brake
(C883) Models Only - Remove the hydraulic pedal, so that hoses are able to move within the
compartment cover from the lift truck to access clamp. See Figure 63.
the mast hose connections.
NOTE: Perform Step 7 for lift truck models
NOTE: Perform Step 5 and Step 6 for lift truck models ERP15-20VT (G807) and ERP16-20VF (A955)
ERP15-20VT (ERP030-040VT) (G807) and manufactured after February, 2016.
ERP16-20VF (ERP30-40VF) (A955) manufactured
NOTE: Before disconnecting any hydraulic hoses, be
before February, 2016 and for lift truck models
sure to tag each hose with a letter: A and B for three
ESC030-40AC (B883) and ESC030-40AD (C883) .
function mast and A, B, C, and D for four function
NOTE: Before disconnecting any hydraulic hoses, be mast, to aid in reconnecting when installing the mast
sure to tag each hose with a letter: A and B for three onto the lift truck. See Figure 66.
function mast and A, B, C, and D for four function
7. Tag and disconnect hydraulic hoses from mast.
mast, to aid in reconnecting when installing the mast
See Figure 66.
onto the lift truck. See Figure 65.
5. Before loosening or removing hose clamps from
lower crossmember, mark hoses using a paint
pen or other permanent marking device. The
marks are used to reinstall hoses in the correct
position. See Figure 63.

79
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

A. MARK HOSES HERE TO ENSURE HOSES AND CLAMP ARE IN SAME POSITION WHEN TIGHTENING
CLAMP.

1. HOSE CLAMP (LOWER CROSSMEMBER) 3. LEFT MAIN LIFT CYLINDER

2. CAPSCREW 4. RIGHT MAIN LIFT CYLINDER

Figure 63. Hose Marking, For Lift Truck Models Manufactured Before February, 2016 And For Lift Truck
Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ESC030-40AC (B883)
and ESC030-40AD (C883)

8. Remove the capscrew, special washer, external

WARNING tooth lockwasher, and rod end pin from the tilt
Use a driver, NOT your fingers, to push the anchor cylinder rod ends on the outer mast. Remove tilt
pins from the clevises on the tilt cylinders. The cylinder rod ends from outer mast. See Figure 64.
cylinder or mast can move and cause serious
injury.

80
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

NOTE: MAST FOR LIFT TRUCK MODELS ERP15-20VT (ERP030-040VT) (G807) AND ERP16-20VF
(ERP30-40VF) (A955) MANUFACTURED BEFORE FEBRUARY, 2016 AND FOR LIFT TRUCK MODELS
ESC030-40AC (B883) AND ESC030-40AD (C883) SHOWN. TILT CYLINDER MOUNTING FOR LIFT TRUCK
MODELS ERP15-20VT (G807) AND ERP16-20VF (A955) MANUFACTURED AFTER FEBRUARY, 2016 IS SIMI-
LAR.

1. TILT CYLINDER ROD END 5. CAPSCREW

2. TILT CYLINDER SHELL 6. GREASE FITTING
3. SPECIAL WASHER 7. ROD END PIN
4. LOCK WASHER EXTERNAL TOOTH

Figure 64. Tilt Cylinder Mounting

81
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

9. Use lifting device and tilt the mast forward until

there is enough space for access to the third and
fourth function (if equipped) header hose clamps
and main lift supply hose connections.

10. Disconnect the third and fourth (if equipped)

function hoses.
See Figure 65 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 66 for lift truck models
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016

NOTE: Perform Step 11 for lift truck models

ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955) manufactured
before February, 2016 and for lift truck models
ESC030-40AC (B883) and ESC030-40AD (C883) .
11. Remove the hose clamps from the lower
crossmember. See Figure 63.

12. Disconnect the main lift supply hose.

See Figure 65 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955) NOTE: BACK VIEW OF MAST SHOWN.
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD A. HEADER HOSE
(C883) B. HEADER HOSE
C. HEADER HOSE
See Figure 66 for lift truck models D. HEADER HOSE
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016 1. FOURTH FUNCTION HOSES
2. THIRD FUNCTION HOSES
3. LIFT CHAIN
4. CHAIN ANCHOR
5. FULL FREE-LIFT SUPPLY TUBE
6. MAIN LIFT SUPPLY HOSE
7. LOWERING CONTROL VALVE

Figure 65. Mast Hydraulic Hose Removal, Lift

Truck Models manufactured before February, 2016
and for lift truck models ERP15-20VT
(ERP030-040VT) (G807) and ERP16-20VF
(ERP30-40VF) (A955) ESC030-40AC (B883) and
ESC030-40AD (C883)

82
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 66.

NOTE: BACK VIEW OF MAST SHOWN.

A. HEADER HOSE
B. HEADER HOSE
C. HEADER HOSE
D. HEADER HOSE

1. FOURTH FUNCTION HOSES

2. THIRD FUNCTION HOSES
3. LIFT CHAIN
4. CHAIN ANCHOR
5. FULL FREE-LIFT SUPPLY TUBE
6. MAIN LIFT SUPPLY HOSE
7. LOWERING CONTROL VALVE

13. Move disconnected mast hoses underneath the

mast.

14. Use the lifting device and move mast back into
vertical position.

Figure 66. Mast Hydraulic Hose Removal, Lift

Truck Models Manufactured After February,
2016ERP15-20VT (G807) and ERP16-20VF (A955)

83
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 67. Two-Stage, Full Free-Lift (FFL) Mast, For Lift Truck Models manufactured before February, 2016
and for lift truck models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF)
(A955) ESC030-40AC (B883) and ESC030-40AD (C883)

84
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 67.

NOTE: REAR VIEW FROM RIGHT SIDE SHOWN.

A. INNER MAST USED ON LIFT TRUCKS MANUFACTURED AFTER JULY, 2012.

1. CAPSCREW 16. LOWERING CONTROL VALVE

2. WASHER 17. LOWERING CONTROL VALVE HOUSING
3. NUT 18. NUT
4. FREE-LIFT CYLINDER BRACKET 19. LOWERING CONTROL VALVE MOUNTING
5. CHAIN GUARD BRACKET BRACKET
6. CROSSHEAD 20. RIGHT MAIN LIFT CYLINDER
7. FREE-LIFT CHAIN 21. LEFT MAIN LIFT CYLINDER
8. FREE-LIFT CYLINDER 22. STRIP BEARING
9. VELOCITY FUSE 23. O-RING
10. FREE-LIFT SUPPLY TUBE 24. SHIM(S)
11. SNAP RING 25. SPACER
12. SHIM 26. OUTER MAST
13. LOAD ROLLER 27. HYDRAULIC FITTING
14. INNER MAST 28. CHAIN ANCHOR
15. LOWER CONTROL VALVE HOSE 29. PLATES

85
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

NOTE: REAR VIEW FROM RIGHT SIDE SHOWN.

1. CAPSCREW 16. LOWERING CONTROL VALVE

2. WASHER 17. LOWERING CONTROL VALVE HOUSING
3. NUT 18. NUT
4. FREE-LIFT CYLINDER BRACKET 19. LOWERING CONTROL VALVE MOUNTING
5. CHAIN GUARD BRACKET BRACKET
6. CROSSHEAD 20. RIGHT MAIN LIFT CYLINDER
7. FREE-LIFT CHAIN 21. LEFT MAIN LIFT CYLINDER
8. FREE-LIFT CYLINDER 22. STRIP BEARING
9. VELOCITY FUSE 23. O-RING
10. FREE-LIFT SUPPLY TUBE 24. SHIM(S)
11. SNAP RING 25. SPACER
12. SHIM 26. OUTER MAST
13. LOAD ROLLER 27. HYDRAULIC FITTING
14. INNER MAST 28. CHAIN ANCHOR
15. LOWER CONTROL VALVE HOSE 29. PLATES

Figure 68. Two-Stage, Full Free-Lift (FFL) Mast, For Lift Truck Models Manufactured After February,
2016ERP15-20VT (G807) and ERP16-20VF (A955)

86
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

NOTE: Make a note of each shim arrangement. The

shim arrangement will be approximately the same CAUTION
during assembly.
Protect the hydraulic system from dirt and
15. Remove the bolts that hold the retainer caps to contaminants when servicing the hydraulic
the mast mount stubshafts. Remove the shims system.
and bushings. See Figure 69.
NOTE: If only the lift cylinders need to be removed
and repaired, see Cylinder Repair (Mast S/N
A270-72, A551, A555, A559, A626, A627, A751-52,
B551, B555, B586-91, B749-54, C661-63, C665,
D507-09, D515, D562-64, E509, E564) 2100YRM1382
for procedures. For header hose installation and
adjustment, see the section Header Hose Installation
and Adjustment for procedures.
1. Clean the area around the hydraulic fittings for
the lift cylinders. Disconnect the fittings at the
main lift cylinders and put caps on the open lines.
See Figure 67 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 68 for lift truck models
1. RETAINER CAP • ERP15-20VT (G807) and ERP16-20VF (A955)
2. BOLTS manufactured after February, 2016
3. SHIM
4. BUSHING 2. Disconnect and remove the chain and header
5. MAST MOUNTING STUBSHAFT hoses from the crosshead. Remove the free-lift
6. GREASE FITTING
cylinder brackets and disconnect the free-lift
Figure 69. Mast Mounting supply tube for the free-lift cylinder. Remove free-
lift cylinder.
NOTE: When placing mast on wooden beams, do not See Figure 67 for the following lift truck models
lay mast with main lift cylinders resting on wooden
• ERP15-20VT (ERP030-040VT) (G807) and
beams.
ERP16-20VF (ERP30-40VF) (A955)
16. Use lifting device or crane to lift mast assembly manufactured before February, 2016
from lift truck. Position the outer mast across • ESC030-40AC (B883) and ESC030-40AD
wooden beams on the floor with the carriage side (C883)
up.
See Figure 68 for lift truck models
DISASSEMBLE • ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016

WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.

87
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

WARNING WARNING
Be careful when removing or installing snap rings. The mast weldments can slide when the mast is
These snap rings can come loose during removal moved. A weldment that slides can cause serious
or installation with enough force to cause an injury.
injury. Always use the correct snap ring pliers, and
wear eye and face protection during removal or 5. Slide the inner mast weldment from the outer
installation. mast weldment approximately 30 cm (12 in.) to
disengage the main lift cylinders from the inner
3. Remove the capscrew, washers, spacer, and nut mast weldment. Remove the spacers, nuts, and
at the mount near the top of each main lift bolts at the bottom mounts for the main lift
cylinder. Remove the snap rings, washers, and cylinders on the outer mast. Remove the main lift
shims from the top of the left main lift cylinder. cylinders from the outer mast weldment.

4. Disconnect the FFL supply tube and remove the 6. Remove the lowering control valve housing for
hydraulic fitting from the top of the right main lift the lowering control valve (see Figure 70) from
cylinder. Remove the snap rings, washers, and the outer mast.
shims from the top of the right main lift cylinder.
See Figure 70.

88
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Figure 70. Main Lift Cylinders and Lowering Control Valve

89
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 70.

1. LEFT MAIN LIFT CYLINDER 9. NUT

2. RIGHT MAIN LIFT CYLINDER 10. FILL SCREW
3. HYDRAULIC FITTING 11. SEAL
4. SNAP RING 12. LOWERING CONTROL VALVE
5. WASHER 13. LOWERING CONTROL VALVE HOUSING
6. SHIMS 14. HYDRAULIC FITTING
7. CAPSCREW 15. HOSE ASSEMBLY
8. SPACER

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

NOTE: Make a note of each shim on load rollers. The

shim arrangement will be approximately the same
during assembly.
7. Remove snap rings, shims and load rollers from
bottom of inner mast and top of outer mast.
See Figure 67 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD 1. STRIP BEARING
(C883) 2. SHIMS
3. TOP OF OUTER MAST
See Figure 68 for lift truck models 4. O-RING
• ERP15-20VT (G807) and ERP16-20VF (A955) Figure 71. Strip Bearings
manufactured after February, 2016

8. Remove strip bearings from top of outer mast.

See Figure 71. WARNING
The mast is heavy. The mast can weigh
approximately 907 kg (2000 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast.

NOTE: If the outer mast is being replaced, copy the

part number and date code information from the old
channel and stamp that information on the channel of
the new outer mast with the letter R at the end to
indicate that it has been replaced.
9. Slide the inner mast half way out of the top of the
outer mast. Connect a lifting device to the center
of the inner mast. See Figure 72.

90
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

11. Remove the hose and chain sheaves from mast,

and the fourth function mini rollers (if equipped),
and disassemble them as necessary for cleaning
and repair.
See Figure 67 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 68 for lift truck models
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016
See Figure 73
Figure 72. Mast Disassembly

10. Slide the inner mast out of the outer mast until the
mast stub shafts of the inner mast are in the
notches of the outer channels. Remove the inner
mast from the outer mast.

91
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

1. CAPSCREW 5. NUT
2. LEFT HEADER HOSE ROLLER BRACKET 6. FREE-LIFT CYLINDER
3. MINI ROLLERS 7. FREE-LIFT CHAIN
4. SPACER 8. RIGHT HEADER HOSE ROLLER BRACKET

Figure 73. Fourth Function Mini Rollers Removal

CLEAN AND INSPECT

WARNING
Cleaning solvents may be flammable and toxic and
CAUTION
can cause severe skin irritation. When using
DO NOT use steam or high-pressure water to clean commercial cleaning solvents, always comply with
the load rollers or the lift chains. Steam and high- solvent manufacturer's recommended safety
pressure water can remove the lubrication from precautions.
the bearings in the load rollers. Water in the
bearings of the sheaves and the link pins of chains
can also shorten the service life of these parts.
WARNING
1. Inspect chain and hose sheaves and load rollers Compressed air can move particles so that they
for wear or damage. DO NOT use steam to clean cause injury to the user or to other personnel.
chain and hose sheaves or load rollers. The Make sure that the path of the compressed air is
bearings in the sheaves and load rollers are away from all personnel. Wear protective goggles
sealed and lubricated. or a face shield to prevent injury to the eyes.

92
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

2. Clean the lift chain by soaking in solvent for 30 3. Inspect the lift chains for wear and damage. A lift
minutes to remove all dirt and grease. Hang lift chain becomes longer when it is worn. If a chain
chain up and remove solvent using compressed is 3% longer than a new lift chain, the lift chain
air. must be replaced.

4. If a chain scale is available (Yale Part No.

WARNING 580037684) , check lift chains as shown in
Never replace only the worn section of a chain. Figure 74. If a chain scale is not available
Replace the complete chain. Never replace only measure 20 links of chain. Measure from the
one chain of a chain pair. Replace both chains. center of a pin to the center of another pin 20
Damage to the lift truck and serious injury can pitches away. Compare the length with the chart
occur if lift chains are not replaced correctly. in Figure 74. Replace chain if the length of 20
links of the worn section is more than the
NOTE: The chain must be inspected in the area of maximum wear limit.
chain that passes over the chain sheave during the
first portion of a lift. These links will show maximum
wear.

93
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE
(YALE PART NO. 580037684) .

Pitch
Total length of 20 links (pitch) of Wear Limit The maximum length
new chain of 20 links

12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE

Figure 74. Lift Chains Check

5. Lubricate lift chain by soaking it in SAE 30 engine

oil for 30 minutes. Hang chain over a drip pan for WARNING
one hour to remove excess oil.
Steam can cause serious burns. Wear protective
6. Inspect the chain anchor and pin. Replace any clothing, gloves, and eye protection. Never expose
parts that are worn or damaged. your skin to steam.

7. Clean the mast weldments with steam or solvent.

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

94
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

WARNING WARNING
Improper welding procedures can damage the The mast is heavy. The mast can weigh
structure of the mast or cause incorrect function approximately 907 kg (2000 lb). Make sure all
of the mast which can result in serious injury to lifting devices (hoists, cables, chains, slings, etc.)
personnel. Contact Resident Service Engineering are suitable and of adequate capacity to lift the
through the Contact Management System before mast.
welding on the mast.
NOTE: For header hose installation and adjustment
8. Inspect the sliding surfaces for wear or damage. procedures, see the section Header Hose Installation
Inspect the load roller contact surfaces for wear and Adjustment.
or damage. Inspect all welds for cracks.
2. Connect a lifting device to the center of inner
mast (see Figure 72). Fit stubshafts through
9. Remove the bushings and shims from the stub
notches in the outer mast. Slide inner mast into
shafts. Inspect the bushings, shims and retainer
the outer mast so stub shafts are seen at the top
caps for wear or damage. See the Parts Manual
and bottom of the weldments.
if any part needs to be replaced.
See Figure 67 for the following lift truck models
10. If lift truck is equipped with a four function mast,
• ERP15-20VT (ERP030-040VT) (G807) and
Inspect header hose roller brackets and mini ERP16-20VF (ERP30-40VF) (A955)
rollers, for wear and damage. See Figure 73. manufactured before February, 2016
Replace any parts that are worn or damaged. If
• ESC030-40AC (B883) and ESC030-40AD
the fourth function mini rollers need to be (C883)
lubricated, see one of the sections below for
lubrication procedures See Figure 68 for lift truck models
Periodic Maintenance 8000YRM1339 for lift • ERP15-20VT (G807) and ERP16-20VF (A955)
truck models manufactured after February, 2016

• ERP15-20VT (ERP030-040VT) (G807) NOTE: The shims for the load rollers keep the
Periodic Maintenance 8000YRM1373 for lift weldments parallel and provide correct clearance.
truck models During assembly, the location of the shims will be
approximately the same as they were before
• ERP16-20VF (ERP30-40VF) (A955) disassembly. Check clearance and adjust shims for
Periodic Maintenance 8000YRM1418 for lift wear or for changes because of repairs. Strip bearings
truck models are also adjusted by using shims. See the section
Mast Adjustments for the instructions to make the
• ESC030-40AC (B883)
necessary adjustments.
Periodic Maintenance 8000YRM2025 for lift 3. Apply multipurpose grease with 2-4%
truck models molybdenum disulfide to strip bearing surface.
• ESC030-40AD (C883) Install the strip bearings, shims, and O-rings to
top of outer mast (see Figure 71). Check the
ASSEMBLE clearance of the strip bearing as described in
Mast Adjustments.
1. Install the hose and chain sheaves to free-lift
cylinder crosshead. If mast is equipped with a 4. Install the load rollers, shims, and snap rings to
fourth function, install the fourth function mini bottom of inner mast and top of outer mast.
rollers and header hose brackets to free-lift Check the clearance of the load rollers and strip
cylinder crosshead using capscrews, spacers, bearings as described in the section Mast
and nuts. See Figure 73. Adjustments.

5. Install main lift cylinders in mounts on bottom of

outer mast. Install shims, washers, and snap ring
at the top of right main lift cylinder.

95
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

See Figure 67 for the following lift truck models INSTALL

• ERP15-20VT (ERP030-040VT) (G807) and 1. Lubricate the bushings with chassis lube and
ERP16-20VF (ERP30-40VF) (A955) install them onto the stub shafts at the bottom of
manufactured before February, 2016 the outer mast weldment. See Figure 69.
• ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 68 for lift truck models WARNING
• ERP15-20VT (G807) and ERP16-20VF (A955) The mast is heavy. The mast can weigh
manufactured after February, 2016 approximately 907 kg (2000 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.)
See Figure 70.
are suitable and of adequate capacity to lift the
mast. Serious injury can occur if the mast falls.
6. Install shims at the top of the left main lift cylinder.
Push the inner mast to engage the rods of the 2. Connect a lifting device to the top of the mast
main lift cylinders. Check the clearance at the top using chains. Make sure all mast uprights are
of the main lift cylinder mounts. Add or remove fastened together. Make sure lift chain will not
shims at the left main lift cylinder until it is even damaged chain sheaves, tubing, or other parts of
with the right main lift cylinder. Install washer and the mast.
snap ring at the top of left main lift cylinder. Install
the hydraulic fitting on the right main lift cylinder. 3. Use the lifting device and install the mast into the
See Figure 67 and Figure 70. transmission housing mounts. Apply Loctite™
#242 adhesive sealant to bolt threads. Install the
7. Install spacers, nuts, and bolts at the bottom bolts, shims and retainer caps. Tighten the bolts
mounts for the main lift cylinders. Tighten bolts to in a diametric pattern to 24 N•m (212 lbf in).
40 N•m (30 lbf ft).
4. Use lifting device and tilt mast forward until there
8. Install the lowering control valve housing and is enough space for access to the third, fourth,
lowering control valve to outer mast. Tighten and main lift supply hose connections.
capscrews and nuts to 18 N•m (159 lbf in). Install
the washer and spring to left hydraulic fitting (see 5. Connect the main lift supply hose.
Figure 70). Connect left and right hydraulic fittings
to bottom of main lift cylinders. See Figure 65 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
9. Install the free-lift cylinder in the mounts on the ERP16-20VF (ERP30-40VF) (A955)
inner mast. Install the free-lift cylinder guard manufactured before February, 2016
brackets for the cylinder and tighten the • ESC030-40AC (B883) and ESC030-40AD
capscrews to 53 N•m (39 lbf ft). (C883)
See Figure 67 for the following lift truck models See Figure 66 for lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and • ERP15-20VT (G807) and ERP16-20VF (A955)
ERP16-20VF (ERP30-40VF) (A955) manufactured after February, 2016
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD 6. Connect the third and fourth (if equipped) hoses.
(C883) See Figure 65 for the following lift truck models
See Figure 68 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) and
• ERP15-20VT (G807) and ERP16-20VF (A955) ERP16-20VF (ERP30-40VF) (A955)
manufactured after February, 2016 manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
10. Connect the free-lift supply tube. Connect the (C883)
free-lift chains to chain anchors at he crosshead.
See Figure 66 for lift truck models
Attach a wire between the end of the lift chain and
the bottom of the mast to control the lift chain • ERP15-20VT (G807) and ERP16-20VF (A955)
during installation. manufactured after February, 2016

96
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

NOTE: Perform Step 7 for lift truck models 13. Raise the mast, without a load to its full height
ERP15-20VT (ERP030-040VT) (G807) and and check for side kicking. Mast side kicking is
ERP16-20VF (ERP30-40VF) (A955) manufactured where the mast, without a load, moves either to
before February, 2016 and for lift truck models the right or left as it is being raised. If the mast is
ESC030-40AC (B883) and ESC030-40AD (C883) . side kicking, see the Mast Adjustments section for
procedures to correct mast side kicking.
7. Install hose clamps to lower crossmember. Be
sure to match clamps to marks on hoses made
14. Lubricate the sliding surfaces and load roller
during removal. Tighten clamp socket head
surfaces along the full length of the channels as
capscrews to 11 N•m (97 lbf in). See Figure 63.
shown in Figure 75. Apply lubricant only to
surfaces indicated in Figure 75.
WARNING
Use a pry bar, NOT your fingers, to align the tilt
cylinder clevises with the outer mast. The tilt
cylinder or mast can shift and cause serious
injury.

8. Apply multipurpose grease with 2-4%

molybdenum disulfide to rod end pin and connect
tilt cylinders to mast using rod end pin, capscrew,
special washer, and external tooth lockwasher.
Tighten capscrews to 38 N•m (28 lbf ft). See
Figure 67.

9. ERP16-20VF (ERP30-40VF) (A955) and

A. UPPER LOAD ROLLERS
ERP15-20VT (ERP030-040VT) (G807) Models B. LOWER LOAD ROLLERS
Only - Connect the accelerator pedal or the Foot
Directional Control pedal, and install floor plate 1. LUBRICATE STRIP BEARING SURFACES
and floor mat. See Figure 62. 2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
10. ESC030-40AC (B883) and ESC030-40AD
(C883) Models Only - Install the hydraulic Figure 75. Mast Lubrication
compartment cover to the lift truck as removed.
HEADER HOSE INSTALLATION AND
11. Install the carriage as described in Carriages ADJUSTMENT
Repair and install the forks as shown in the
section Fork Replacement. Install

12. Check the tilt cylinder adjustment. See the section

Cylinder Repair (Mast S/N A270-72, A551, WARNING
A555, A559, A626, A627, A751-52, B551, B555, Always wear the proper protective equipment
B586-91, B749-54, C661-63, C665, D507-09, including eye protection and petroleum-resistant
D515, D562-64, E509, E564) 2100YRM1382 for gloves when handling hydraulic oil. Thoroughly
procedures. Operate the mast and check for wash oil from exposed areas of skin as soon as
leaks and check to ensure mast is operating possible.
correctly. Check lift chains as described in the
section Lift Chains Adjustment.
WARNING
NOTE: Before checking for mast side kicking, the Never check for leaks by putting hands on
mast must be fully assembled to include the carriage, hydraulic lines or components under pressure.
forks, load backrest and any attachments if the lift Hydraulic oil under pressure can be injected into
truck is equipped with one. the skin.

97
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

NOTE: The carriage height must be correct before the

WARNING header hoses can be installed. See Lift Chains
Adjustment for carriage adjustment procedures.
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this 1. Mark each hose with a single letter: A, B, C, and
section. D.
See Figure 76 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
CAUTION ERP16-20VF (ERP30-40VF) (A955)
Disposal of lubricants and fluids must meet local manufactured before February, 2016
environmental regulations.
• ESC030-40AC (B883) and ESC030-40AD
(C883)
Before installing the header hoses, make sure you
know the lift height of the mast. The tension on the See Figure 77 for lift truck models
header hoses is adjusted according to lift height. The • ERP15-20VT (G807) and ERP16-20VF (A955)
lift height is on the Nameplate of the lift truck and on manufactured after February, 2016
the right side of the outer mast.
See Figure 78
NOTE: This procedure is for the four-function option.
The three-function option will have hoses A and B
only.

98
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Figure 76. Header Hose Alignment for Two-Stage Full Free-Lift Mast, For Lift Truck Models Manufactured
Before February, 2016 and For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF
(ERP30-40VF) (A955) ESC030-40AC (B883) and ESC030-40AD (C883)

99
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 76.

NOTE: REAR VIEW SHOWN. PARTS OF THE MAST AND CARRIAGE OMITTED FOR CLARITY. FOUR FUNC-
TION MAST SHOWN.

A. HEADER HOSE C. HEADER HOSE

B. HEADER HOSE D. HEADER HOSE

NOTE: REAR VIEW SHOWN. PARTS OF THE MAST AND CARRIAGE OMITTED FOR CLARITY. FOUR FUNC-
TION MAST SHOWN.

A. HEADER HOSE C. HEADER HOSE

B. HEADER HOSE D. HEADER HOSE

Figure 77. Header Hose Alignment for Two-Stage Full Free-Lift Mast, For Lift Truck Models Manufactured
After February, 2016ERP15-20VT (G807) and ERP16-20VF (A955)

100
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

NOTE: VIEW FROM FRONT OF MAST SHOWN.

A. HEADER HOSE D. HEADER HOSE

B. HEADER HOSE E. THREE AND FOUR FUNCTION SHOWN
C. HEADER HOSE F. THREE FUNCTION ONLY SHOWN

1. CAPSCREW 4. BRACKET
2. NUT 5. HOSE SHEAVE
3. SPACER

Figure 78. Header Hose Alignment, Free-Lift Cylinder, for Two-Stage Full Free-Lift Mast

NOTE: Dimensions E and G is determined by the 3. Place a mark on all the hoses at dimensions E
height of outer mast channel from the ground and the and G. All measurements are made from the
length of outer mast channel. These marks will be carriage end of the hose (the smaller fitting). See
used to pretension the header hoses during Figure 79.
installation. See Figure 79, Table 4, and Table 5.
2. Clamp the end of the hose (the smaller fitting)
that attaches to the carriage in a vise (DO NOT
clamp on the threads), and pull on the other end
until the hose is straight. DO NOT apply enough
force to stretch the hose. See Figure 79.

101
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 79. Header Hose Measurement For Two-Stage Full Free-Lift Mast

102
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 79.

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE

Table 4. Two-Stage Full Free-Lift (FFL) Hose Dimensions, Three Function Mast
Channel
Dimension "G" Hose Dimension "G" Hose
Lift Height Length Dimension "E"
A B
(Reference)
mm in. mm mm in. mm in. mm in.
2978 117.2 1890 1320 51.9 2850 112.2 2725 107.2
3178 125.1 1990 1391 54.7 3074 121.0 2954 116.2
3478 136.9 2140 1565 61.6 3345 131.6 3220 126.7
3678 144.8 2240 1638 64.4 3571 140.5 3450 135.8
4298 169.2 2590 1982 78.0 4265 167.9 4145 163.1

Table 5. Two-Stage Full Free-Lift (FFL) Hose Dimensions, Four Function Mast
Channel
Dimension "G" Hose Dimension "G" Hose
Lift Height Length Dimension "E"
C D
(Reference)
mm in. mm mm in. mm in. mm in.
2978 117.2 1890 180 7.1 1705 67.1 1585 62.4
3178 125.1 1990 251 9.9 1934 76.1 1814 71.4
3478 136.9 2140 230 9.0 2005 78.9 1885 74.2
3678 144.8 2240 300 11.8 2233 87.9 2113 83.2
4298 169.2 2590 251 9.9 2534 99.7 2414 95.0
NOTE: When determining hose dimensions for four function mast, also include information found in Table 4.

4. Install bracket (item #21 in Figure 80) onto free-lift 5. Install channel on free-lift cylinder and left main lift
cylinder with clamp. cylinder with clamps. See Figure 80.

103
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 80. Header Hoses for Two-Stage Full Free-Lift Mast

104
4000 YRM 1405 Two-Stage Mast With Full Free-Lift Repair

Legend for Figure 80.

A. ALIGN MARK G AT TOP OF THIS CLAMP. B. ALIGN MARK E AT BOTTOM OF THIS CLAMP.

1. CHANNEL 12. HOSE GUARD

2. CAPSCREW 13. SPACER
3. NUT 14. CHAIN
4. BRACKET 15. HEADER HOSES
5. CHAIN ANCHOR 16. COWL HOSES
6. STRAP CLAMP 17. RIGHT MAIN LIFT CYLINDER
7. LEFT MAIN LIFT CYLINDER 18. FULL FREE-LIFT CYLINDER
8. CLAMP 19. FULL FREE-LIFT BRACKET
9. FITTING 20. CHAIN SHEAVE
10. TUBE 21. BRACKET
11. CLAMP ASSEMBLY 22. HOSE SHEAVES

6. Install brackets to carriage with capscrew. Tighten 7. Chain the carriage up so that there is slack on the
capscrews to 19 N•m (168 lbf in). Attach the free-lift chain. See Figure 82. Remove free-lift
hoses and fittings to the carriage bracket with chain guard from free-lift cylinder crosshead.
clamps and nuts. See Figure 81.
NOTE: Add a thin coat of multipurpose grease to
shaft before installing hose sheaves.
8. Install hose sheaves onto crosshead using
crosshead pin. install hoses onto hose sheaves.
Install free-lift chain guard to free-lift cylinder
crosshead. See Figure 78.

NOTE: COMPONENTS OMITTED FOR CLARITY.

1. CARRIAGE BRACKETS
2. CAPSCREW
3. FITTING
4. NUT
5. CHAIN ANCHOR

Figure 81. Hose Attachment To Carriage

105
Two-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

1. HOOK 2. SHACKLE

Figure 82. Chaining the Carriage (FFL)

NOTE: To make the alignment of dimension E easier, See Figure 77 for lift truck models
use a crane with a capacity at least 907.2 kg (2000 lb) ERP15-20VT (G807) and ERP16-20VF (A955)
•
to raise the carriage high enough to install a safety manufactured after February, 2016
chain. See Figure 82.
See Figure 80
9. Align mark E at the bottom of the clamp. Tighten
the hardware to 9 N•m (80 lbf in). 12. Use the rubber clamps and strap clamps to attach
the hoses to the main lift cylinders. DO NOT allow
10. Apply a spray lubricant on the hoses in the area the cowl hoses to stretch or fold while tilting the
that will contact the channels. Make sure the mast fully forward and backward.
hoses are properly aligned in the channels. Put
the clamps over the hoses and attach the clamps Adjust
to the channels. Tighten the hardware to
8 N•m (71 lbf in). When properly adjusted, the hoses will not be so tight
that they compress when they pass over the sheaves,
11. Connect the header hoses C and D to the cowl nor will they be so loose that they touch the load
hoses. Connect the header hoses A and B to the backrest or any crossmember that is next to a sheave.
tubes.
1. Cap off hoses when attachments have been
See Figure 76 for the following lift truck models removed.
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955) 2. Check that hoses and cables are routed properly.
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD 3. Slowly raise the free-lift and main cylinders to
(C883) take up slack in the lift chains.

106
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

4. Tighten strap clamps at the bracket weldment. 7. If the tension of the hoses is incorrect, loosen the
clamps and pull the hoses down (if too loose) or
5. Cycle the mast a few times to ensure proper push the hoses up (if too tight) so they can move
tracking of hoses. 15.0 mm (0.6 in.) side to side. Re-tighten the
hardware to 9 N•m (80 lbf in).
6. Secure hose assemblies to main lift cylinders with
hose clamp and screw clamp. 8. With no load on the forks, check the header hose
NOTE: If the hose tension between the carriage and adjustment by operating the mast through the full
the clamp at the free-lift bracket is correct, go to lift cycle two times. When properly adjusted, the
Step 7. hoses will not be so tight that they compress
when they pass over the sheaves nor will they be
If the hose tension between the carriage and the so loose that they touch the load backrest or any
clamp at the free-lift bracket is incorrect, loosen crossmember that is next to a sheave. If
the clamps and pull (if the hoses are loose) or necessary, repeat until the hoses are properly
push (if the hoses are tight) on the hoses so they adjusted. See Table 4 and Table 5.
move 15.0 mm (0.6 in.) side to side. Tighten the
hardware to 8 N•m (71 lbf in).

NOTE: If the hose tension between the clamp at the

upper bracket and the clamp at the free-lift bracket is
correct, go to Step 8.

Three-Stage Mast With Full Free-Lift Repair

REMOVE see the section Header Hose Installation and
Adjustment.

WARNING 1. Fully lower all mast weldments. Tilt the mast fully
forward. Connect a crane with a capacity of at
The mast is heavy. The mast can weigh
least 907 kg (2000 lb) to all top crossmembers of
approximately 907 kg (2000 lb). Make sure all
the mast weldments using chains to support the
lifting devices (hoists, cables, chains, slings, etc.)
mast in an upright position when the tilt cylinders
are suitable and of adequate capacity to lift the
are disconnected. See the section Safety
mast. Serious injury can occur if the mast falls.
Procedures When Working Near Mast.

CAUTION WARNING
Make sure all the mast weldments are fastened Hydraulic oil is hot after system operation and can
together. Make sure the safety chains will not cause burns. DO NOT disconnect any hydraulic
damage the sheaves, tubing, or other parts of the hoses until the oil in the system has cooled.
mast.
Completely lower forks to relieve hydraulic
NOTE: If the mast needs to be disassembled, remove pressure before disconnecting any hoses.
the forks and carriage. See the sections Fork
Replacement and Carriages Repair for procedures. If
only the main lift cylinders, tilt cylinders, or free-lift CAUTION
cylinder need to be repaired, the mast does not need Protect the hydraulic system from dirt and
to be removed from the lift truck. See the section contaminants when disconnecting hydraulic hoses
Cylinder Repair (Mast S/N A270-72, A551, A555, from the mast. If hydraulic system becomes
A559, A626, A627, A751-52, B551, B555, B586-91, contaminated, damage to hydraulic system can
B749-54, C661-63, C665, D507-09, D515, D562-64, occur.
E509, E564) 2100YRM1382 for procedures. For
header hose installation and adjustment procedures,

107
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

3. ERP16-20VF (ERP30-40VF) (A955) and

CAUTION ERP15-20VT (ERP030-040VT) (G807) Models
Only - Remove the floor mat. Lift the floor plate
Disposal of lubricants and fluids must meet local
up enough to disconnect the electrical connectors
environmental regulations.
from the accelerator pedal or Foot Directional
2. Position a drip pan with a capacity of Control pedal, and remove floor plate with
21 liter (22.5 qt) under the area of the hydraulic accelerator pedal or Foot Directional Control still
fittings. attached. See Figure 83.

108
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

Figure 83. Floor Plate and Accelerator Pedal, Remove

109
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 83.

NOTE: FLOOR MAT REMOVED FOR CLARITY. STANDARD ACCELERATOR PEDAL IS SHOWN. PROCE-
DURES TO REMOVE FLOOR PLATE WITH A FOOT DIRECTIONAL CONTROL PEDAL ARE THE SAME.
MODELSERP16-20VF (ERP30-40VF) (A955) AND ERP15-20VT (ERP030-040VT) (G807) ONLY.

A. TOP VIEW B. BOTTOM VIEW

1. CAPSCREW 5. ACCELERATOR PEDAL MOUNTING PLATE

2. ACCELERATOR PEDAL 6. ACCELERATOR PEDAL POSITION SENSOR
3. FLOOR PLATE 7. ELECTRICAL CONNECTORS
4. PEDAL BASE 8. NUTS

4. ESC030-40AC (B883) and ESC030-40AD function mast and A, B, C, and D for four function
(C883) Models Only - Remove the hydraulic mast, to aid in reconnecting when installing the mast
compartment cover from the lift truck to access onto the lift truck. See Figure 86.
the mast hose connections.
5. Before loosening or removing hose clamps from
lower crossmember, mark hoses using a paint
NOTE: Perform Step 5 and Step 6 for lift truck models
pen or other permanent marking device. The
ERP15-20VT (ERP030-040VT) (G807) and
marks are used to reinstall hoses in the correct
ERP16-20VF (ERP30-40VF) (A955) manufactured
position. See Figure 84.
before February, 2016 and for lift truck models
ESC030-40AC (B883) and ESC030-40AD (C883) .
6. Loosen hose clamp, located just below the brake
NOTE: Before disconnecting any hydraulic hoses, be pedal, so that hoses are able to move within the
sure to tag each hose with a letter: A and B for three clamp without stretching. See Figure 84.

110
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

A. MARK HOSES HERE TO ENSURE HOSES AND CLAMP ARE IN SAME POSITION WHEN TIGHTENING
CLAMP.

1. HOSE CLAMP 3. LEFT MAIN LIFT CYLINDER

2. CAPSCREW 4. RIGHT MAIN LIFT CYLINDER

Figure 84. Hose Marking, Lift Truck Models Manufactured Before February, 2016 and For Lift Truck
Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ESC030-40AC (B883)
and ESC030-40AD (C883)

111
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

NOTE: Perform Step 7 for lift truck models

ERP15-20VT (G807) and ERP16-20VF (A955) WARNING
manufactured after February, 2016. Use a driver, NOT your fingers, to push the anchor
NOTE: Before disconnecting any hydraulic hoses, be pins from the clevises on the tilt cylinders. The
sure to tag each hose with a letter: A and B for three cylinder or mast can move and cause serious
function mast and A, B, C, and D for four function injury.
mast, to aid in reconnecting when installing the mast
onto the lift truck. See Figure 87. 8. Remove the capscrew, special washer, external
tooth lockwasher, and rod end pin from the tilt
7. Tag and disconnect hydraulic hoses from mast. cylinder rod ends on the outer mast. Remove tilt
See Figure 87. cylinder rod ends from outer mast. See Figure 85.

112
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

NOTE: TWO-STAGE FFL MAST SHOWN. TILT CYLINDER ARRANGEMENT IS THE SAME ON TWO-STAGE
LFL AND THREE-STAGE FFL MASTS.

1. TILT CYLINDER ROD END 5. CAPSCREW

2. TILT CYLINDER SHELL 6. GREASE FITTING
3. SPECIAL WASHER 7. ROD END PIN
4. LOCK WASHER EXTERNAL TOOTH

Figure 85. Tilt Cylinder Mounting

113
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

9. Use lifting device and tilt the mast forward until ERP16-20VF (ERP30-40VF) (A955) manufactured
there is enough space for access to the third and before February, 2016 and for lift truck models
fourth function (if equipped) header hose clamps ESC030-40AC (B883) and ESC030-40AD (C883) .
and main lift supply hose connections.
11. Remove the hose clamps from the lower
crossmember. See Figure 84.
10. Disconnect the third and fourth (if equipped)
function hoses.
12. Disconnect the main lift supply hose.
See Figure 86 for lift truck models
See Figure 86 for lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
• ESC030-40AC (B883) and ESC030-40AD
(C883)
(C883)
See Figure 87 for lift truck models
See Figure 87 for lift truck models
• ERP15-20VT (G807) and ERP16-20VF (A955)
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016
manufactured after February, 2016
NOTE: Perform Step 11 for lift truck models
ERP15-20VT (ERP030-040VT) (G807) and

114
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

Figure 86. Mast Hydraulic Hose Removal, Lift Truck Models Manufactured Before February, 2016 and For
Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF)
(A955) ESC030-40AC (B883) and ESC030-40AD (C883)

115
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 86.

NOTE: BACK VIEW OF MAST SHOWN.

A. HEADER HOSE C. HEADER HOSE

B. HEADER HOSE D. HEADER HOSE

1. FOURTH FUNCTION HOSES 5. THIRD FUNCTION HOSES

2. LIFT CHAIN 6. MAIN LIFT SUPPLY HOSE
3. CHAIN ANCHOR 7. LOWERING CONTROL VALVE
4. FREE-LIFT SUPPLY TUBE

116
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

NOTE: BACK VIEW OF MAST SHOWN.

A. HEADER HOSE C. HEADER HOSE

B. HEADER HOSE D. HEADER HOSE

1. FOURTH FUNCTION HOSES 5. THIRD FUNCTION HOSES

2. LIFT CHAIN 6. MAIN LIFT SUPPLY HOSE
3. CHAIN ANCHOR 7. LOWERING CONTROL VALVE
4. FREE-LIFT SUPPLY TUBE

Figure 87. Mast Hydraulic Hose Removal, Lift Truck Models Manufactured After February,
2016ERP15-20VT (G807) and ERP16-20VF (A955)

13. Move disconnected hoses underneath the mast. 15. Remove the bolts that hold the retainer caps to
the mast mount stubshafts. Remove the shims
14. Use the lifting device and move mast into vertical and bushings. See Figure 88.
position.

NOTE: Make a note of each shim arrangement. The

shim arrangement will be approximately the same
during assembly.

117
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.

NOTE: If only the main lift cylinders, tilt cylinders, or

free-lift cylinder need to be repaired, the mast does not
need to be removed from the lift truck. See the section
Cylinder Repair (Mast S/N A270-72, A551, A555,
A559, A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515, D562-64,
E509, E564) 2100YRM1382 for procedures. For
header hose installation and adjustment procedures,
see the section Header Hose Installation and
Adjustment.
1. Clean the area around the hydraulic fittings for
the main lift cylinders. Disconnect the fittings at
1. RETAINER CAP the main lift cylinders and put caps on the open
2. BOLTS lines. Disconnect the free-lift chains from the
3. SHIM chain anchor.
4. BUSHING
5. MAST MOUNTING STUBSHAFT See Figure 89 for lift truck models
6. GREASE FITTING
• ERP15-20VT (ERP030-040VT) (G807) and
Figure 88. Mast Mounting ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
NOTE: When placing mast on wooden beams, do not • ESC030-40AC (B883) and ESC030-40AD
lay mast with main lift cylinders resting on wooden (C883)
beams. See Figure 90 for lift truck models
16. Use lifting device or crane to lift mast assembly • ERP15-20VT (G807) and ERP16-20VF (A955)
from lift truck. Position the outer mast across manufactured after February, 2016
wooden beams on the floor with the carriage side
up.

DISASSEMBLE

WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.

118
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

Figure 89. Three-Stage, Full Free-Lift (FFL) Mast, Lift Truck Models Manufactured Before February, 2016
and For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF)
(A955) ESC030-40AC (B883) and ESC030-40AD (C883)

119
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 89.

A. INNER MAST USED ON LIFT TRUCKS MANUFACTURED AFTER JULY, 2012

1. OUTER MAST 18. BAR

2. LOAD ROLLER 19. INTERMEDIATE MAST
3. SHIM 20. FREE-LIFT SUPPLY TUBE
4. SNAP RING 21. LOWERING CONTROL VALVE
5. WASHER 22. LOWERING CONTROL VALVE SPRING AND
6. RIGHT MAIN LIFT CYLINDER WASHER
7. COTTER PIN 23. LOWERING CONTROL VALVE MOUNTING
8. CHAIN ANCHOR PIN BRACKET
9. NUT 24. BOTTOM CROSSMEMBER
10. SPACER 25. CHAIN ANCHOR
11. LEFT MAIN LIFT CYLINDER 26. MIDDLE CROSSMEMBER
12. CAPSCREW 27. CROSSHEAD PIN
13. STRIP BEARING 28. FREE-LIFT CYLINDER GUARD BRACKET
14. BALL BEARING 29. CHAIN GUARD
15. CHAIN SHEAVE 30. HOSE BRACKET
16. HOSE SHEAVE 31. FREE-LIFT CHAIN
17. STUBSHAFT 32. FREE-LIFT CYLINDER
33. INNER MAST
34. PLATES

120
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

Figure 90. Three-Stage, Full Free-Lift (FFL) Mast, Lift Truck Models Manufactured After February,
2016ERP15-20VT (G807) and ERP16-20VF (A955)

121
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 90.

1. OUTER MAST 18. BAR

2. LOAD ROLLER 19. INTERMEDIATE MAST
3. SHIM 20. FREE-LIFT SUPPLY TUBE
4. SNAP RING 21. LOWERING CONTROL VALVE
5. WASHER 22. LOWERING CONTROL VALVE SPRING AND
6. RIGHT MAIN LIFT CYLINDER WASHER
7. COTTER PIN 23. LOWERING CONTROL VALVE MOUNTING
8. CHAIN ANCHOR PIN BRACKET
9. NUT 24. BOTTOM CROSSMEMBER
10. SPACER 25. CHAIN ANCHOR
11. LEFT MAIN LIFT CYLINDER 26. MIDDLE CROSSMEMBER
12. CAPSCREW 27. CROSSHEAD PIN
13. STRIP BEARING 28. FREE-LIFT CYLINDER GUARD BRACKET
14. BALL BEARING 29. CHAIN GUARD
15. CHAIN SHEAVE 30. HOSE BRACKET
16. HOSE SHEAVE 31. FREE-LIFT CHAIN
17. STUBSHAFT 32. FREE-LIFT CYLINDER
33. INNER MAST
34. PLATES

2. Remove the header hoses. header hose roller brackets and mini rollers (see
Figure 91) and remove the hose and chain
3. Disconnect and remove the free-lift supply tube. sheaves from free-lift cylinder and disassemble
Remove the free-lift cylinder guard brackets. them as necessary for cleaning, inspection, and
Remove free-lift cylinder from mast. If lift truck is repair.
equipped with a four function mast, remove

122
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

1. CAPSCREW 5. NUT
2. LEFT HEADER HOSE ROLLER BRACKET 6. FREE-LIFT CYLINDER
3. MINI ROLLERS 7. FREE-LIFT CHAIN
4. SPACER 8. RIGHT HEADER HOSE ROLLER BRACKET

Figure 91. Fourth Function Mini Rollers Removal

• ERP15-20VT (ERP030-040VT) (G807) and

WARNING ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
Be careful when removing or installing snap rings.
These snap rings can come loose during removal • ESC030-40AC (B883) and ESC030-40AD
or installation with enough force to cause an (C883)
injury. Always use the correct snap ring pliers, and See Figure 90 for lift truck models
wear eye and face protection during removal or ERP15-20VT (G807) and ERP16-20VF (A955)
•
installation. manufactured after February, 2016
4. Disconnect the main lift chains from the chain 6. Remove strip bearings from top of intermediate
anchors near the top of the main lift cylinders. mast. See Figure 92.
Disconnect the other end of the main lift chains at
the bottom of the inner mast. Push the inner mast
towards the bottom of the mast assembly until the
bottom load rollers can be seen.

5. Remove the lowering control valve housing for

the lowering control valve from the outer mast.
See Figure 89 for lift truck models

123
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

WARNING
The mast is heavy and can weigh approximately
907 kg (2000 lb). Make sure all lifting devices
(hoists, cables, chains, slings, etc.) are suitable
and of adequate capacity to lift the mast.

8. Slide the inner mast halfway out of the top of the

intermediate mast. Connect a crane with a
capacity of at least 907 kg (2000 lb) to the center
of the inner mast. See Figure 93. Slide the inner
mast out of the intermediate mast until the
stubshafts are in the notches of the intermediate
mast. Remove the inner mast from the
intermediate mast.

1. STRIP BEARING
2. SHIMS
3. TOP OF OUTER MAST
4. O-RING

Figure 92. Strip Bearings

WARNING
The mast weldments can slide when the mast is
moved. A weldment that slides can cause serious
injury.
Figure 93. Mast Disassembly
7. Remove the load rollers, shims, and snap rings at
the bottom of the inner mast. Remove the load
rollers, shims, and snap rings at the top of the WARNING
intermediate mast. Make note of each shim
Be careful when removing or installing snap rings
arrangement and load roller location. The shim
on the load rollers. These snap rings can come
arrangement will be approximately the same
loose during removal or installation with enough
during assembly.
force to cause an injury. Always use the correct
See Figure 89 for lift truck models snap ring pliers and wear eye and face protection
• ERP15-20VT (ERP030-040VT) (G807) and when removing and installing snap rings onto load
ERP16-20VF (ERP30-40VF) (A955) rollers.
manufactured before February, 2016
9. Remove snap rings, shims, and washers from the
• ESC030-40AC (B883) and ESC030-40AD
top of the main lift cylinders.
(C883)
See Figure 90 for lift truck models 10. Remove the nut, capscrew, washer, and spacer at
• ERP15-20VT (G807) and ERP16-20VF (A955) the mount near the top of each main lift cylinder.
manufactured after February, 2016 See Figure 89 for lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016

124
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

• ESC030-40AC (B883) and ESC030-40AD 1. Inspect chain sheaves and load rollers for wear or
(C883) damage. DO NOT use steam to clean lift chain
See Figure 90 for lift truck models sheaves or load rollers. The bearings in the
sheaves and load rollers are sealed and
• ERP15-20VT (G807) and ERP16-20VF (A955) lubricated.
manufactured after February, 2016

11. Push the intermediate mast to disengage the

main lift cylinders. Remove main lift cylinders. WARNING
Cleaning solvents may be flammable and toxic and
NOTE: If the outer mast is being replaced, copy the can cause severe skin irritation. When using
part number and date code information from the old commercial cleaning solvents, always comply with
channel and stamp that information on the channel of solvent manufacturer's recommended safety
the new outer mast with the letter R at the end to precautions.
indicate that it has been replaced.
12. Slide the intermediate mast halfway out of the top
of the outer mast. Connect a crane [the capacity WARNING
of the crane must be at least 907 kg (2000 lb)] to Compressed air can move particles so that they
the center of the intermediate mast weldment. cause injury to the user or to other personnel.
See Figure 93. Slide the intermediate mast Make sure that the path of the compressed air is
weldment out of the outer mast weldment until the away from all personnel. Wear protective goggles
mast stubshafts of the inner mast weldment are in or a face shield to prevent injury to the eyes.
the notches of the outer channels. Remove the
intermediate mast weldment from the outer mast 2. Clean the lift chains by soaking in solvent for 30
weldment. minutes to remove all dirt and grease. Hang lift
chains up and remove solvent using compressed
13. Remove the hose and chain sheaves from air.
intermediate mast and disassemble them as
necessary for cleaning and repair.
WARNING
See Figure 89 for lift truck models
Never replace only the worn section of a chain.
• ERP15-20VT (ERP030-040VT) (G807) and Replace the complete chain. Never replace only
ERP16-20VF (ERP30-40VF) (A955) one chain of a chain pair. Replace both chains.
manufactured before February, 2016 Damage to the lift truck and serious injury can
• ESC030-40AC (B883) and ESC030-40AD occur if lift chains are not replaced correctly.
(C883)
See Figure 90 for lift truck models NOTE: The chains must be inspected in the area of
chain that passes over the chain sheave during the
• ERP15-20VT (G807) and ERP16-20VF (A955) first portion of a lift. These links will show maximum
manufactured after February, 2016 wear.
CLEAN AND INSPECT 3. Inspect the lift chains for wear and damage. A lift
chain becomes longer when it is worn. If a chain
is 3% longer than a new lift chain, the lift chain
CAUTION must be replaced.
DO NOT use steam or high-pressure water to clean
the load rollers or the lift chains. Steam and high- 4. If a chain scale is available (Yale Part No.
pressure water can remove the lubrication from 580037684) , check lift chains as shown in
the bearings in the load rollers. Water in the Figure 94. If a chain scale is not available
bearings of the sheaves and the link pins of chains measure 20 links of chain. Measure from the
can also shorten the service life of these parts. center of a pin to the center of another pin 20
pitches away. Compare the length with the chart
in Figure 94. Replace chain if the length of 20
links of the worn section is more than the
maximum wear limit.

125
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE
(YALE PART NO. 580037684) .

Pitch
Total length of 20 links (pitch) of Wear Limit The maximum length
new chain of 20 links

12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.4 in.)
25.4 mm (1.0 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE

Figure 94. Lift Chains Check

5. Lubricate lift chains by soaking them in SAE 30

engine oil for 30 minutes. Hang chains over a drip WARNING
pan for one hour to remove excess oil.
Steam can cause serious burns. Wear protective
6. Inspect chain anchors, pins, and cotter pins for clothing, gloves, and eye protection. Never expose
damage. Replace if damaged. your skin to steam.

7. Clean the mast weldments with steam or solvent.

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

126
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

During assembly, the shim arrangement will be

WARNING approximately the same as before disassembly. Check
Improper welding procedures can damage the the clearance and adjust the shims for wear or for
structure of the mast or cause incorrect function changes caused by repairs. The strip bearings are
of the mast which can result in serious injury to also adjusted by using shims. See the section Mast
personnel. Contact Resident Service Engineering Adjustments for the adjustment procedures.
through the Contact Management System before NOTE: When the mast has header hoses installed,
welding on the mast. see the procedures in the section Header Hose
Installation and Adjustment.
8. Inspect the sliding surfaces for wear or damage.
Inspect the load roller contact surfaces for wear 1. Install the hose and chain sheaves to
or damage. Inspect all welds for cracks. intermediate mast.

9. Remove the bushings and shims from the 2. Put the outer mast on the floor with the carriage
stubshafts. See Figure 88. Inspect the bushings, side up. Connect a crane with a capacity of at
shims and retainer caps for wear or damage. See least 907 kg (2000 lb) to the center of the
the Parts Manual if any part needs to be intermediate mast weldment. Fit the lower stub
replaced. shafts of the intermediate mast into the notches in
the top of the outer mast. Slide the intermediate
10. If lift truck is equipped with a four function mast, mast into the outer mast so that the stub shafts
Inspect header hose roller brackets and mini are seen at the top and bottom of both
rollers, for wear and damage. See Figure 91. weldments.
Replace any parts that are worn or damaged. If
the fourth function mini rollers need to be NOTE: The load rollers must be in place before strip
lubricated, see one of the sections below for bearing can be shimmed.
lubrication procedures. 3. Apply multipurpose grease with 2 to 4%
Periodic Maintenance 8000YRM1339 for lift molybdenum disulfide to the bearing surfaces and
truck models install the strip bearings and the shims on the
channels of the outer mast. See Figure 95. Check
• ERP15-20VT (ERP030-040VT) (G807) the clearance of the strip bearings as described in
Periodic Maintenance 8000YRM1373 for lift Mast Adjustments.
truck models
• ERP16-20VF (ERP30-40VF) (A955)
Periodic Maintenance 8000YRM1418 for lift
truck models
• ESC030-40AC (B883)
Periodic Maintenance 8000YRM2025 for lift
truck models
• ESC030-40AD (C883)

ASSEMBLE

WARNING
The mast is heavy. The mast can weigh
approximately 907 kg (2000 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast. Serious injury can occur if mast falls.

NOTE: The shims for the load rollers keep the

weldments parallel and provide correct clearance.

127
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

• ERP15-20VT (G807) and ERP16-20VF (A955)

manufactured after February, 2016

6. Install the lowering control valve housing and

lowering control valve to outer mast. Tighten nut
to 18 N•m (159 lbf in). Connect the hydraulic lines
and fittings between the housing and main lift
cylinders.

7. Install the snap rings, washers, nuts, and

capscrews at the mounts for the main lift
cylinders. Tighten capscrews to 53 N•m (39 lbf ft).

8. Connect a crane with a capacity of at least

907 kg (2000 lb) to the center of the inner mast
weldment. Slide inner mast into intermediate mast
so the stubshafts are seen at the top and bottom.

NOTE: The load rollers must be in place before strip

bearings can be shimmed.
1. STRIP BEARING 9. Install the strip bearings and the shims on the
2. SHIM channels of the intermediate mast. Apply thin coat
3. TOP OF OUTER MAST of multipurpose grease with 2 to 4% molybdenum
4. O-RING disulfide to bearing surface. Install the load rollers
and the shims on the intermediate and inner
Figure 95. Strip Bearings
masts. Before doing Step 10, adjust the inner
mast as described in Mast Adjustments.
4. Install the load rollers and the shims on the outer
mast and at the bottom of the intermediate mast.
10. Connect the main lift chains to the chain anchors
Before doing Step 5, adjust the intermediate mast
at the main lift cylinder mounts. Put lift chains
and check the clearance of the load rollers as
over the chain sheaves and connect them to the
described in Mast Adjustments.
anchors at the bottom of the inner mast.
NOTE: The clearance check and adjustment in Step 5 See Figure 89 for lift truck models
is only and initial setup. The final check and • ERP15-20VT (ERP030-040VT) (G807) and
adjustment is done after the mast is installed on the lift ERP16-20VF (ERP30-40VF) (A955)
truck. manufactured before February, 2016
5. Install the main lift cylinders. Push the • ESC030-40AC (B883) and ESC030-40AD
intermediate mast to engage the main lift (C883)
cylinders. Check the clearance at the top of the See Figure 90 for lift truck models
main lift cylinder mounts. Add or remove shims at
the top of the cylinder rods until they are even. • ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016
Install the snap rings and washers at the top of
the main lift cylinders.
NOTE: The nuts for the free-lift cylinder guard are
See Figure 89 for lift truck models installed on the bracket side of the free-lift cylinder.
• ERP15-20VT (ERP030-040VT) (G807) and 11. Install the free-lift cylinder in the mounts on the
ERP16-20VF (ERP30-40VF) (A955) inner mast. Install the free-lift cylinder guards for
manufactured before February, 2016 the free-lift cylinder. Tighten capscrews and nuts
• ESC030-40AC (B883) and ESC030-40AD to 53 N•m (39 lbf ft).
(C883)
See Figure 90 for lift truck models

128
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

12. Install the hose sheaves for the free-lift cylinder. NOTE: Perform Step 6 for lift truck models
Tighten capscrew for hose sheave to ERP15-20VT (ERP030-040VT) (G807) and
66 N•m (49 lbf ft). If mast is equipped with a ERP16-20VF (ERP30-40VF) (A955) manufactured
fourth function, install mini rollers and header before February, 2016 and for lift truck models
hose roller brackets to free-lift cylinder. See ESC030-40AC (B883) and ESC030-40AD (C883) .
Figure 91. Install the hydraulic hose and free-lift
6. Install hose clamps to lower crossmember. Be
supply tube.
sure to match clamps to marks on hoses made
during removal. See Figure 84. Tighten clamp
13. Connect the free-lift chains to the chain anchors
socket head capscrews to 11 N•m (97 lbf in).
at the crosshead. Attach a wire between the end
of the lift chain and the bottom of the mast to
control the lift chain during mast installation.
WARNING
INSTALL Use a pry bar, NOT your fingers, to align the tilt
cylinder clevises with the outer mast. The tilt
1. Lubricate the bushings with chassis lube and cylinder or mast can shift and cause serious
install them onto the stub shafts at the bottom of injury.
the outer mast weldment. See Figure 88.
7. Apply multipurpose grease with 2 to 4%
molybdenum disulfide to rod end pin and connect
WARNING tilt cylinders to mast using rod end pin, capscrew,
The mast is heavy. The mast can weigh special washer, and external tooth lockwasher.
approximately 907 kg (2000 lb). Make sure all Tighten capscrews to 38 N•m (28 lbf ft). See
lifting devices (hoists, cables, chains, slings, etc.) Figure 85.
are suitable and of adequate capacity to lift the
mast. Serious injury can occur if the mast falls. 8. ERP16-20VF (ERP30-40VF) (A955) and
ERP15-20VT (ERP030-040VT) (G807) -
2. Connect a lifting device to the top of the mast Connect the accelerator pedal or Foot Directional
using chains. Make sure all mast uprights are Control pedal, and install floor plate and floor
fastened together. Make sure chains will not mat. See Figure 84.
damage chain sheaves, tubing, or other parts of
the mast. 9. ESC030-40AC (B883) and ESC030-40AD
(C883) Models Only - Install the hydraulic
3. Use the lifting device and install the mast into the compartment cover to the lift truck as removed.
transmission housing mounts. Apply Loctite™
#242 adhesive sealant to bolt threads. Install the 10. Install the carriage as described in Carriages
bolts, shims and retainer caps. Tighten the bolts Repair and install the forks as shown in the
in a diametric pattern to 24 N•m (212 lbf in). section Fork Replacement.

4. Use lifting device and tilt mast forward until there 11. Check the tilt cylinder adjustment. See the section
is enough space for access to the third, fourth, Cylinder Repair (Mast S/N A270-72, A551,
and main lift supply hose connections. A555, A559, A626, A627, A751-52, B551, B555,
B586-91, B749-54, C661-63, C665, D507-09,
5. Connect the third and fourth (if equipped) hoses. D515, D562-64, E509, E564) 2100YRM1382 for
procedures. Operate the mast and check for
See Figure 86 for lift truck models
leaks and to ensure mast is operating correctly.
• ERP15-20VT (ERP030-040VT) (G807) and Check lift chains as described in the section Lift
ERP16-20VF (ERP30-40VF) (A955) Chains Adjustment.
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD NOTE: Before checking for mast side kicking, the
(C883) mast must be fully assembled to include the carriage,
See Figure 87 for lift truck models forks, load backrest and any attachments, if the lift
truck is equipped with one.
• ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016

129
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

12. Raise the mast, without a load to its full height HEADER HOSE INSTALLATION AND
and check for side kicking. Mast side kicking is ADJUSTMENT
where the mast, without a load, moves either to
the right or left as it is being raised. If the mast is Install
side kicking, see the Mast Adjustments section for
procedures to correct mast side kicking.
WARNING
13. Lubricate the sliding surfaces and load roller Before working on or near the mast, see Safety
surfaces along the full length of the channels as Procedures When Working Near Mast in this
shown in Figure 96. Apply lubricant only to section.
surfaces indicated in Figure 96.
NOTE: This procedure is for the four-function option.
The three-function option will have hoses A and B
only.
NOTE: The carriage height must be correct before the
header hoses can be adjusted. See Lift Chains
Adjustment for the carriage adjustment procedure.
1. Mark each hose with a single letter: A, B, C, and
D.
See Figure 97 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
• ESC030-40AC (B883) and ESC030-40AD
(C883)
See Figure 98 for lift truck models
A. UPPER LOAD ROLLERS • ERP15-20VT (G807) and ERP16-20VF (A955)
B. LOWER LOAD ROLLERS manufactured after February, 2016
1. LUBRICATE STRIP BEARING SURFACES See Figure 99
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER

Figure 96. Mast Lubrication

130
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

Figure 97. Header Hose Alignment for Three-Stage Full Free-Lift Mast, Lift Truck Models Manufactured
Before February, 2016 and For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF
(ERP30-40VF) (A955) ESC030-40AC (B883) and ESC030-40AD (C883)

131
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 97.

A. HEADER HOSE A C. HEADER HOSE C

B. HEADER HOSE B D. HEADER HOSE D

A. HEADER HOSE A C. HEADER HOSE C

B. HEADER HOSE B D. HEADER HOSE D

Figure 98. Header Hose Alignment for Three-Stage Full Free-Lift Mast, Lift Truck Models Manufactured
After February, 2016ERP15-20VT (G807) and ERP16-20VF (A955)

132
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

NOTE: FRONT VIEW OF MAST SHOWN.

A. HEADER HOSE D. HEADER HOSE

B. HEADER HOSE E. THREE AND FOUR FUNCTION SHOWN
C. HEADER HOSE F. THREE FUNCTION ONLY SHOWN

1. CAPSCREW 4. BRACKET
2. NUT 5. HOSE SHEAVE
3. SPACER

Figure 99. Header Hose Alignment, Free-Lift Cylinder

2. Dimensions E and G are determined by the

height of the outer mast channel from the ground
and the length of the outer mast channel. See
Figure 100, Table 6, and Table 7 for dimensions E
and G.

133
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 100. Header Hose Measurement for Three-Stage Full Free-Lift Mast

134
4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 100.

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE

Table 6. Three-Stage Full Free-Lift (FFL) Hose Dimensions, Three Function Mast
Channel
Dimension "E" Third Dimension "G" Third Dimension "G" Third
Lift Height Length
Function Function Hose A Function Hose B
(Reference)
mm in. mm mm in. mm in. mm in.
4260 167.7 1840 1244 49 3440 135 3491 137

4560 179.5 1940 1342 53 3637 143 3688 145

4860 191.3 2040 1441 57 3834 151 3885 153
5160 203.1 2190 1588 63 4130 163 4181 165
5460 215.0 2290 1687 66 4327 170 4378 172

Table 7. Three-Stage Full Free-Lift (FFL) Hose Dimensions, Four Function Mast
Channel Dimension "G" Dimension "G"
Dimension "E" Fourth
Lift Height Length Fourth Function Fourth Function Hose
Function
(Reference) Hose C D
mm in. mm mm in. mm in. mm in.
4260 167.7 1840 202 8 2450 96 2398 94

4560 179.5 1940 202 8 2548 100 2497 98

4860 191.3 2040 300 12 2745 108 2694 106
5160 203.1 2190 251 10 2844 112 2792 110
5460 215.0 2290 350 14 3041 120 2989 118

3. Clamp the end of the hose (the smaller fitting) 5. Install hose guides to bottom of inner mast.
that attaches to the carriage in a vise (DO NOT Tighten capscrews to 48 N•m (35 lbf ft). Apply
clamp on the threads), and pull on the other end small amount of multipurpose grease to bottom of
until the hose is straight. DO NOT apply enough hose guide.
force to stretch the hose.
6. Install bracket to full free-lift cylinder. Attach
NOTE: These marks will be used to pretension the bracket with clamp.
header hose during installation.
7. Install carriage brackets to carriage. Tighten
4. Place a mark on all the hoses at dimensions E
capscrews to 19 N•m (168 lbf in). Install hoses
and G (all measurements are made from the
and fittings to carriage brackets. See Figure 101.
carriage end of the hose [the smaller fitting]). See
Figure 100, Table 6, and Table 7.

135
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

10. Attach the hoses to the carriage bracket with

clamps. Apply spray lubricant to the surface of the
hose guide that contacts the hoses.

11. Place the hoses over the top of the free-lift chains
and under the hose guides. Attach the hose
guides to the lower crossmember and tighten the
mounting hardware to 33 N•m (24 lbf ft). Make
sure the bracket is between the crossmember
and the hose guide. Put the clamps over the
hoses and attach the clamps to the free-lift
bracket. DO NOT tighten the hardware.
See Figure 97 for the following lift truck models
• ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
manufactured before February, 2016
1. CARRIAGE BRACKETS • ESC030-40AC (B883) and ESC030-40AD
2. CAPSCREW (C883)
3. FITTING
4. NUT See Figure 98 for lift truck models
5. CHAIN ANCHOR
6. CHAIN • ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016
Figure 101. Carriage Brackets and Hose See Figure 99
Attachment
NOTE: To make the alignment of dimension E easier,
8. Chain the carriage up so that there is slack on the use a crane with a capacity of at least
free-lift chain. See Figure 102. Remove free-lift 907.2 kg (2000 lb) to raise the carriage high enough to
chain guard from free-lift cylinder crosshead. attach a safety chain. See Figure 102.

NOTE: Add a thin coat of multipurpose grease to

shaft before installing hose sheaves.
9. Install hose sheaves onto crosshead using
crosshead pin. install hoses onto hose sheaves.
Install free-lift chain guard to free-lift cylinder
crosshead.

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4000 YRM 1405 Three-Stage Mast With Full Free-Lift Repair

1. HOOK 2. SHACKLE

Figure 102. Chaining the Carriage (FFL)

12. Align the mark for dimension E at the bottom of 15. Align mark G on hoses A and D at the bottom
the clamp to create the proper hose tension. See edge of clamp to create the proper tension. Align
Figure 103. Tighten the hardware to mark G on hoses B and C at the top edge of
8 N•m (71 lbf in). Install the hose guards. Tighten clamp to create the proper tension. Tighten the
the capscrews that mount the guards to hardware to 8 N•m (71 lbf in).
18 N•m (13 lbf ft).
See Figure 97 for the following lift truck models
13. Position the hoses at the hose sheave. The hose • ERP15-20VT (ERP030-040VT) (G807) and
sheave and stub shaft must be installed on the ERP16-20VF (ERP30-40VF) (A955)
hose before they are attached to the mast. manufactured before February, 2016
Tighten the hardware to 66 N•m (49 lbf ft). • ESC030-40AC (B883) and ESC030-40AD
(C883)
14. Put the clamps over the hoses and attach the See Figure 98 for lift truck models
clamps to the upper brackets. DO NOT tighten
the hardware. • ERP15-20VT (G807) and ERP16-20VF (A955)
manufactured after February, 2016
NOTE: To make the alignment of dimension G easier,
use a crane to raise the inner channel high enough to 16. Install the clamps. See Figure 103.
install a safety chain.

137
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 103. Header Hoses for Three-Stage Full Free-Lift (FFL) Mast

138
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 103.

NOTE: FOUR-FUNCTION MAST SHOWN.

A. ALIGN HOSE MARK G AT BOTTOM OF THIS B. ALIGN HOSE MARK E AT BOTTOM OF THIS
CLAMP CLAMP

1. CLAMP 5. FREE-LIFT CYLINDER

2. HOSE GUARD 6. FITTING
3. CHAIN ANCHOR 7. CHAIN SHEAVE
4. CHAIN

17. Connect the header hoses to the cowl hoses. If the hose tension between the carriage and the
clamp at the free-lift bracket is incorrect, loosen
18. Use the rubber clamps and strap clamps to attach the clamps and pull (if the hoses are loose) or
the hoses to the main lift cylinders. Make sure the push (if the hoses are tight) on the hoses so they
hoses do not stretch or fold while tilting the mast move 15.0 mm (0.6 in.) side to side. Tighten the
fully forward and backward. hardware to 8 N•m (71 lbf in).

Adjust NOTE: If the hose tension between the clamp at the

upper bracket and the clamp at the free-lift bracket is
When properly adjusted, the hoses will not be so tight
correct, go to Step 8.
that they compress when they pass over the sheaves,
nor will they be so loose that they touch the load 7. If the tension of the hoses is incorrect, loosen the
backrest or any crossmember that is next to a sheave. clamps and pull the hoses down (if too loose) or
push the hoses up (if too tight) so they can move
1. Cap off hoses when attachments have been 15.0 mm (0.6 in.) side to side. Re-tighten the
removed. hardware to 8 N•m (71 lbf in).

2. Check that hoses and cables are routed properly. 8. With no load on the forks, check the header hose
adjustment by operating the mast through the full
3. Slowly raise the free-lift and main cylinders to lift cycle two times. When properly adjusted, the
take up slack in the lift chains. hoses will not be so tight that they compress
when they pass over the sheaves nor will they be
4. Tighten strap clamps at the bracket weldment. so loose that they touch the load backrest or any
crossmember that is next to a sheave. If
5. Cycle the mast a few times to ensure proper necessary, repeat until the hoses are properly
tracking of hoses. adjusted.
6. Secure hose assemblies to main lift cylinders with
hose clamp and screw clamp.
NOTE: If the hose tension between the carriage and
the clamp at the free-lift bracket is correct, go to
Step 7.
Four-Stage Mast With Full Free-Lift Repair
NOTE: The information in this section applies only to REMOVE
lift truck models ERP030-040VT (G807),
ESC030-40AC (B883), and ESC030-40AD (C883) .
WARNING
The mast is heavy. The mast can weigh
approximately 1100 kg (2385 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast. Serious injury can occur if the mast falls.

139
Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

CAUTION
Make sure all the mast weldments are fastened
together. Make sure the safety chains will not
damage the sheaves, tubing, or other parts of the
mast.

NOTE: If the mast needs to be disassembled, remove

the forks and carriage. See the sections Fork
Replacement and Carriages Repair for procedures. If
the free-lift cylinder or tilt cylinders need to be
repaired, the mast does not need to be removed from
the lift truck. See the section Cylinder Repair (Mast
S/N A270-72, A551, A555, A559, A626, A627,
A751-52, B551, B555, B586-91, B749-54, C661-63,
C665, D507-09, D515, D562-64, E509, E564)
2100YRM1382 for procedures. For header hose
installation and adjustment procedures, see the
section Header Hose Installation and Adjustment.
1. Remove the forks from the mast. Refer to Fork
Replacement. Fully lower all mast weldments and
tilt mast fully forward.

2. Securely attach the chains of an overhead lifting

device to the top crossmember of the outer mast.
Tighten the chains to remove slack until there is
no more than 50 mm (2 in.) of side to side
movement. See Figure 104.

1. ATTACH OVERHEAD LIFTING DEVICE

2. HYDRAULIC SUPPLY HOSE
3. STUB SHAFT
4. LOWERING CONTROL VALVE

Figure 104. Mast Removal

WARNING
Hydraulic oil is hot after system operation and can
cause burns. DO NOT disconnect any hydraulic
hoses until the oil in the system has cooled.
Completely lower forks to relieve hydraulic
pressure before disconnecting any hoses.

140
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

4. Disconnect and tag lift truck hydraulic supply

CAUTION hose from the lowering control valve. Plug hose
end and cap lowering control valve fitting. See
Protect the hydraulic system from dirt and
Figure 104.
contaminants when disconnecting hydraulic hoses
from the mast. If hydraulic system becomes
NOTE: If the mast will be disassembled, go to Step 5.
contaminated, damage to hydraulic system can
If mast will not be disassembled, go to Step 6.
occur.
NOTE: Tag header hoses prior to removal to aid in
connecting and installation.
CAUTION 5. Disconnect and remove header hoses and
Disposal of lubricants and fluids must meet local attaching hardware; upper and lower hose
environmental regulations. guides, hose clamps, hose brackets, and plates.
See Figure 105.
3. Position a drip pan under the mast to prevent
spills when disconnecting the hydraulic fittings.

141
Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 105. Header Hoses Attaching Hardware, Remove

142
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 105.

NOTE: SOME MAST COMPONENTS OMITTED FOR CLARITY. COMPONENTS AND HARDWARE FOR A
FOUR FUNCTION MAST SHOWN.

1. CAPSCREW 11. LEFT LOWER HOSE GUIDE

2. HOSE CLAMP BAR 12. OUTER INTERMEDIATE MAST
3. HOSE CLAMP 13. PLATE
4. LOCKWASHER 14. BLOCK
5. WASHER 15. LOWER BRACKET
6. RESTRAINT 16. BRACKET
7. RIGHT UPPER HOSE GUIDE 17. NUT
8. LEFT UPPER HOSE GUIDE 18. FITTING
9. OUTER MAST 19. INNER MAST
10. RIGHT LOWER HOSE GUIDE

6. Remove free-lift cylinder from mast. See Cylinder

Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100YRM1382 for
procedures.

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

7. Remove the capscrew, special washer, external

tooth lockwasher, and rod end pin from the tilt
cylinder rod ends on the outer mast. Remove tilt
cylinder rod ends from outer mast. See
Figure 106.

NOTE: SEVERAL MAST COMPONENTS OMITTED

FOR CLARITY.

1. TILT CYLINDER 5. CAPSCREW

ROD END 6. GREASE FITTING
2. TILT CYLINDER 7. ROD END PIN
SHELL
3. SPECIAL WASHER
4. LOCK WASHER
EXTERNAL TOOTH

Figure 106. Tilt Cylinder Mounting

8. Remove bolts that hold retainer caps to mast

mount stubshafts. See Figure 107.

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Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Completely lower forks to relieve hydraulic

pressure before disconnecting any hydraulic
hoses.

WARNING
The mast is heavy. The mast can weigh
approximately 1100 kg (2385 lb). Make sure all
lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the
mast. Serious injury can occur if the mast falls.

CAUTION
Protect the hydraulic system from dirt and
contaminants when disconnecting hydraulic hoses
from the mast. If hydraulic system becomes
contaminated, damage to the hydraulic system can
NOTE: THREE-STAGE FFL MAST SHOWN. FOUR- occur.
STAGE FFL MAST IS MOUNTED THE SAME WAY.
NOTE: Before disassembling the mast, remove the
1. RETAINER CAP 4. BUSHING forks, carriage, and load backrest. See the sections
2. BOLTS 5. MAST MOUNTING Fork Replacement and Carriages Repair for
3. SHIM STUBSHAFT
6. GREASE FITTING procedures. If the free-lift cylinder or tilt cylinders need
to be repaired, the mast does not need to be removed
Figure 107. Mast Mounting from the lift truck. See the section Cylinder Repair
(Mast S/N A270-72, A551, A555, A559, A626, A627,
A751-52, B551, B555, B586-91, B749-54, C661-63,
WARNING C665, D507-09, D515, D562-64, E509, E564)
DO NOT stand the mast vertically once removed 2100YRM1382 for procedures. For header hose
unless it is properly chained to a support device. installation and adjustment procedures, see the
section Header Hose Installation and Adjustment.
1. Remove main lift cylinder from mast. See the
WARNING section Cylinder Repair (Mast S/N A270-72,
DO NOT stand on or near the mast while it is A551, A555, A559, A626, A627, A751-52, B551,
suspended by an overhead hoist. B555, B586-91, B749-54, C661-63, C665,
D507-09, D515, D562-64, E509, E564)
9. Slowly lift the mast from the lift truck using the 2100YRM1382 for procedures.
overhead lifting device. Move the mast away from
the lift truck and place, horizontally (carriage side NOTE: Tag chains prior to removal to aid in
facing up) on wooden beams or a pallet. reassembly.
2. Remove free-lift chain anchors and chains from
10. Remove shims and bushings from mast mount inner mast crossmember.
stubshafts. See Figure 107.
3. Disconnect free-lift cylinder hose from tube and
DISASSEMBLE remove tube assembly. See Figure 108.

NOTE: Tag chains prior to removal to aid in

WARNING
reassembly.
Hydraulic oil is hot after system operation and can
cause burns. DO NOT disconnect any hydraulic 4. Disconnect lift chains from chain anchors at
hoses until the oil in the system has cooled. bottom of inner mast and top of outer
intermediate mast. See Figure 108.

144
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

Figure 108. Four-Stage, Full Free-Lift Mast (FFL)

145
Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 108.

1. OUTER MAST 20. BRACKET

2. STRIP BEARING 21. TUBE ASSEMBLY
3. LOAD ROLLER 22. RIGHT MAIN LIFT CYLINDER
4. CHAIN ANCHOR 23. VALVE
5. COTTER PIN 24. STOP
6. CHAIN ANCHOR PIN 25. DOWEL
7. NUT 26. PAD
8. SHIM 27. INNER INTERMEDIATE MAST
9. LOCKWASHER 28. SHAFT
10. CAPSCREW 29. RETAINER
11. LOWERING CONTROL VALVE MOUNTING 30. HOSES SHEAVE
BRACKET 31. INNER MAST
12. LOWERING CONTROL VALVE 32. CROSSHEAD
13. FITTING 33. BAND
14. OUTER INTERMEDIATE MAST 34. SCREW
15. BUMPER 35. FREE-LIFT CYLINDER
16. CLAMP 36. SPRING GUIDE
17. LEFT MAIN LIFT CYLINDER 37. SPRING
18. SNAP RING 38. PISTON
19. CHAIN SHEAVE

146
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

5. Push inner mast toward bottom of mast assembly 11. Remove strip bearing at top of outer intermediate
until bottom load rollers are seen. See mast. Remove load rollers at bottom of inner
Figure 109. intermediate mast. Remove load rollers at top of
outer intermediate mast. Make a note of each
NOTE: The lower end of inner mast must be raised so shim arrangement and load roller location. The
that lift chains can clear the inner intermediate mast shim arrangements will be approximately the
lower crossmember. same during assembly.
6. Tag and remove inner mast lift chains.
12. Slide inner intermediate mast halfway out of top
7. Remove strip bearings at top of inner of outer intermediate mast. Connect crane to
intermediate mast. Remove load rollers at bottom center of inner intermediate mast. See
of inner mast. Remove load rollers at top of inner Figure 109. Slide inner intermediate mast out until
intermediate mast. See Figure 108. Make a note stub shafts are in notches of outer intermediate
of each shim arrangement and load roller mast. Remove inner intermediate mast.
location. The shim arrangements will be
13. Slide outer intermediate mast from bottom of
approximately the same during assembly.
outer mast approximately 30 cm (12 in.). Remove
8. Slide inner mast halfway out of top of inner strip bearings at top of outer mast. Remove snap
intermediate mast. Connect crane to center of rings and load rollers from both mast weldments.
inner mast. See Figure 109. Slide inner mast out Make a note of each shim arrangement and load
until stub shafts are in notches of inner roller location. The shim arrangements will be
intermediate mast. Remove inner mast from inner approximately the same during assembly.
intermediate mast.
14. Slide outer intermediate mast halfway out of top
NOTE: Tag chains prior to removal to aid in of outer mast. Connect crane to center of outer
reassembly. intermediate mast. Slide outer intermediate mast
out of outer mast until stub shafts are in notches
9. Disconnect lift chains at bottom of inner of outer mast. Remove outer intermediate mast
intermediate mast and top of outer mast. Remove from outer mast.
lift chains and chain anchors. Push inner
intermediate mast toward bottom of mast 15. Remove and disassemble chain and hose
assembly until bottom load rollers are seen. See sheaves as necessary for repair and cleaning.
Figure 109.

10. Remove lower stop from bottom of outer

intermediate mast. See Figure 108.

147
Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Figure 109. Mast Weldments, Remove

148
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

Legend for Figure 109.

A. REMOVE INNER MAST C. REMOVE OUTER INTERMEDIATE MAST

B. REMOVE INNER INTERMEDIATE MAST

1. MOVE TOWARD TOP OF MAST 7. STOP

2. LIFT CHAIN 8. LOAD ROLLER
3. MOVE TOWARD BOTTOM OF MAST 9. CHAIN ANCHORS
4. INNER MAST 10. OUTER INTERMEDIATE MAST
5. INNER INTERMEDIATE MAST 11. STRIP BEARINGS
6. STUB SHAFT

CLEAN AND INSPECT

WARNING
Cleaning solvents may be flammable and toxic and
WARNING
can cause severe skin irritation. When using
Never replace only the worn section of a chain. cleaning solvents, always follow the solvent
Replace the complete chain. Never replace only manufacturer's recommended safety precautions.
one chain of a chain pair. Replace both chains.
Always wear protective clothing and eye
protection when working with compressed air.
CAUTION
DO NOT use steam to clean lift chains, sheaves, or
load rollers. The bearings in the sheaves and load CAUTION
rollers are sealed and lubricated. Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
CAUTION
or a face shield to prevent injury to the eyes.
Lift chains, which were not checked before
removal, must be checked for correct length again 3. Clean the lift chains by soaking in solvent for 30
once installed in the mast and the mast installed minutes and remove all dirt and grease. Hang lift
on the lift truck. chains over a drip pan and let drip. Remove
residual solvent using compressed air.
1. Inspect the chain and hose sheaves and load
rollers for wear or damage. 4. Lubricate the chains by soaking them in SAE 30
engine oil for 30 minutes. Hang chains over a drip
NOTE: The chains must be inspected in the area of
pan for one hour to remove excess oil.
chain that passes over the chain sheave during the
first portion of a lift. Those links will show maximum 5. Inspect the chain anchors and pins. Replace any
wear. parts that are worn or damaged.
2. Inspect the lift chains for wear or damage. A lift
chain becomes longer when it is worn. If a chain
is 3% longer than a new lift chain, the lift chain WARNING
must be replaced. If a chain scale is available Be careful when cleaning with steam. Steam can
(Yale Part No. 580037684) , check the lift chain cause serious burns. Wear protective clothing,
as shown in Figure 110. If a chain scale is not gloves, and eye protection. Never expose your
available, measure 20 links of the lift chain. skin to steam.
Compare the measurement with the lengths given
in Figure 110. 6. Clean the mast weldments with steam or solvent.

149
Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

7. Inspect sliding surfaces for wear or damage.

WARNING Inspect load roller contact surfaces for wear or
Improper welding procedures can damage the damage. Inspect all welds for cracks.
structure of the mast or cause incorrect function
of the mast. Consult Resident Service Engineering
through the Contact Management System for
approval before welding on the mast.

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE
(YALE PART NO. 580037684).

1. WORN PINS 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR 8. CHAIN WEAR SCALE

Pitch
Total length of 20 links (pitch) of Wear Limit The maximum length
new chain of 20 links

12.7 mm (0.50 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.63 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.75 in.) 381.0 mm (15.0 in.) 392.4 mm (15.5 in.)
25.4 mm (1.00 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)

Figure 110. Lift Chains Check

ASSEMBLE by repairs. The strip bearings may also be adjusted

using shims. See Mast Adjustments, in this section for
NOTE: The shims for the load rollers keep the mast the adjustment procedures.
uprights parallel and provide correct clearance. During
assembly, the shim arrangement will be approximately 1. Put outer mast across wooden beams or a pallet,
the same as before disassembly. Check clearance and with mast pivots toward floor.
adjust strip bearings for wear or for changes caused

150
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

2. Connect crane to center of outer intermediate 7. Install strip bearings and shims on channels of
mast. See Figure 109. Fit lower stub shafts of outer intermediate mast. Apply multipurpose
outer intermediate mast into notches in top of grease with 2 to 4% molybdenum disulfide to strip
outer mast. Slide outer intermediate mast into bearing surfaces. Install load rollers and shims on
outer mast so stub shafts are seen at top and both inner and outer intermediate masts.
bottom of both mast uprights.
8. Install chain sheaves at top of outer intermediate
3. Install strip bearing and shims into the channels mast. Install outer intermediate mast chain
at top of outer mast. See Figure 111. Apply anchors and chains.
multipurpose grease with 2 to 4% molybdenum
disulfide to strip bearing surfaces. 9. Install chain sheaves and connect lift chains to
chain anchors at outer mast. Put lift chains over
chain sheaves on outer intermediate mast and
connect them to anchors at bottom of inner
intermediate mast.

10. Connect crane to center of inner mast. See

Figure 109. Slide mast into inner intermediate
mast so stub shafts are seen at top and bottom of
both uprights.

11. Install strip bearings and shims on channels of

inner intermediate mast. See Figure 111. Apply
multipurpose grease with 2 to 4% molybdenum
disulfide to strip bearing surfaces. Install load
rollers and shims on inner intermediate mast and
inner mast.

12. Connect lift chains to chain anchors at top of

outer intermediate mast. Put lift chains over chain
sheaves on inner intermediate mast and connect
1. SHIM 3. STUB SHAFT them to anchors at bottom of inner weldment.
2. STRIP BEARING 4. SHIMS
5. LOAD ROLLER 13. Install free-lift supply tube assembly and connect
6. MAST CHANNEL free-lift supply hose. See Figure 108.

Figure 111. Strip Bearings and Load Rollers 14. Install free-lift chain anchors and chains to inner
mast crossmember.
4. Install load rollers and shims onto stub shaft at
top of outer mast and at bottom of outer 15. Install main lift cylinders to mast. See the section
intermediate mast. Install chain sheaves, shims, Cylinder Repair (Mast S/N A270-72, A551,
and snap rings on outer intermediate mast. See A555, A559, A626, A627, A751-52, B551, B555,
Figure 108. B586-91, B749-54, C661-63, C665, D507-09,
D515, D562-64, E509, E564) 2100YRM1382 for
5. Install chain sheaves and snap rings on inner procedures.
intermediate mast.
INSTALL
6. Connect crane to center of inner intermediate
mast. Slide inner intermediate mast into outer 1. Lubricate the bushings with multipurpose grease
intermediate mast so stub shafts are seen at top with 2 to 4% molybdenum disulfide and install
and bottom of both mast uprights. See bushings and shims onto the stub shafts at the
Figure 109. bottom of the outer mast weldment. See
Figure 107.

151
Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

NOTE: If mast was disassembled, then the header

WARNING hoses and attaching hardware need to be installed. Go
Mast parts are heavy and can shift. Distances to Step 7 before going to Step 8. If header hoses and
between parts are small. Serious injury can result attaching hardware were not removed, proceed to
if part of the body is hit by parts of the mast or the Step 8.
carriage. 7. Install header hoses and attaching hardware as
noted during removal. See Header Hose
Installation and Adjustment for procedures.
WARNING
The mast is heavy. The mast can weigh 8. Install carriage and load backrest. See Carriages
approximately 1100 kg (2385 lb). Make sure all Repair for procedures.
lifting devices (hoists, cables, chains, slings, etc.)
9. Check the tilt cylinder adjustment. See the section
are suitable and of adequate capacity to lift the
Cylinder Repair (Mast S/N A270-72, A551,
mast. Serious injury can occur if the mast falls.
A555, A559, A626, A627, A751-52, B551, B555,
2. Lift the mast using an overhead lifting device with B586-91, B749-54, C661-63, C665, D507-09,
chain hooks attached to the upper outer D515, D562-64, E509, E564) 2100YRM1382 for
crossmember. Make sure all mast weldments are procedures. Operate the mast and check for
fastened together. Make sure chains will not leaks and to ensure mast is operating correctly.
damage chain sheaves, tubing, or other parts of Check lift chains as described in the section Lift
the mast assembly. Chains Adjustment.

3. Use lifting device and install mast into NOTE: Before checking for mast side kicking, the
transmission housing mounts. Apply Loctite™ mast must be fully assembled to include the carriage,
#242 adhesive sealant to bolt threads. Install the forks, load backrest and any attachments if the lift
bolts, shims and retainer caps. See Figure 107. truck is equipped with one.
Tighten bolts in a diametric pattern to 10. Raise the mast, without a load to its full height
24 N•m (212 lbf in). and check for side kicking. Mast side kicking is
where the mast, without a load, moves either to
the right or left as it is being raised. If the mast is
WARNING side kicking, see the Mast Adjustments section for
Use a driver, NOT your fingers, to push the anchor procedures to correct mast side kicking.
pins from the clevises on the tilt cylinders. The tilt
cylinder or mast can move and cause serious 11. Lubricate the sliding surfaces and load roller
injury. surfaces with multipurpose grease with 2 to 4%
molybdenum disulfide along the full length of the
4. Apply multipurpose grease with 2 to 4% channels as shown in Figure 112. Apply grease
molybdenum disulfide to rod end pin and connect only to surfaces indicated in Figure 112.
tilt cylinders to mast using rod end pin, capscrew,
special washer, and external tooth lockwasher.
Tighten capscrews to 38 N•m (28 lbf ft). See
Figure 106.

5. Install free-lift cylinder to mast. See Cylinder

Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100YRM1382 for
procedures.

6. Connect the lift truck hydraulic supply hose to the

lowering control valve. See Figure 104. Connect
hydraulic hoses as tagged during removal.

152
4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

1. CHAIN SHEAVE 5. STUB SHAFT

2. CAPSCREW 6. HOSE GUARD
A. LOWER LOAD ROLLERS 3. HOSE SHEAVE 7. NUT
B. UPPER LOAD ROLLERS 4. SPACER 8. FREE-LIFT CHAIN
1. LUBRICATE STRIP BEARING SURFACES Figure 113. Free-Lift Crosshead Assembly
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
2. Install carriage hose bracket to center tab on
Figure 112. Mast Lubrication lower carriage bar. See Figure 114.

3. Install fittings to bracket. See Figure 115.

HEADER HOSE INSTALLATION AND
ADJUSTMENT a. Three Function Mast - Install fittings to the left
The four-stage mast covered in this manual can have or right side. Finger tighten fittings.
either three functions or four functions. The header
hose installation and adjustment procedures for a four b. Four Function Mast - Install fittings to the left
function mast are covered below. If mast is three- and right side. Finger tighten fittings.
function, there are four hoses: two free-lift #6, one rear
inside and one rear outside hoses, and one lower and
upper hose guide.

NOTE: Before installing new header hoses, verify the

lift height of the mast. The lift height is on the
Nameplate of the lift truck and on the right side of the
outer mast.
1. Make sure free-lift cylinder hose guards and hose
sheaves are installed on free-lift cylinder. See the
section Cylinder Repair (Mast S/N A270-72,
A551, A555, A559, A626, A627, A751-52, B551,
B555, B586-91, B749-54, C661-63, C665,
D507-09, D515, D562-64, E509, E564)
2100YRM1382 for procedures. The capscrew on
hose guard should be finger tight only. See
Figure 113.

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Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

4. Install lower bracket to blocks at bottom of inner

mast. See Figure 105 or Figure 116. Tighten
capscrews to 71 N•m (52 lbf ft). DO NOT install
plate.

5. Install lower hose guides to outer intermediate

mast. Tighten capscrews to 41 N•m (30 lbf ft).
Install hose clamps to lower hose guide. Finger
tighten capscrews.

6. Completely lower the carriage.

NOTE: A three function mast will only have one set of

free-lift #6 hoses.
7. Route free-lift #6 and free-lift #4 hoses down
behind carriage bar to carriage bracket fittings.
See Figure 116.

8. Connect free-lift #6 and #4 hose ends to fittings

1. CARRIAGE 3. HOSE BRACKET and tighten fittings with fingers. If mast has four
2. FITTING functions, connect free-lift #4 hose ends to the
two fitting on right side. See Figure 115.
Figure 114. Installing Hose Bracket to Lower
Carriage Bar 9. Pull free-lift #6 and #4 hoses over free-lift
crosshead hose sheaves (item #8, Figure 116).

1. THREE FUNCTION (RIGHT)

2. THREE FUNCTION (LEFT)
3. FOUR FUNCTION

Figure 115. Fittings Configuration

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4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

Figure 116. Header Hose Arrangement, Four-Stage FFL Mast

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Four-Stage Mast With Full Free-Lift Repair 4000 YRM 1405

Legend for Figure 116.

A. BACK VIEW C. THREE FUNCTION ARRANGEMENT

B. FRONT VIEW D. FOUR FUNCTION ARRANGEMENT

1. REAR OUTSIDE HOSE 10. ROUTE HOSES BELOW BOTTOM OF LOWER

2. REAR INSIDE HOSE HOSE CLAMP
3. LOWER BRACKET 11. PULL HOSES UNDER HOSE CLAMPS AT TOP OF
4. CARRIAGE BRACKET FITTING UPPER HOSE GUIDE
5. CARRIAGE BRACKET 12. PULL HOSES UP TOWARD TOP OF MAST
6. CONNECT HOSES HERE 13. INNER INTERMEDIATE SHEAVE
7. UPPER HOSE GUIDE 14. LOWER HOSE GUIDE
8. ROUTE HOSES OVER FREE-LIFT 15. ROUTE FREE-LIFT HOSES BETWEEN FREE-LIFT
CROSSHEAD CYLINDER AND CROSSMEMBER
9. ROUTE HOSES DOWN TO LOWER HOSE 16. INNER MAST BRACKET
GUIDE 17. FREE-LIFT #6 HOSE
18. FREE-LIFT #4 HOSE

10. Route free-lift #6 and #4 hoses down between 18. Loop the hoses 125 mm (5 in.) below the bottom
free-lift cylinder and crossmember (#15, of lower hose clamps and rout hoses into upper
Figure 116). Tighten hose ends at the hose hose guide (item #10, Figure 116).
bracket on lower carriage bar. See Figure 114.
19. Install hose clamps to upper hose guide. Finger
11. Connect the rear inside and rear outside hoses to tighten capscrews.
free-lift #6 #4 hoses behind free-lift cylinder (item
#6, Figure 116). The rear outside hoses are 20. Pull rear inside, rear outside, and free-lift #6 and
approximately 102 mm (4 in.) shorter than the #4 hoses under hose clamps at top of upper hose
rear inside hoses. guide (item #11, Figure 116). Finger tighten
capscrews.
12. Pull down on rear inside, rear outside, and free-lift
#6 and #4 hoses to remove slack from hoses. 21. Route hoses under hose clamps at the bottom of
Clamp hoses to lower bracket on crossmember of upper hose guide. See Figure 117. Finger tighten
inner mast. Tighten clamp capscrews to capscrews.
7 to 11 N•m (62 to 97 lbf in).
22. Tighten free-lift crosshead hose guard capscrew
13. Position rear inside, rear outside, and free-lift #6 to 71 N•m (52 lbf ft). See Figure 116.
and #4 hoses on inner mast bracket (item #16,
Figure 116). 23. Make sure hoses are aligned properly and are
centered on free-lift hose sheaves. Hoses should
14. Install plate to lower bracket. See Figure 105. travel parallel to each other. Tighten fittings to
Tighten capscrews to 41 N•m (30 lbf ft). prevent hoses from twisting.

15. Pull hoses toward top of mast, following inner 24. Loosen hose clamps at top of lower hose guide.
mast lift chains, and over inner intermediate mast See Figure 117. Pull down on hoses with enough
hose sheave (item #12, Figure 116). force to remove slack from hoses. Tighten clamp
capscrews to 7 to 11 N•m (62 to 97 lbf in). See
16. Route rear inside, rear outside, and free-lift #6 Figure 117.
and #4 hoses down to lower hose guides (item
#9, Figure 116). Place hoses under hose clamp at 25. Tighten upper hose clamp capscrews on upper
top of lower hose guides. Pull downward on hose guide to 7 to 11 N•m (62 to 97 lbf in). See
hoses with enough force to remove slack from Figure 117.
hoses. Tighten clamp capscrews
7 to 11 N•m (62 to 97 lbf in). 26. Raise and lower the mast slowly through several
cycles to check for proper hose alignment,
17. Install upper hose guides to outer mast. Tighten clearances and hose tracking in the hose upper
capscrews to 41 N•m (30 lbf ft). See Figure 105. and lower guides.

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4000 YRM 1405 Four-Stage Mast With Full Free-Lift Repair

27. After completing installation and adjustment of

header hoses, go to section Install and complete
Step 8 through Step 11.

Figure 117. Header Hose Clamps

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Lift Chains Adjustment 4000 YRM 1405

Legend for Figure 117. 3. HOSE CLAMP

4. HOSE CLAMP
1. CROSSHEAD SHAFT 5. UPPER HOSE GUIDE
2. CHAIN AND HOSE GUARD 6. LOWER HOSE GUIDE
7. CONNECTION TO CARRIAGE BRACKET
FITTINGS

Lift Chains Adjustment

1. When adjusting the lift chains on forklift trucks
WARNING equipped with either pin or hook-type forks
installed, go to Step 2. If the forklift truck is
When working on or near the mast, see the section
normally equipped with a hook-type carriage and
Safety Procedures When Working Near Mast.
has an attachment without forks, go to Step 3. If
During test procedures for the hydraulic system, the forklift truck is normally equipped with a pin-
fasten the load to the carriage with chains to type carriage and has an attachment without
prevent it from falling. Keep all personnel away forks, go to Step 4.
from the lift truck during the tests.
NOTE: Prior to performing adjustment procedures,
Never allow anyone under a raised carriage. DO
make sure the forklift truck is parked on a level surface
NOT put any part of your body in or through the lift
and the mast is in the vertical position.
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED. 2. Adjust the chain anchors that support the
carriage, until the bottom of the fork heel is
Never check for leaks by putting hands on
12 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above the
hydraulic lines or components under pressure.
floor level. See Figure 118.
Hydraulic oil under pressure can be injected into
the skin.
3. Adjust the chain anchors that support the
When the lift chains are correctly adjusted: carriage, until the bottom of the lower carriage bar
is above the floor level as shown in Table 8 and
• The tension will be the same on each chain of Figure 119.
the chain set. Check tension by pushing on both
chains at the same time. Table 8. Chain Adjustment With Attachment
• The chain length will be correct. Installed
• The chains must travel freely through the Class II and III 82.5 ±3.0 mm (3.25 ±0.12 in.)
complete cycle.
Class IV 133.5 ±3.0 mm (5.26 ±0.12 in.)
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 ½-20,
4.5 N•m (39.8 lbf in) for ⅝-18 nuts,
6.0 N•m (53.1 lbf in) for ¾-16 of torque cannot be
reached; replace locknut. The chain anchors, after
adjustment, must be able to move on their mountings.
NOTE: When directed to a step from step 1, perform
that step only.

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4000 YRM 1405 Lift Chains Adjustment

Table 9. Pin-Type Carriage Chain Adjustment

4-5.5T Class III 545.0 ±3.0 mm
(21.5 ±0.12 in.)
4-5.5T Class IV 708.0 ±3.0 mm
(27.87 ±0.12 in.)
6-7T Class IV 907.0 ±3.0 mm
(35.71 ±0.12 in.)

1. MAST
2. CARRIAGE
3. FORK
4. HEEL OF FORK IS
12 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) ABOVE
FLOOR LEVEL

Figure 118. Lift Chain Adjustment, Forks

1. LOAD BACK REST

1. MAST 2. FORK PIN
2. CARRIAGE 3. DISTANCE FROM FORK PIN TO FLOOR
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR Figure 120. Lift Chain Adjustment, Pin-Type
Carriage
Figure 119. Lift Chain Adjustment With Attachment
Installed

4. See Figure 120. Adjust the chain anchors, which

support the carriage, until the center line of the
fork pin is above the floor level as shown in
Table 9.

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Carriage Adjustments 4000 YRM 1405

Carriage Adjustments
1. Install the load rollers on the carriage. Install the 4. Keep shim arrangement on each side of carriage
shims for the load rollers onto the stubshaft in the approximately equal. The carriage must be
same sequence as when disassembled. On centered within the inner mast within
carriages equipped with six load rollers, there are +1.50 mm (0.06 in.).
no shims under the top load rollers.

2. Use a lifting device to raise carriage. Find the CAUTION

point of tightest fit between the carriage load Too much grease will cause the rollers to slide and
rollers and inner mast channels. wear flat areas on the rollers and introduce
contamination into and on mast channels.
3. Remove carriage from mast. Adjust shim
arrangement for each roller for clearance 5. After adjustment, lubricate channels with a thin
between roller and inner channel. Repeat Step 1 layer of grease. Adjust hydraulic hoses and make
and Step 2 until there is zero clearance at the sure connections are correct, if the carriage is
point of tightest fit. equipped with hydraulic attachments.

Tilt Cylinders Adjustment

To adjust the tilt cylinders, see the service manual B749-54, C661-63, C665, D507-09, D515, D562-64,
Cylinder Repair (Mast S/N A270-72, A551, A555, E509, E564) 2100YRM1382 for adjustment
A559, A626, A627, A751-52, B551, B555, B586-91, procedures.

Mast Adjustments
LOAD ROLLER, ADJUST the clearance and adjust shims after repairs have
been completed.
NOTE: Shims are installed on both sides of the load
rollers. DO NOT add to or remove shims from the stub 1. The load rollers control the alignment of the mast
shafts. To change the position of the roller on the stub uprights. See Figure 121. The alignment
shaft, move the shims from one side of the load roller conditions are given on a list below with the most
to the other. important condition first.
During assembly, the shim arrangement will be
approximately the same as before disassembly. Check

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4000 YRM 1405 Mast Adjustments

NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO GIVE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO GIVE ZERO CLEARANCE
AT POINT OF TIGHTEST FIT.

A. TOP VIEW C. CARRIAGE FRONT VIEW

B. MAST FRONT VIEW

1. CHANNEL 7. ZERO CLEARANCE AT POINT OF TIGHTEST FIT

2. LOAD ROLLER 8. EQUAL SPACE ±1.5 mm (0.060 in.)
3. STUB SHAFT 9. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
4. SNAP RING 10. PUT SPACER ON OUTSIDE OF TOP LOAD
5. SHIMS ROLLER, UNDER SNAP RING
6. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.) 11. SHIM FOR ZERO CLEARANCE AT POINT OF
TIGHTEST FIT

Figure 121. Mast Adjustments

a. The mast uprights must be parallel to each c. The number of shims under a load roller must
other. be approximately the same as the stub shaft in
the opposite side of the upright. This ensures
b. Use shims to adjust load rollers so there is the uprights will be approximately in the center.
zero clearance between load roller and
channel at point of tightest fit. 2. Perform the following steps to adjust the mast
load rollers:

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Mast Adjustments 4000 YRM 1405

a. Use a crowbar to move mast uprights from d. Measure distance between channels of mast
side to side to measure movement. Measure uprights on top and bottom. Change shims to
movement in a minimum of three different keep distance equal between top and bottom
positions of each mast upright. so mast uprights are parallel. Also make sure
the mast uprights are parallel within
b. Separate mast uprights and change shim 1.5 mm (0.060 in.).
arrangements as required. Assemble uprights.
Slide upright all the way to the top and bottom 3. Adjust strip bearings. See Figure 122. Insert
to find the tightest fit. shims under strip bearing. Adjust clearance until
there is less than 0.8 mm (0.030 in.) at the
c. Repeat Step a and Step b until there is zero tightest fit. See Figure 121.
clearance at the point of the tightest fit.

1. STRIP BEARING 4. SHIMS

2. LOAD ROLLER 5. O-RING
3. MAST UPRIGHT

Figure 122. Strip Bearings Arrangement

MAST SIDE KICKING, ADJUST 3. If the mast is moving to the left, shims will need to
either be added or removed from the top of the
Mast side kicking is where the mast, without a load, right main lift cylinder. If mast moves to the right,
moves either to the right or left as it is being fully shims will need to either be added or removed
raised. When this happens, it is an indication that one from the top of the left main lift cylinder. .
of the main lift cylinders is raising at a faster rate then
the other. Before checking for mast side kicking, the 4. If shims will be added, use the smallest shim size
mast must be completely assembled to include the that can be used on the mast that is being
carriage, forks, load backrest, and any attachments if adjusted. See the Parts Manual for shim sizes
the lift truck is equipped with one. and part numbers.
To adjust the mast for side kicking, do the following:
5. Raise the mast again and visually inspect it to
1. Place the lift truck on a level surface and apply ensure that it is no longer side kicking. If side
the parking brake. kicking is still present, repeat Step 3 and Step 4.

2. Raise the mast and visually inspect it as it

reaches its full height.

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