Maintenance

MAST REPAIR
(S/N A698 AND A699)
GLC050LX
[A967];GLP/GDP20-25LX
(GLP/GDP050LX) [B974]

PART NO. 550109117 4000 YRM 1773

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions
contained in the Service Manual could result in damage to the products, personal injury, property damage
or death.
• 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 YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Safety Procedures When Working Near Mast .......................................................................................................... 1
Forks Replacement ...................................................................................................................................................3
Remove .................................................................................................................................................................3
Install .....................................................................................................................................................................4
Checks .................................................................................................................................................................. 4
Adjustment ............................................................................................................................................................ 5
Carriage Repair ........................................................................................................................................................ 5
Standard Carriage .................................................................................................................................................6
Remove .............................................................................................................................................................6
Clean and Inspect ............................................................................................................................................. 7
Install .................................................................................................................................................................8
Integral Sideshift Carriage Prior to December, 2016 ............................................................................................ 9
Remove .............................................................................................................................................................9
Disassemble ....................................................................................................................................................11
Clean and Inspect ........................................................................................................................................... 11
Assemble ........................................................................................................................................................ 12
Install ...............................................................................................................................................................12
Integral Sideshift Carriage After December, 2016 .............................................................................................. 13
Remove ...........................................................................................................................................................13
Disassemble ....................................................................................................................................................16
Clean and Inspect ........................................................................................................................................... 16
Assemble ........................................................................................................................................................ 16
Install ...............................................................................................................................................................17
Disconnecting Attachment Hydraulic Quick Disconnect Hoses .......................................................................... 18
Connecting Attachment Hydraulic Quick Disconnect Hoses .............................................................................. 18
Two-Stage Mast With Limited Free-Lift Repair ....................................................................................................... 18
Mast .................................................................................................................................................................... 18
Remove ...........................................................................................................................................................18
Disassemble ....................................................................................................................................................19
Clean and Inspect ........................................................................................................................................... 22
Assemble ........................................................................................................................................................ 23
Install ...............................................................................................................................................................24
Header Hoses, Installation and Adjustment ........................................................................................................25
Install ...............................................................................................................................................................25
Adjustment ...................................................................................................................................................... 30
Three-Stage Mast With Full Free-Lift Repair .......................................................................................................... 30
Remove ...............................................................................................................................................................30
Disassemble ....................................................................................................................................................... 31
Clean and Inspect ............................................................................................................................................... 37
Assemble ............................................................................................................................................................ 38
Install ...................................................................................................................................................................39
Header Hose Installation and Adjustment ...........................................................................................................40
Standard ..........................................................................................................................................................40
Install ...........................................................................................................................................................40
Adjust .......................................................................................................................................................... 44
Optional Equipment, Lift Truck GLP/GDP050LX (B974) .................................................................................45
Install ...........................................................................................................................................................45
Adjust .......................................................................................................................................................... 52
Main Lift Cylinder Repair ........................................................................................................................................ 52
Lift and Tilt System Leak Check ............................................................................................................................. 52
Tilt Cylinders Adjustment ........................................................................................................................................ 52

©2018 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Lift Chain Adjustment ..............................................................................................................................................52
Mast Adjustments ................................................................................................................................................... 53
Load Roller Adjustment .......................................................................................................................................54
Mast Side Kicking Adjustment ............................................................................................................................ 56
Carriage Adjustment ............................................................................................................................................... 57

This section is for the following models:

(GLC050LX) [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [B974]

ii
4000 YRM 1773
General
WARNING
Before working on or near the mast, see the
section
Safety Procedures When Working Near Mast in
this YRM .
NOTE: Hoses have a service life that is determined
by application and time. Install a new hose if the hose
Safety Procedures When Working Near Mast
The following procedures MUST be used when
inspecting or working near the mast. Additional
precautions and procedures can be required when
repairing or removing the mast.
WARNING
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury or death
can result if part of the body is hit by parts of the
mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are
completely lowered or a safety chain is
installed. Also make sure that the power is
OFF and the key is removed. Put a DO NOT
OPERATE tag in the operator's
compartment. Disconnect the battery and
put a tag or lock on the battery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• Mast repairs require disassembly and
removal of parts and can require removal of
the mast or carriage. Follow the repair
procedures in this section.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely:
Turn the key switch to the ON position and
push the lift/lower control lever forward until
there is no movement in the mast. Make sure
that all parts of the mast that move are fully
lowered.
General
is worn, damaged, soft or hard, and no longer flexible.
If necessary, compare old hose to a new hose that is
the correct replacement for the hose you are
inspecting.
This section has the repair procedures for the Two-
Stage, Limited Free-Lift (LFL) and Three-Stage, Full
Free-Lift (FFL). Procedures for adjusting the carriage,
lift chains, and mast are located at the end of this
manual.
OR
• If parts of the mast must be in a raised
position, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
these procedures:
1. Put mast in vertical position.
2. Raise mast to align bottom crossmember of mast
upright that moves in outer mast with
crossmember on outer mast. On the two-stage
mast, the moving part is the inner mast. On the
three-stage mast, it is the intermediate mast. See
Figure 1.
3. Use a 3/8-inch minimum safety chain with a hook
to fasten the crossmembers together so the
movable member cannot lower. Put hook on back
side of mast. Make sure hook is completely
engaged with a link in the chain. Make sure safety
chain does not touch lift chains or chain sheaves,
tubes, hoses, fittings, or other parts on the mast.
4. Lower mast until there is tension in safety chain
and free-lift cylinder (full free-lift models) is
completely retracted.
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power, and remove
key. Put a DO NOT OPERATE tag in the operator's
compartment. Disconnect battery and put a tag or lock
on battery connector.
1
Safety Procedures When Working Near Mast 4000 YRM 1773

5. Install another safety chain (9.5 mm (3/8 in.)

minimum) between the top or bottom bar of the
carriage (6) and a crossmember on the outer
mast as a secondary safety device. Install a DO
NOT REMOVE tag on the safety chain(s).

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

1. OUTER MAST 5. FREE-LIFT CYLINDER

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

Figure 1. Safety Chaining the Mast

2
4000 YRM 1773 Forks Replacement

Forks Replacement
The forks are held on the carriage by hooks. The forks
are kept in position by lock pins that fit through the top
fork hooks and into slots in the top bar carriage. If lock
pin does not remain engaged in carriage slot, replace
with new lock pin. Always check that the lock pins for
the forks keep the forks in position on the carriage.
Replace damaged fork lock pin parts. The forks can be
removed from the carriage by aligning the forks with
the fork removal notch. The fork removal notch is in
the bottom bar of the carriage. See Figure 2.
REMOVE
WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
NOTE: Forks must be removed or installed by trained
personnel only.
NOTE: Forks are to be replaced only in sets, not
individually.
A fork can be removed from the carriage for
replacement of the fork or other maintenance. Slide
the fork to the fork removal notch in the bottom bar of
the carriage. See Figure 2. Lower the fork onto blocks
so the bottom hook of the fork moves through the fork
removal notch. See Figure 3. Lower the carriage
further so the top hook of the fork is disengaged from
the top carriage bar. Move the carriage away from the
fork or use a lifting device to move the fork away from
the carriage.

1. LOAD BACKREST 6. WEDGE

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

Figure 2. Carriage and Forks

3
Forks Replacement 4000 YRM 1773

Some applications may require closer alignment.

If forks do not meet specification, they both must
be replaced.

CAUTION
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment.

2. Replace any damaged or broken parts that are

used to keep forks locked in position.

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
1. CARRIAGE BARS Figure 5.
2. HOOK FORK
3. BLOCKS
a. Determine normal thickness of "N" of fork
Figure 3. Hook Fork Removal using scale or ruler portion of caliper ruler.
Measurement has to be done on fork shank
INSTALL using caliper ruler.

NOTE: Forks must be removed or installed by trained
personnel only.
NOTE: Forks are to be replaced only in sets, not
individually.
Move the fork and carriage so the top hook on the fork
can engage the upper carriage bar. Raise the carriage
to move the lower hook through the fork removal
notch. Slide the fork on the carriage so both upper and
lower hooks engage the carriage bars. Engage the
lock pin with a notch in the upper carriage bar.
CHECKS
b. Position caliper at end of heel internal radius
(item A, Figure 4) with opening corresponding
to measured thickness of fork shank in Step a
above. (e.g. for N 1.75 use N 1.75 opening).
This is typically the section of fork where wear
is greatest. Note that opening distance has
been reduced by 10% from nominal thickness.
c. If fork enters opening, it is mandatory to
replace it. DANGER OF BREAKING.
Furthermore, a 10% reduction in fork blade
thickness results in 20% reduction in operating
capacity.

WARNING
DO NOT try to correct fork tip alignment by
bending the forks or adding shims. Replace bent
forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special
procedures. Replace damaged forks. Forks are to
be replaced only in sets and not individually.

1. Inspect forks for cracks and wear. Check

alignment of fork tips. The difference in height of
fork tips must be less than three percent of length
of forks. See Table 1 and Figure 4.

4
4000 YRM 1773 Forks Replacement

Table 1. Fork Tip Alignment

Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip Dif-
ference1
mm (in.) mm (in.)
914 (36) 27 (1.08)
1000 (39 30 (1.17
1067 (42) 32 (1.26)
1100 (43) 33 (1.29)
1200 (47) 36 (1.42)
1219 (48) 37 (1.44)
1Differenceof alignment between fork tips must be no
more than 3% of the total fork length.

Figure 5. Fork Wear Check

ADJUSTMENT
NOTE: Forks must be removed or installed by trained
personnel only.
NOTE: Forks are to be replaced only in sets, not
individually.
NOTE: During adjustment of the forks, the heel of the
forks should not be touching the ground.
The forks are connected to the carriage by hooks and
lock pins. See Figure 2. The lock pins are installed
through the top fork hooks and fit into slots in the top
A. HEEL OF FORK (MUST BE 90% OF DIMENSION carriage bar. If lock pin does not remain engaged in
B) carriage slot, replace with new lock pin.
B. ORIGINAL FORK THICKNESS (DIMENSION B)
Adjust forks as far apart as possible for maximum
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF support of the load. Hook forks will slide along the
FORK LENGTH) carriage bars to adjust for the load to be lifted. Raise
2. CRACKS the lock pin in each fork to slide the fork on the
3. MAXIMUM ANGLE 93° carriage bar. Make sure the lock pin is engaged in the
4. FORK REMOVAL NOTCH carriage bar to lock the fork in position after the width
5. CARRIAGE
adjustment is made.
Figure 4. Fork Check

5
Carriage Repair 4000 YRM 1773

Carriage Repair
STANDARD CARRIAGE
WARNING
Remove
When disconnecting the lift chains, keep control of
1. Put a one-quarter capacity load on forks. The the ends. Use wire to temporarily connect the ends
load must provide carriage with stability and not of the lift chains to the mast. This procedure will
allow carriage to fall when it is disconnected from prevent the lift chains from falling from the
mast. sheaves and causing an injury or damage.

2. Lower carriage and forks onto blocks to loosen lift
chains. See Figure 3.
3. Remove four capscrews, washers, nuts, and load
backrest from carriage. See Figure 6.
4. Remove cotter pin and chain pin from each chain
anchor at carriage. See Figure 7. Disconnect lift
chains from carriage. Use wire to connect ends of
the lift chains to a part of the mast. Make sure
chains can move freely when inner mast is raised.

1. CAPSCREW
2. WASHER
3. NUT
4. LOAD BACKREST

Figure 6. Load Backrest Removal

6
4000 YRM 1773 Carriage Repair

1. SNAP RING 6. LOAD ROLLER

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

Figure 7. Standard Carriage

7. Connect a lifting device to carriage. Remove load

WARNING from forks with another lift truck. Remove forks
To help prevent possible injury, make sure the from carriage. See Forks Replacement for
carriage is stable when the inner mast is above the procedures. Remove blocks and lower carriage to
load rollers of the carriage. the floor so load rollers are facing up.

5. Use lift cylinders to raise inner or intermediate Clean and Inspect

mast. If hydraulic system cannot be used,
disconnect lift cylinders from inner mast. For
procedures, see Cylinder Repair (Mast S/N
A698 and A699) 2100YRM1770. Connect a
crane [the capacity of the crane must be at least
681 kg (1501 lb)] to the top of inner mast.
Carefully raise inner mast until it is above load
rollers of carriage. Install safety chains to secure
mast in its extended position and disconnect
crane. See
Safety Procedures When Working Near Mast.
NOTE: Shims are installed on the bottom and middle
rollers only.
1. If any of the load rollers must be replaced, make
a note of the location and number of shims. Install
shims, load rollers, and snap rings. For the top
rollers, install spacers. See Carriage Adjustment
for correct adjustment of load rollers.

6. Move lift truck away from carriage. Completely

lower inner mast so it cannot move.

7
Carriage Repair
WARNING
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
or a face shield to prevent injury to the eyes.
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
CAUTION
DO NOT use cleaning solvent, compressed air, or
steam to clean lift chain sheaves or load rollers.
The bearings in the lift chain sheaves and load
rollers are sealed and lubricated. Cleaning solvent,
compressed air, and steam can damage the load
roller bearings.
2. Clean any oil, grease, dirt, and other debris from
the carriage frame. Use a cleaning solvent and
compressed air to dry.
WARNING
Improper welding procedures can damage the
structure of the mast or cause mast to function
incorrectly. Consult your Yale lift truck dealer for
more information before welding on the mast.
3. If the carriage bars have any protruding welds or
damaged notches, repair by grinding, filing, or
welding.
4. Clean and inspect the chain anchors, chain
anchor pins, and chain pins. See Figure 7. Check
chain anchors, chain anchor pins, and chain pins
for wear and serviceability. Discard worn or
unserviceable chain anchors, chain anchor pins,
and chain pins. Discard cotter pins.
Install
1. Use hydraulic system of lift truck (if it has not
been disconnected) to raise inner mast. If
hydraulic system cannot be used, connect a
crane [the capacity of the crane must be at least
681 kg (1501 lb)] to top of inner mast. Carefully
8
4000 YRM 1773
raise inner mast until it is above load rollers of
carriage. Install safety chains to secure mast in its
extended position and disconnect crane. See
Safety Procedures When Working Near Mast.
2. Move lift truck toward carriage until inner mast is
aligned with carriage rollers. If inner mast has
been raised and secured using a crane and
safety chains, connect crane, raise inner mast,
and remove safety chains. Carefully lower inner
mast until it engages all of the load rollers.
Disconnect crane, if attached, and reconnect lift
cylinders. See section Cylinder Repair (Mast
S/N A698 and A699) 2100YRM1770.
3. Check clearance of load rollers. See
Carriage Adjustment in this manual.
NOTE: Use new cotter pins each time chain pins are
removed.
4. Connect lift chains to chain anchors at carriage.
Install cotter pins in chain pins. Be sure cotter
pins are installed on the outside of chain anchor.
See Figure 8. Bend both legs of cotter pin against
chain anchor pin. Adjust lift chains as described in
Lift Chain Adjustment in this manual.
1. COTTER PIN
2. CHAIN PIN
3. CHAIN ANCHOR
4. CHAIN ANCHOR PIN
5. SNAP RING
Figure 8. Cotter Pin Installation
5. Install four capscrews, washers, and nuts
securing load backrest to carriage. See Figure 6.
Tighten nuts to 53 N•m (39 lbf ft).
6. Install forks. See Forks Replacement.
4000 YRM 1773
INTEGRAL SIDESHIFT CARRIAGE PRIOR
TO DECEMBER, 2016
Remove
1. Lower carriage completely. Remove forks. See
Forks Replacement for removal procedures.
2. Remove four capscrews and load backrest from
carriage. See Figure 6.
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.
3. Relieve hydraulic pressure to the sideshift
cylinder by moving sideshift lever in both
directions several times.
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.
Carriage Repair
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.
NOTE: Tag hydraulic lines and fittings prior to
disconnecting to aid in connecting during installation.
NOTE: If lift truck is equipped with hydraulic quick
disconnect hoses, see section
Disconnecting Attachment Hydraulic Quick Disconnect
Hoses.
4. Disconnect hydraulic lines from sideshift cylinder.
Put caps and plugs on open lines and cylinder
ports.
5. Remove lower mounting hooks by removing four
capscrews securing hooks. See Figure 9.
6. Remove two cotter pins, two pins, and sideshift
cylinder from carriage. See Figure 9.
7. Use a crane with a capacity of at least
450 kg (992 lb) to lift outer frame away from the
inner frame (see Figure 10). Lay the outer frame
flat on a pallet or workbench.
9
Carriage Repair 4000 YRM 1773

1. INNER FRAME 11. LUBE FITTING

2. OUTER FRAME 12. PIN
3. SIDESHIFT CYLINDER 13. CHAIN ANCHOR
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. COTTER PIN
6. LOWER HOOK 16. LOAD ROLLER
7. CAPSCREW 17. SHIMS
8. WASHER 18. SPACER
9. CLEVIS PIN 19. FORK REMOVAL NOTCH
10. PIN

Figure 9. Integral Sideshift Carriage

10
4000 YRM 1773 Carriage Repair

1. OUTER FRAME
2. LIFTING HOOK
3. LIFTING DEVICE
A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
Figure 10. Remove Outer Frame 1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
Disassemble MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.

1. Remove upper and lower bearings from inner Figure 11. Lower Mounting Hooks Wear Limit and
frame. See Figure 12. Clearance Adjustment

2. If damaged, remove lube fittings from outer

frame. See Figure 9.
3. Disassemble side shift cylinder. See Cylinder
Repair (Mast S/N A698 and A699)
2100YRM1770 for procedures.
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.

Clean and Inspect
1. Inspect lower mounting hooks for wear. Replace
hooks if they are worn beyond wear limit. Wear
limit clearance range is 0.76 mm (0.03 in.)
minimum and 1.52 mm (0.06 in.) maximum. See
A in Figure 11.
2. Clean and inspect carriage bars for damage and
smoothness. Ensure bars are parallel and ends
are flush. If carriage bars have any protruding
welds or damaged notches, repair by grinding,
filing, or welding.
3. Clean bearing areas. Inspect sideshift bearings
for wear as follows:

a. Remove upper bearings from upper carriage

bar. If either upper bearing is worn to less than
2.5 mm (0.1 in.) thickness, replace both upper
bearings by driving upper bearings from upper
carriage bar. See Figure 9.

b. Remove lower bearings from lower carriage

bar. If either lower bearing is worn to less than
2.5 mm (0.1 in.) thickness, replace both lower
bearings by prying lower bearings from lower
carriage bar. See Figure 9.

11
Carriage Repair 4000 YRM 1773

4. Inspect sideshift cylinder. Replace entire cylinder 2. If lube fittings were removed, install new lube
assembly if a cylinder rod is bent or scored or if fittings into outer frame. See Figure 9.
there is damage on the outside of cylinder shell
that could impair performance or cause leaks Install
under pressure. See Cylinder Repair (Mast S/N
1. If necessary, install new upper and lower sideshift
A698 and A699) 2100YRM1770 for more
bearings as follows:
information on inspecting and repairing the
sideshift cylinder.
a. To install new upper bearings, align pin on the
bottom side of bearing to notches on top
5. Clean load rollers and inspect for wear and
carriage bar and slide into place on top
damage. If any load rollers must be replaced,
carriage. See Figure 12.
make a note of the location and number of shims.
Install shims, load rollers, and snap rings. For top
b. To install new lower bearings, align the circular
rollers, install spacers. See Carriage Adjustment.
pins on backside of lower bearing to holes on
lower carriage bar and tap bearing into place
Assemble on lower carriage bar using a rubber or brass
1. Assemble sideshift cylinder. See Cylinder Repair hammer. See Figure 12.
(Mast S/N A698 and A699) 2100YRM1770 for
procedures.

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 12. Replacing Upper and Lower Bearings

12
4000 YRM 1773
NOTE: The pin, located on the left top of the cylinder
looking from the front of the carriage, is for alignment
purposes and to prevent the cylinder from rolling to the
front or to the back.
2. Install sideshift cylinder onto carriage with pin in
the up position. Install two pins and two cotter
pins. See Figure 9.
3. Use a crane with a capacity of at least
450 kg (992 lb) to install outer frame on inner
frame.
4. Install lower mounting hooks using four
capscrews. Tighten capscrews to
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
between bottom of hooks and outer frame. See B
in Figure 11.
NOTE: If lift truck is equipped with hydraulic quick
disconnect hoses, see section
Connecting Attachment Hydraulic Quick Disconnect
Hoses.
5. Connect hydraulic lines, as noted during removal,
to sideshift cylinder.
6. Install load backrest on sideshift carriage. Tighten
nuts to 53 N•m (39 lbf ft). See Figure 6.
7. Install forks. See section Forks Replacement in
this service manual for procedures.
INTEGRAL SIDESHIFT CARRIAGE AFTER
DECEMBER, 2016
Remove
1. Lower carriage completely. Remove forks. See
Forks Replacement for removal procedures.
2. Remove four capscrews, washers, nuts, and load
backrest from carriage. See Figure 6.
Carriage Repair
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.
3. Relieve hydraulic pressure to the sideshift
cylinder by moving sideshift lever in both
directions several times.
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.
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.
NOTE: Tag hydraulic lines and fittings prior to
disconnecting to aid in connecting during installation.
NOTE: If lift truck is equipped with hydraulic quick
disconnect hoses, see section
Disconnecting Attachment Hydraulic Quick Disconnect
Hoses.
4. Disconnect hydraulic lines from sideshift cylinder.
Put caps and plugs on open lines and cylinder
ports. See Figure 13.
13
Carriage Repair 4000 YRM 1773

A. TWO-STAGE LFL INTEGRAL SIDESHIFT B. THREE-STAGE FFL INTEGRAL SIDESHIFT

CARRIAGE CARRIAGE

1. HYDRAULIC HOSE FITTING 3. INTEGRAL SIDESHIFT CYLINDER

2. INTEGRAL SIDESHIFT HYDRAULIC HOSES

Figure 13. Integral Sideshift Carriage After December, 2016, Hydraulic Hose Connections

5. Remove four capscrews, four washers, and two 6. Use a crane with a capacity of at least
lower mounting hooks from lower mounting 40 kg (88 lb) to lift outer frame away from the
plates. See Figure 14. inner frame (see Figure 15). Lay the outer frame
flat on a pallet or workbench.

14
4000 YRM 1773 Carriage Repair

Figure 14. Integral Sideshift Carriage After December, 2016, Component Parts

15
Carriage Repair 4000 YRM 1773

Legend for Figure 14.

A. FRONT VIEW B. REAR VIEW

1. OUTER FRAME 11. FORK REMOVAL NOTCH

2. LUBE FITTING 12. COTTER PIN
3. CAPSCREW 13. CHAIN ANCHOR
4. WASHER 14. CHAIN PIN
5. LOWER MOUNTING HOOK 15. RING
6. LOWER RETENTION PLATE 16. SELF-ALIGNING NUT
7. LOWER BEARING 17. LOAD ROLLER
8. UPPER BEARING 18. SPACER
9. SIDESHIFT CYLINDER ROD ASSEMBLY 19. SNAP RING
10. INNER FRAME 20. SHIM

Clean and Inspect

1. Clean and inspect carriage bars for damage and
smoothness. Ensure carriage bars are parallel
and end are flush. If carriage bars have any
protruding welds or damaged notches, repair by
grinding, filing, or welding.

2. Clean bearing areas. Inspect side shift 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 bearings from inner frame.
See Figure 16and Step 1 in the Assembly
section for replacement procedures.

b. If either lower bearing is worn to less than

2.5 mm (0.1 in.) thickness, replace both lower
bearings by driving bearings from inner frame.
See Figure 16 and Step 1 in the Assembly
section for replacement procedures.
1. OUTER FRAME
2. LIFTING HOOK
3. LIFTING DEVICE 3. Inspect sideshift cylinder. See Cylinder Repair
(Mast S/N A698 and A699) 2100YRM1770 for
Figure 15. Remove Outer Frame procedures.

Disassemble 4. Inspect load rollers for wear and damage. If load

rollers must be replaced, make a note of the
1. Remove upper and lower bearings from inner location and number of shims to ensure correct
frame. See Figure 16. installation. See Figure 14.
2. If damaged, remove lube fittings from outer
Assemble
frame. See Figure 14.
1. Assemble sideshift cylinder. See Cylinder Repair
3. Disassemble side shift cylinder. See Cylinder (Mast S/N A698 and A699) 2100YRM1770 for
Repair (Mast S/N A698 and A699) procedures.
2100YRM1770 for procedures.
2. If lube fittings were removed, install new lube
fittings into outer frame. See Figure 14.

16
4000 YRM 1773
A. MINIMUM THICKNESS, 2.5 mm (0.1 in.)
1. LOWER BEARINGS
2. CARRIAGE BARS
*bold arrows indicate which side to apply grease
Figure 16. Upper and Lower Bearings
NOTE: Use a wood block or a plastic hammer to fully
seat upper bearings onto inner frame. Proper lower
hook clearance requires upper bearings be fully
seated.
3. Apply a 1 mm (0.040 in.) layer of multipurpose
grease to upper and lower bearing surfaces.
Install upper and lower bearings onto inner frame:
a. To install new upper bearing, align pins on
bottom side of bearing to notches on top
carriage bar and slide into place on top
carriage bar. See Figure 16.
b. To install new lower bearing, align circular pins
on backside of lower bearing to holds on lower
carriage bar and tap bearing into place on
lower carriage bar using a rubber or brass
hammer. See Figure 16.
Carriage Repair
3. UPPER BEARINGS
Install
1. Install two lower mounting hooks, four washers,
and four capscrews on inner frame. Tighten
capscrews to 165 ±15 N•m (120 ±12 lbf ft). See
Figure 14.
2. Use a crane with a capacity of at least
40 kg (88 lb) to install outer frame onto inner
frame. See Figure 15.
NOTE: If lift truck is equipped with hydraulic quick
disconnect hoses, see section
Connecting Attachment Hydraulic Quick Disconnect
Hoses.
3. Connect the hydraulic lines, as noted during
removal, to the sideshift cylinder.
4. Install four capscrews, washers, nuts, and load
backrest on the sideshift carriage. Tighten nuts to
53 N•m (39 lbf ft). See Figure 6.
17
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1773

5. Install the forks. See section Forks Replacement 4. Move the manual hydraulic levers forward and
in this service manual for procedures. backwards, and check the hydraulic system for
leaks.
DISCONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT HOSES
1. Turn the key switch or keyless switch to the OFF
position.

2. Disconnect the negative terminal of the battery.

3. Move the manual hydraulic levers forward and

backward to relieve the system hydraulic
pressure.

4. Disconnect the Quick-Disconnect hose

connections. See Figure 17.

CONNECTING ATTACHMENT HYDRAULIC

QUICK DISCONNECT HOSES
1. Connect the Quick-Disconnect hose connections.
See Figure 17.

2. Connect the negative terminal of the battery.

1. QUICK-DISCONNECT FITTINGS
3. Turn the key switch or keyless switch to the ON 2. HYDRAULIC TUBES
position and start the engine.
Figure 17. Quick Disconnect Hoses

Two-Stage Mast With Limited Free-Lift Repair

MAST
Remove
WARNING
The mast is heavy. The mast can weigh
approximately 380 kg (838 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.
cylinders need to be repaired or replaced, the mast
does not need to be removed from lift truck. See
Cylinder Repair (Mast S/N A698 and A699)
2100YRM1770 for cylinder removal procedures.
NOTE: The length of lift chains must be checked
before removing the mast. See Lift Chain Adjustment.
1. Fully lower inner mast.
2. Connect a lifting device to all top crossmembers
of the mast weldments. See . Raise lifting device
so the mast has stability.

CAUTION 3. Disconnect header hoses.

Make sure all mast weldments are fastened
together. Make sure safety chains will not damage
the sheaves, tubing, or other parts of the mast.
NOTE: If mast needs to be disassembled, remove the
forks and carriage. See the sections
Forks Replacement and Carriage Repair for removal
procedures. If only the main lift cylinders or tilt
4. Remove self-aligning nuts and base rings from
chain anchors. Remove lift chains from chain
sheaves. See Figure 20.
5. Remove lift and tilt cylinders following procedures
found in Cylinder Repair (Mast S/N A698 and
A699) 2100YRM1770.

18
4000 YRM 1773 Two-Stage Mast With Limited Free-Lift Repair

6. Remove four capscrews, washers, and two 2. Remove strip bearings, shims, and O-rings.
trunnion caps from mast mounts. See Figure 18. Discard O-rings. See Figure 19.

NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.

1. CAPSCREW 1. STRIP BEARING

2. WASHER 2. SHIMS
3. TRUNNION CAP 3. TOP OF OUTER MAST
4. MAST MOUNT 4. O-RING

Figure 18. Mast Mounts Figure 19. Strip Bearings

7. Remove mast from lift truck. Put mast in a
position so the crossmembers are on the floor.
Disassemble
1. Slide inner mast from the bottom of outer mast
approximately 30 mm (12 in.).
NOTE: Note shim placement to aid in assembly.
3. Remove snap rings, shims, and load rollers from
stub shafts at the bottom of inner mast. Remove
snap rings, shims and load rollers from stub
shafts top of outer mast. Make a note of each
shim arrangement and load roller location. The
shim arrangements will be approximately the
same during assembly. See Figure 20.

19
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1773

Figure 20. Two-Stage Mast With Limited Free-Lift

20
4000 YRM 1773 Two-Stage Mast With Limited Free-Lift Repair

Legend for Figure 20.

NOTE: MAIN LIFT CYLINDERS AND ATTACHING PARTS SHOWN FOR REFERENCE ONLY.

1. OUTER MAST 15. CHAIN ANCHOR

2. SNAP RING 16. PIN
3. LOAD ROLLER 17. COTTER PIN
4. SHIM 18. LIFT CHAIN
5. STUB SHAFT 19. LOWERING CONTROL VALVE WASHER
6. O-RING 20. SPRING
7. BEARING STRIP 21. SPECIAL FITTING
8. WASHER 22. HOSE ASSEMBLY
9. CAPSCREW 23. FITTING
10. THIN WALL SPACER 24. VALVE
11. NUT 25. LOWERING CONTROL VALVE HOUSING
12. MAIN LIFT CYLINDER 26. CHAIN SHEAVE
13. SELF-ALIGNING NUT 27. INNER MAST
14. BASE RING

4. Slide inner mast halfway out of the top of outer

mast. Connect a crane to the center of inner
mast. See Figure 21.

1. TILT ROD BUSHING

Figure 22. Mast Bushing Location

7. Remove two capscrews, two nuts, and lowering

1. INNER MAST control valve housing from outer mast. See
2. OUTER MAST Figure 20.
Figure 21. Inner Mast
8. Disconnect hose assemblies from fitting (item 23,
Figure 20).
5. Slide inner mast out of outer mast until stub
shafts are in the notches of the outer mast.
9. Remove lowering control valve washer, spring,
Remove inner mast from outer mast.
and special fitting from hose assemblies. See
Figure 20.
6. Using a brass drift pin, remove tilt rod bushing
from outer mast. Discard tilt rod bushing. See
10. Remove three fittings and valve from lowering
Figure 22.
control valve housing. See Figure 20.

11. Remove snap rings and chain sheaves from stub

shafts at the top of inner mast. Disassemble chain
sheaves as necessary for cleaning and repair.
See Figure 20.

21
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1773

Clean and Inspect b. Replace chain if the length of 20 links of the

worn section is more than the maximum wear
limit. Lubricate chains with SAE 30W engine
CAUTION oil. The best procedure is to remove lift chains
DO NOT use steam or high-pressure water to clean from lift truck and soak them in SAE 30W
the load rollers or the lift chains. Steam and high- engine oil.
pressure water can remove the lubrication from
the bearings in the load rollers. Water in the
bearings of the sheaves and the link pins of chains
can also shorten the service lift of these parts.

1. Inspect sheaves and load rollers for wear or

damage. DO NOT use steam to clean lift chains,
sheaves, or load rollers. The bearings in the
sheaves and load rollers are sealed and
lubricated.

2. Inspect chain anchors, pins, and cotter pins for

damage. Replace if damaged.

WARNING
Commercial 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.
NOTE: THE INSTRUCTIONS FOR MEASURING
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE .
WARNING
Never replace just the worn section of a chain. 1. CHAIN WEAR SCALE
Replace the complete chain. Never replace just
one chain of a chain pair. Replace both chains. Pitch Wear Limit The
Total length of
maximum
3. Clean lift chains with solvent. Inspect lift chains 20 links (pitch)
length of 20
for wear or damage. See Figure 23. A lift chain of new chain
links
becomes longer when it is worn. If a section of
chain is 3% longer than a similar section of new 12.7 mm 254.0 mm 261.6 mm
chains, the chain is worn and must be replaced. (0.5 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
a. If a chain scale is available, check lift chains as (0.6 in.) (12.5 in.) (12.9 in.)
shown in Figure 23. If a chain scale is not 19.1 mm 381.0 mm 392.4 mm
available measure 20 links of chain. Measure (0.8 in.) (15.0 in.) (15.5 in.)
from the center of a pin to the center of another 25.4 mm 508.0 mm 523.3 mm
pin 20 pitches away. Compare length with the (10 in.) (20.0 in.) (20.6 in.)
chart in Figure 23.
Figure 23. Lift Chains Check

22
4000 YRM 1773 Two-Stage Mast With Limited Free-Lift Repair

Assemble

WARNING
The mast is heavy. The mast can weigh
approximately 380 kg (838 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.

NOTE: The shims for the load rollers keep the

weldments parallel and provide correct clearance.
During assembly, the shim arrangement will be
approximately the same as before disassembly. Check
the clearance and adjust the shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims. See
Carriage Adjustment in this section for the adjustment
procedures.
NOTE: When the mast has header hoses, see section
Header Hoses, Installation and Adjustment. 1. STRIP BEARINGS
2. SHIMS
1. Connect lifting device to center of inner mast. See 3. TOP OF OUTER MAST
Figure 21. 4. O-RING

2. If removed, put stub shafts through notches in
outer mast. Using lifting device, slide inner mast
into outer mast so stub shafts are seen at top and
bottom of outer mast.
3. Install new O-rings, shims as noted during
disassembly, and strip bearings. See Figure 24.
Apply grease to bearing surface.
Figure 24. Strip Bearings
4. Install shims, load rollers, and snap rings to top of
outer mast and bottom of inner mast. Check
clearance of load rollers as described in
Mast Adjustments. See Figure 20.
5. Install new tilt rod bushing in outer mast. See
Figure 25.

23
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1773

4. Place lift chains over sheaves and connect them

to chain anchors at bottom of inner mast.

5. Install chain anchor through lift cylinder mount.

Install base ring and self-aligning nut on chain
anchor. Tighten self-aligning nut to
40 N•m (30 lbf ft). Repeat for opposite lift chain.
See Figure 20.

6. Connect a lifting device to the top of the mast

assembly. Make sure inner and outer mast are
fastened together. Make sure the chains DO NOT
damage any of the hydraulic lines or other parts.

7. Raise mast assembly to a vertical position. Move

mast assembly into correct position.
1. TILT ROD BUSHING
8. Install tilt cylinders. See service manual Cylinder
Figure 25. Mast Bushing Location
Repair (Mast S/N A698 and A699)
2100YRM1770 for procedures.
6. Install valve and three fittings on lowering control
housing. See Figure 20.
9. Install trunnion cap, two washer, and two
capscrews on mast mount. Tighten capscrews to
7. Connect hose assemblies to fitting (item 23,
115 N•m (85 lbf ft). See Figure 26. Repeat for
Figure 20).
opposite mast mount.
8. Install lowering control valve housing, two
capscrews, and two nuts on outer mast. See
Figure 20.

9. Install chain sheaves and snap rings on stub

shafts at the top of inner mast. See Figure 20.

Install
1. Install lift cylinders. See service manual Cylinder
Repair (Mast S/N A698 and A699)
2100YRM1770 for procedures. Check clearance
at top of lift cylinder mounts. Add or remove
shims at the top of main lift cylinder rods until they
are even. Install washer and snap ring at the top
of main lift cylinders.

2. Install special fitting, spring, and lowering control

valve washer on hose assemblies. Connect hose
assemblies to main lift cylinders. See Figure 20.
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.
NOTE: Both legs of cotter pin must be bent against
1. CAPSCREW
chain anchor pin. Make sure cotter pin is positioned as 2. WASHER
noted during removal. 3. TRUNNION CAP
3. If removed, install pin and cotter pin on lift chain 4. MAST MOUNT
and chain anchor. Repeat for opposite lift chain.
Figure 26. Mast Mounts
See Figure 20.
10. Install header hoses. See
Header Hoses, Installation and Adjustment.

24
4000 YRM 1773 Two-Stage Mast With Limited Free-Lift Repair

HEADER HOSES, INSTALLATION AND

ADJUSTMENT
Install

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.

WARNING
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
the skin.

WARNING
Before working on or near the mast, see
Safety Procedures When Working Near Mast in
this section.

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

NOTE: Before installing header hoses, make sure you

know the lift height of the mast. The tension on header
hoses is adjusted according to lift height. Lift height is
on the Nameplate of lift truck and right-hand side of
outer mast.
Some lift trucks are equipped with auxiliary hydraulic
functions that are fastened to the carriage. Examples
of these auxiliary functions are sideshift carriages or
roll clamps. These auxiliary function require header
hoses for their operation.
1. For header hose placement, see Figure 27. NOTE: FOUR-FUNCTION MAST SHOWN.

A. HEADER HOSE A (THREE-FUNCTION)

B. HEADER HOSE B (THREE-FUNCTION)

1. CLAMP
2. ALIGN MARK E FOR HOSES A AND B AT
BOTTOM OF CLAMP
3. CONNECTION TO COWL HOSES

Figure 27. Two-Stage LFL Header Hose

Arrangement

25
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1773

NOTE: The lift chains and carriage height must be
correctly adjusted before the header hoses can be
adjusted. See section Lift Chain Adjustment for
procedures.
2. Mark each hose with a single letter: A and B. See
Figure 27.
NOTE: Dimension E is determined by the height of
outer mast channel from the ground and the length of
outer mast channel. See dimensions Y and Z in
Figure 28. To determine E use Table 2 or Table 3 to
determine pre-calculated tension mark locations.
4. Place a mark on all the hoses at dimension E.

3. Clamp 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 28.

26
4000 YRM 1773 Two-Stage Mast With Limited Free-Lift Repair

1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE

Figure 28. Header Hose Measurement

27
Two-Stage Mast With Limited Free-Lift Repair 4000 YRM 1773

Table 2. Standard Mast Height; Header Hose Tension Mark Location Lift Truck Models GLP/GDP20-25LX
(B974)
Tension Marker from Carriage End Di-
Lift Height Channel Length (Reference)
mension "E"
mm in. mm in. mm in.
3292 129.6 2090 82.3 2353 92.6
3792 149.3 2340 92.1 2598 102.3

Table 3. Standard Mast Height; Header Hose Tension Mark Location Lift Truck Models GLP050LX (B967)
Tension Marker from Carriage End Di-
Lift Height Channel Length (Reference)
mension "E"
mm in. mm in. mm in.
2032 80.0 1440 56.7 1705 67.1
3292 129.6 2090 82.3 2308 90.1
3792 149.3 2340 92.1 2554 100.

5. Lift carriage off the ground approximately 10. Put the clamps over the hoses and attach the
76 mm (3 in.). Place blocks under carriage for clamps to upper brackets. DO NOT tighten the
support. hardware.

6. Install carriage brackets to carriage. Tighten NOTE: To make alignment of dimension E easier, use
capscrews to 18 N•m (159 lbf in). See Figure 29. a crane with a capacity of at least 907.2 kg (2000 lb) to
raise carriage high enough to install a safety chain.
7. Install hoses to carriage brackets with the clamps See .
and tighten capscrews to 18 N•m (159 lbf in). See
11. Align dimension mark E, which is determined
Figure 29.
using Figure 28, at bottom of clamps. Tighten
8. Apply a thin coat of multipurpose grease with hardware to 8 N•m (71 lbf in). See Figure 27.
molybdenum disulfide to hose sheave stubshafts
12. Connect header hoses to the truck hoses.
before installing hose sheaves. Place the hose at
the location of the hose sheave. See Figure 27.
13. Use rubber clamps and hose clamps to attach
hoses to main lift cylinders and just below the
9. The sheave(s) and stubshafts must be
middle crossmember on the outer mast. Make
assembled, and the hose(s) must be routed onto
sure hoses DO NOT stretch or fold while tilting
the sheave(s) before hose(s) are attached to the
mast fully forward and backward.
mast. Tighten the hose clamp hardware to
8 N•m (71 lbf in) and the sheave assembly
14. With no load on forks, check head hose
capscrews to 66 N•m (49 lbf ft). See Figure 29.
adjustment by operating mast through full lift
Install clamps to main lift cylinders. Tighten
cycle two times.
capscrews and nuts to 25 N•m (221 lbf in).

28
4000 YRM 1773 Two-Stage Mast With Limited Free-Lift Repair

Figure 29. Header Hoses for Two-Stage Limited Free-Lift Mast

29
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Legend for Figure 29.

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

Adjustment 6. Secure hose assemblies to main lift cylinders with

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

Three-Stage Mast With Full Free-Lift Repair

REMOVE
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 the mast falls.
CAUTION
Make sure all mast weldments are fastened
together. Make sure safety chains will not damage
the sheaves, tubing, or other parts of the mast.
or free-lift cylinder needs to be removed, the mast
does not need to be removed from lift truck. See
Cylinder Repair (Mast S/N A698 and A699)
2100YRM1770 for removal procedures.
NOTE: The length of lift chains must be checked
before removing the mast. See Lift Chain Adjustment.
1. Fully lower all of the mast weldments. Tilt the
mast fully forward. Connect a crane with a
capacity of at least 907 kg (2000 lb) to the top of
the mast using chains to support the mast in an
upright position when the tilt cylinders are
disconnected. See the section
Safety Procedures When Working Near Mast in
this manual.

NOTE: If mast needs to be disassembled, remove the

forks and carriage. See the sections
Forks Replacement and Carriage Repair for removal
procedures. If only the main lift cylinders, tilt cylinders,

30
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

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.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of the lift
pump or disconnecting any hoses.
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 1. CAPSCREW
system. 2. WASHER
3. RETAINER CAP
2. Position a drip pan under the area of the hydraulic 4. BUSHING
fittings. Disconnect the hydraulic line at the 5. LUBE FITTING
lowering control valve on the outer mast. See
Figure 32. Figure 30. Mast Mounts, Outer Mast

See Figure 33 for lift truck GLP/GDP050LX DISASSEMBLE

(B974), equipped with optional mast.

3. Remove tilt cylinder rod end from outer mast. See
manual Cylinder Repair (Mast S/N A698 and
A699) 2100YRM1770 for procedures.
NOTE: Allow the mast to tilt forward enough to gain
access to the mast mount capscrews.
4. Remove capscrews and washers that hold
retainer caps and bushings to mast mounts. See
Figure 30.
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 the mast falls.
5. Use the crane to lift the mast assembly from the
lift truck. Position the mast across wooden beams
on the floor with the carriage side up.
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 the mast falls.
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 lift truck. See Cylinder
Repair (Mast S/N A698 and A699) 2100YRM1770 for
procedures. For header hose installation and
adjustment procedures, see section
Header Hose Installation and Adjustment.
1. Clean area around hydraulic fittings for main lift
cylinders. Disconnect fittings at main lift cylinders
and put caps on open lines. Disconnect free-lift
chains from chain anchors. See Figure 32.
See Figure 33 for lift truck GLP/GDP050LX
(B974), equipped with optional mast.
2. Disconnect header hoses.

31
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

3. Remove free-lift cylinder. Remove hose and chain

7. Remove the load rollers, shims, and snap rings at
sheaves from free-lift cylinder and disassemble
the bottom of inner mast. Remove the load
them as necessary for cleaning, inspection and
rollers, shims, and snap rings at the top of the
repair. See Cylinder Repair (Mast S/N A698 and
intermediate mast weldment. Make a note of each
A699) 2100YRM1770 for procedures.
shim arrangement and load roller location. The
shim arrangements will be approximately the
same during assembly. See Figure 32.
WARNING
Be careful when removing or installing snap rings. See Figure 33 for lift truck GLP/GDP050LX
These snap rings can come loose during removal (B974), equipped with optional mast.
and installation with enough force to cause an
injury. Always use the correct snap ring pliers, and
wear eye and face protection during removal or
installation

4. Disconnect main lift chains from chain anchors

near top of main lift cylinders. Disconnect other
end of main lift chains at bottom of inner mast.
Push inner mast towards the bottom of mast
assembly until the bottom load rollers can be
seen. See Figure 32.
See Figure 33 for lift truck GLP/GDP050LX
(B974), equipped with optional mast.

5. Remove lowering control valve housing from

outer mast. See Figure 32.
See Figure 33 for lift truck GLP/GDP050LX
(B974), equipped with optional mast.

6. Remove strip bearings from top of intermediate

mast. See Figure 31. 1. STRIP BEARING
2. SHIMS
3. TOP OF OUTER MAST
WARNING 4. O-RING
The weldments can slide when the mast is moved. Figure 31. Strip Bearings
A weldment that slides can cause injury. Use a
crane to turn the mast slowly and carefully.

32
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

Figure 32. Three-Stage Full Free-Lift (FFL) Mast

33
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Legend for Figure 32.

NOTE: THREE-FUNCTION MAST SHOWN. DOES NOT INCLUDE OPTIONAL MAST SHOWN IN FIGURE 33.

1. NUT 17. MAIN LIFT CHAIN

2. WASHER 18. HOSE SHEAVE
3. FREE-LIFT CYLINDER BRACKET 19. BUSHING
4. FREE-LIFT CHAINS 20. BALL BEARING
5. FREE-LIFT CYLINDER 21. CHAIN SHEAVE
6. CAPSCREW 22. CHAIN ANCHOR
7. INNER MAST 23. CHAIN ANCHOR PIN
8. STRIP BEARING 24. COTTER PIN
9. SHIM(S) 25. LEFT MAIN LIFT CYLINDER
10. O-RING 26. LOWERING CONTROL VALVE HOUSING
11. SNAP RING 27. LOWERING CONTROL VALVE
12. LOAD ROLLER 28. CLAMP
13. INTERMEDIATE MAST 29. OUTER MAST
14. STUBSHAFT 30. SPACER
15. BAR 31. RIGHT MAIN LIFT CYLINDER
16. HOSE 32. CHAIN ANCHOR CAP

34
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

Figure 33. Three-Stage Full Free-Lift (FFL) Optional Mast for Lift Trucks GLP/GDP050LX (B974)

35
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Legend for Figure 33.

1. OUTER MAST 19. HOSE

2. LOAD ROLLER 20. LOWERING CONTROL VALVE
3. SHIM 21. CAPSCREW
4. SNAP RING 22. CLAMP
5. STUBSHAFT 23. TUBE
6. O-RING 24. SPACER
7. SHIM STRIP 25. LOCK NUT
8. BEARING STRIP 26. INTERMEDIATE MAST
9. CHAIN 27. SHEAVE STUBSHAFT
10. COTTER PIN 28. CHAIN SHEAVE ASSEMBLY
11. PIN 29. SHEAVE
12. CHAIN ANCHOR 30. INNER MAST
13. WASHER 31. CHAIN GUARD
14. NUT 32. CROSSHEAD
15. FREE-LIFT CYLINDER 33. BRACKET
16. MAIN LIFT CYLINDER 34. VALVE ASSEMBLY (FLOW LIMITING)
17. BUSHING 35. HOUSING
18. FITTING

9. Remove main lift cylinders. See Cylinder Repair

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 the mast falls.
8. Slide the inner mast weldment halfway out of the
top of the intermediate mast weldment. Connect a
crane with a capacity of at least 907 kg (2000 lb)
to the center of the inner mast. See Figure 34.
Slide the inner mast weldment out of the
intermediate mast weldment until the stub shafts
are in the notches of the intermediate mast
weldment. Remove the inner mast weldment from
the intermediate mast weldment.
(Mast S/N A698 and A699) 2100YRM1770 for
procedures.
10. Slide the intermediate mast from the bottom of
the outer mast approximately 30 cm (12 in.).
Remove the strip bearings at the top of the outer
mast weldment. See Figure 31. Remove the snap
rings and load rollers from both weldments. Make
a note of each shim arrangement and load roller
location. The shim arrangements will be
approximately the same during assembly.
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 the mast falls.

NOTE: If 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.
11. Slide the intermediate mast halfway out of the top
of the outer mast. Connect a crane with a
capacity of at least 907 kg (2000 lb) to the center
of the intermediate mast. See Figure 34. Slide the
intermediate mast out of the outer mast until the
stub shafts are in the notches of the outer mast.
Remove the intermediate mast from the outer
Figure 34. Mast Disassembly mast.

36
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

12. Disassemble the chain sheaves as necessary for
repair and cleaning. Remove the hydraulic lines
and fittings from the weldments as necessary.
CLEAN AND INSPECT
1. Inspect the chain sheaves and load rollers for
wear or damage. DO NOT use steam to clean the
lift chains, sheaves, or load rollers. The bearings
in the sheaves and load rollers are sealed and
lubricated.
WARNING
Cleaning solvents may be flammable and toxic and
can cause severe skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer's recommended safety precautions.
Cleaning solvents may be flammable and toxic and
can cause severe skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer's recommended safety precautions.
6. Clean the mast weldments with steam or solvent.
WARNING
Incorrect welding procedures can damage the
structure of the mast or cause the mast to operate
incorrectly. Obtain information from your Yale lift
truck dealer before welding on the mast.
7. Inspect the sliding surfaces for wear or damage.
Inspect the load roller contact surfaces for wear
or damage. Inspect all welds for cracks.

2. Clean the lift chains with solvent. Remove all dirt

and grease. Inspect the lift chains for wear or
damage. The lift chains must be installed in the
mast and the mast must be installed on the lift
truck before they can be checked for correct
length.

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.

3. A lift chain becomes longer when it is worn. If a

chain is 3% longer than a new lift chain, the lift
chain must be replaced. If a chain scale is
available, check the lift chain as shown in
Figure 35. If a chain scale is not available,
measure 20 links of the lift chain. Compare the
measurement with the lengths given in Figure 35. Figure 35. Lift Chains Check
Lubricate the chains with SAE 30W engine oil.
The best procedure is to soak them in engine oil.

4. Inspect chain anchors, pins, and cotter pins for

damage. Replace if damaged.

5. Inspect chain anchor caps (if equipped) on chain

anchors for free lift cylinder. Replace if damaged.

WARNING
Be careful when cleaning with steam. Steam can
cause serious burns. Wear protective clothing,
gloves, and eye protection. Never expose your
skin to steam.

37
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Legend for Figure 35. intermediate mast weldment into the outer mast
weldment so the stub shafts are seen at the top
Pitch Wear Limit The and bottom of both weldments.
Total length of
maximum
20 links (pitch) NOTE: The load rollers must be in place before strip
length of 20
of new chain bearing can be shimmed.
links
12.7 mm 254.0 mm 261.6 mm 3. Apply multipurpose grease with 2 to 4%
(0.5 in.) (10.0 in.) (10.3 in.) molybdenum disulfide to bearing surfaces and
15.9 mm 317.5 mm 327.0 mm install strip bearing and shim on channels of outer
(0.6 in.) (12.5 in.) (12.9 in.) mast. See Figure 31. Check the clearance of the
19.1 mm 381.0 mm 392.4 mm strip bearings as described in
(0.8 in.) (15.0 in.) (15.4 in.) Carriage Adjustment.
25.4 mm 508.0 mm 523.3 mm
(1.0 in.) (20.0 in.) (20.6 in.) 4. Install the load rollers and the shims on the outer
mast weldment and at the bottom of the
NOTE: THE INSTRUCTIONS FOR MEASURING intermediate mast weldment. Before doing the
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR next step, adjust the intermediate mast weldment
SCALE (YALE P/N 580037684) and check the clearance of the load rollers as
described in Carriage Adjustment.
1. CHAIN WEAR SCALE

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 the mast falls.
NOTE: The shims for the load rollers keep the
weldments parallel and provide correct clearance.
During assembly, the shim arrangement will be
approximately the same as before disassembly. Check
the clearance and adjust the shims for wear or for
changes caused by repairs. The strip bearings are
also adjusted by using shims. See
Carriage Adjustment in this section for the adjustment
procedures.
NOTE: When the mast has header hoses, see section
Header Hose Installation and Adjustment.
1. Apply multipurpose grease with 2 to 4%
molybdenum disulfide to hose sheave stub shaft
and install hose sheave to intermediate mast.
Install chain sheave to intermediate mast.
2. Put outer mast on floor with carriage side up.
Connect a crane with a capacity of at least
907 kg (2000 lb) to the center of the intermediate
mast weldment. Fit the lower stub shafts of the
intermediate mast weldment into the notches in
the top of the outer mast weldment. Slide the
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal
and installation with enough force to cause an
injury. Always use the correct snap ring pliers, and
wear eye and face protection during removal or
installation
NOTE: The clearance check and adjustment in Step 5
is only an initial setup. The final check and adjustment
is done after the mast is installed on the lift truck.
5. Install the main lift cylinders. See Cylinder
Repair (Mast S/N A698 and A699)
2100YRM1770 for procedures. Push the
intermediate mast weldment to engage the lift
cylinders. Check the clearance at the top of the lift
cylinder mounts. Add or remove shims at the top
of the main lift cylinder rods until they are even.
Install the snap ring and washer at the top of the
lift cylinders.
6. Install lowering control valve housing and
lowering control valve to outer mast weldment.
Tighten the nuts to 18 N•m (159 lbf in). Connect
the hydraulic lines and fittings between the
lowering control valve housing and main lift
cylinders. See Figure 32.
See , , for lift truck GLP/GDP050LX (B974),
equipped with optional mast.

38
4000 YRM 1773
7. Connect a crane with a capacity of at least
907 kg (2000 lb) to the center of the inner mast
weldment. See Figure 34. Slide the inner mast
weldment into the intermediate mast weldment so
the stub shafts are seen at the top and bottom of
both weldments.
NOTE: The load rollers must be in place before strip
bearings can be shimmed.
8. Install the strip bearings and the shims on the
channels of the intermediate mast weldment. See
Figure 31. Apply chassis lube to the bearing
surfaces.
9. Install the load rollers and the shims on the
intermediate and inner mast weldments. Before
doing Step 10, adjust the inner mast weldment as
described in Mast Adjustments.
10. Connect main lift chains to chain anchors at the
main lift cylinder mounts. Put lift chains over chain
sheaves and connect them to the chain anchors
at the bottom of the inner mast weldment.
11. Install the free-lift cylinder in the mounts on the
inner mast. See Cylinder Repair (Mast S/N
A698 and A699) 2100YRM1770 for procedures.
12. Install the hose sheave for the free-lift cylinder.
Tighten the capscrew for the hose sheave to
66 N•m (49 lbf ft). Install the hydraulic hose and
tubing for the free-lift cylinder.
13. Connect the free-lift chains to the chain anchors
at the crossmember. Attach a wire between the
end of the lift chain and the bottom of the mast to
control the lift chain during mast installation.
INSTALL
1. Lubricate bushings with chassis lube and install
them into the mounts at bottom of outer mast.
See Figure 30.
Three-Stage Mast With Full Free-Lift Repair
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 the mast falls.
CAUTION
Make sure the chains will not damage the sheaves,
tubing, or other parts of the mast.
2. Connect a crane with a capacity of at least
907 kg (2000 lb) to top of mast using chains.
Make sure all mast weldments are fastened
together. Make sure chains will not damage the
sheaves, tubing, or other parts of the mast.
3. Install mast on drive axle. Install capscrews and
washers that hold retainer caps and mast
assembly to drive axle. Tighten capscrews to
115 N•m (85 lbf ft).
4. Install tilt cylinder rod end to outer mast. See
Cylinder Repair (Mast S/N A698 and A699)
2100YRM1770 for procedures.
5. Connect hydraulic line to lowering control valve.
See Figure 32.
See Figure 33 for lift truck GLP/GDP050LX
(B974), equipped with optional mast.
6. Install the carriage and forks. See sections
Carriage Repair and Forks Replacement.
7. Check tilt cylinder adjustment. Operate mast and
check tilt cylinders for leaks. See section
Cylinder Repair (Mast S/N A698 and A699)
2100YRM1770 for procedures. Check lift chains
as described in Lift Chain Adjustment.
NOTE: The load rollers and sheaves have sealed
bearings and do not need additional lubrication.
8. Lubricate sliding surfaces and load roller surfaces
along the full length of the channels as shown in
Figure 36. Apply chassis lube only to surfaces
indicated in Figure 36.
39
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS

1. LUBRICATE STRIP BEARINGS SURFACES

WITH CHASSIS LUBE
2. LUBRICATE LOAD ROLLER SURFACES WITH
CHASSIS LUBE
3. LOAD ROLLER

Figure 36. Mast Lubrication

HEADER HOSE INSTALLATION AND

ADJUSTMENT
NOTE: If working on lift truck model GLP/GDP050LX
(B974) equipped with optional mast, see
Optional Equipment, Lift Truck GLP/GDP050LX
(B974) for header hose procedures.

Standard
Install

WARNING
Before working on or near the mast, see
Safety Procedures When Working Near Mast in NOTE: PARTS OF MAST OMITTED FOR CLARITY.
this section. THREE-FUNCTION MAST SHOWN.
NOTE: The carriage height must be correct before A. HEADER HOSE A
header hoses can be adjusted. See B. HEADER HOSE B
Lift Chain Adjustment for carriage adjustment
procedures. 1. ALIGN MARK G FOR HOSE A AND B AT
BOTTOM OF CLAMP
NOTE: This procedure is for the four-function option. 2. CLAMP
The three-function option will only have hoses A and 3. ALIGN MARK E FOR HOSES A AND B AT
B. BOTTOM OF CLAMP
4. CONNECTION TO COWL HOSES
1. Mark each hose with a single letter: A and B. See
Figure 37. Figure 37. Three-Stage FFL Header Hose
Arrangement
2. Determine dimensions E, G, and H. See
Figure 38 and Table 4, Table 5, and Table 6.

40
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

1. DIMENSION G 5. TOP OUTER CHANNEL

2. DIMENSION E 6. BOTTOM OUTER CHANNEL
3. VISE 7. GROUND LEVEL
4. HOSE

Figure 38. Header Hose Measurement

41
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Table 4. Dimensions E and G (Three-Function Option, Hoses A and B)

Lift Height Channel Dim. E Dim. G Dim. E Dim. G
Length
MM Inch. MM (In.) Pneu. MM Pneu. MM Cushion MM Cushion MM
(In.) (In.) (In.) (In.)
4285 168.7 1915 mm 1610 mm 3855 mm 1595 mm 3840 mm
(75.4 in.) (63.4 in.) (151.8 in.) (62.8 in.) (151.1 in.)
4735 186.4 2065 mm 1760 mm 4150 mm 1740 mm 4130 mm
(81.3 in.) (69.4 in.) (164.4 in.) (68.5 in.) (162.6 in.)
5035 198.2 2165 mm 1860 mm 4345 mm 1840 mm 4330 mm
(85.2 in.) (73.2 in.) (171.1 in.) (72.4 in.) (170.5 in.)

Table 5. Dimensions E, G, and H (Four-Function Option, Hose C)

Lift Height Channel Dim. E Dim. G Dim. H Dim. E Dim. G Dim. H
Length
MM Inch. MM (In.) Pneu. MM Pneu. MM Pneu. MM Cushion Cushion Cushion
(In.) (In.) (In.) MM (In.) MM (In.) MM (In.)
4285 168.7 1915 mm 1610 mm 4100 mm 2240 mm 1595 mm 4085 mm 2225 mm
(75.4 in.) (63.4 in.) (161.4 in.) (88.2 in.) (62.8 in.) (160.8 in.) (87.6 in.)
4735 186.4 2065 mm 1760 mm 4405 mm 2395 mm 1740 mm 4385 mm 2375 mm
(81.3 in.) (69.4 in.) (173.4 in.) (94.3 in.) (68.5 in.) (172.6 in.) (93.5 in.)
5035 198.2 2165 mm 1860 mm 4610 mm 2600 mm 1840 mm 4595 mm 2585 mm
(85.2 in.) (73.2 in.) (181.5 in.) (102.4 in.) (72.4 in.) (181.0 in.) (102 in.)

Table 6. Dimensions E, G, and H (Four-Function Option, Hose D)

Lift Height Channel Dim. E Dim. G Dim. H Dim. E Dim. G Dim. H
Length
MM Inch. MM (In.) Pneu. MM Pneu. MM Pneu. MM Cushion Cushion Cushion
(In.) (In.) (In.) MM (In.) MM (In.) MM (In.)
4285 168.7 1915 mm 1610 mm 4045 mm 2185 mm 1595 mm 4030 mm 2170 mm
(75.4 in.) (63.4 in.) (159.3 in.) (86.0 in.) (62.8 in.) (159.0 in.) (85.4 in.)
4735 186.4 2065 mm 1760 mm 4350 mm 2395 mm 1740 mm 4330 mm 2320 mm
(81.3 in.) (69.4 in.) (171.3 in.) (94.3 in.) (68.5 in.) (170.5 in.) (91.3 in.)
5035 198.2 2165 mm 1860 mm 4555 mm 2545 mm 1840 mm 4540 mm 2530 mm
(85.2 in.) (73.2 in.) (179.3 in.) (100.2 in.) (72.4 in.) (178.7 in.) (99.6 in.)

3. Clamp the end of hose (the smaller fitting) that
attaches to the carriage in a vise (DO NOT clamp
on threads). Pull on the other end until hose is
straight. DO NOT apply enough force to stretch
the hose. See Figure 38.
4. Mark all hoses with dimensions E, G, and H. All
measurements are made from carriage end of
hose (the smaller fitting).
5. Attach hose to carriage bracket with clamp.
Tighten hardware for clamps to
18 N•m (159 lbf in). Apply grease to surface of
hose guide that contacts hoses. See Figure 39.

42
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

Figure 39. Header Hoses, Three-Stage FFL Mast

43
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Legend for Figure 39.

NOTE: THREE-FUNCTION MAST SHOWN. FOUR-FUNCTION MAST SIMILAR.

1. CAPSCREW 13. LOWER HOSE GUIDE

2. HOSE GUARD 14. NUT
3. SNAP RING 15. BOTTOM CLAMP
4. HOSE GUIDE 16. HEADER HOSES
5. FREE-LIFT CYLINDER CROSSHEAD 17. FREE-LIFT CHAIN
6. WASHER 18. CLAMP
7. SPACER 19. COWL HOSES
8. HOSE SHEAVE 20. UPPER BRACKET
9. HOSE GUARD 21. CARRIAGE BRACKET
10. CLAMP 22. CLAMP
11. LOWER BRACKET 23. STUBSHAFT
12. HOSE RESTRAINT

6. Place hoses over the top of free-lift chains and
under the hose guides. See Figure 39. Attach the
hose guides to the lower crossmember and
tighten mounting hardware to 33 N•m (24 lbf ft).
Make sure bracket is between crossmember and
hose guide. Put clamps over hoses and attach
the clamps to free-lift bracket (DO NOT tighten
the hardware). Align marks for H with top of
clamp.
NOTE: To make the alignment of dimension E easier,
use a crane with a capacity of at least 907 kg (2000 lb)
to raise carriage high enough to attach a safety chain.
See Safety Procedures When Working Near Mast.
7. Align the mark for dimension E at the bottom of
the clamp to create the proper hose tension.
Tighten hardware to 8 N•m (71 lbf in). Install hose
guards. Tighten capscrews that mount the guards
to 66 N•m (49 lbf ft).
12. Connect header hoses to cowl hoses. See
Figure 37.
13. Use rubber clamps and strap clamps to attach
header hoses to main lift cylinders. Make sure
header hoses do not stretch or fold while tilting
the mast fully forward or backward.
14. With no load on the forks, check the header hose
adjustment by operating the mast through the full
lift cycle two times.
15. When properly adjusted, the header hoses will
not be so tight that they compress when they
pass over the sheaves nor will they be so loose
that they touch the load backrest or any
crossmember that is next to a sheave. If the
header hoses require additional adjustment, see
Adjust.

8. Position hoses at hose sheaves. See Figure 39.

The hose sheaves and stubshaft must be
installed on the hose before they are attached to
the mast. Tighten hardware to 53 N•m (39 lbf ft)
9. Put clamps over hoses and attached clamps to
upper brackets (DO NOT tighten the hardware).
NOTE: To make the alignment of dimension G easier,
use a crane to raise the inner channel high enough to
install a safety chain. See
Safety Procedures When Working Near Mast.
10. Align mark G on hose A at the bottom edge of
clamp to create the proper tension. Align mark G
on hose B at the top edge of clamp to create the
proper tension. Tighten hardware to
8 N•m (71 lbf in). See Figure 37.
11. Install the clamps.
Adjust
1. If the tension of the header hoses is correct
between the carriage and the clamp at the free-lift
bracket, go to Step 2. If the tension of the header
hoses is wrong, loosen the clamps and pull (if
hoses are loose) or push (if hoses are tight) on
the hoses so they move 15 mm (0.6 in.). Tighten
the hardware to 8 N•m (71 lbf in). See Figure 37
and Figure 39.
2. If the tension of the header hoses is correct
between the clamp at the upper bracket and the
clamp at the free-lift bracket, go to Step 3. If the
tension of the header hoses is wrong, loosen the
clamps and pull (if hoses are too loose) or push (if
hoses are too tight) on header hoses so they
move 15 mm (0.6 in.), plus the amount the
header hoses were moved in Step 1. Tighten the
hardware to 8 N•m (71 lbf in).

44
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

3. With no load on the forks, check the header hose

adjustment by operating the mast through the full
lift cycle two times. When properly adjusted, the
header hoses will not be so tight that they
compress when they pass over the sheaves nor
will they be so loose that they touch the load
backrest or any crossmember that is next to a
sheave. If necessary, repeat Step 1 and Step 2
until the header hoses are properly adjusted.
NOTE: This procedure is for the three-function option
and will have hoses A and B only.
NOTE: The lift chains and carriage height must be
correctly adjusted before the header hoses can be
adjusted. See the section Lift Chain Adjustment for
adjustment procedures.
1. Mark each hose (1) with a single letter: A or B at
dimension D. See Figure 40.

Optional Equipment, Lift Truck GLP/

GDP050LX (B974)
Install

WARNING
Before working on or near the mast, see
Safety Procedures When Working Near Mast in
this section.

45
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Figure 40. Header Hose Arrangement for Three-Stage Full Free-Lift Mast (Sheet 1 of 3)

46
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

Figure 40. Header Hose Arrangement for Three-Stage Full Free-Lift Mast (Sheet 2 of 3)

47
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

Figure 40. Header Hose Arrangement for Three-Stage Full Free-Lift Mast (Sheet 3 of 3)

48
4000 YRM 1773 Three-Stage Mast With Full Free-Lift Repair

Legend for Figure 40.

NOTE: SOME MAST COMPONENT PARTS OMITTED FOR CLARITY.

A. HOSE A E. ALIGN HOSE MARK E AT BOTTOM OF THIS

CLAMP
B. HOSE B
F. REAR VIEW
C. FRONT VIEW
G. ALIGN HOSE MARK G AT BOTTOM OF CLAMP
D. ALIGN HOSE MARK D AT BOTTOM OF THIS
CLAMP

1. HOSE 4. HOSE GUARD BRACKET

2. HOSE GUIDE 5. HOSE SHEAVE ASSEMBLY
3. CARRIAGE BRACKET

2. Determine dimensions E and G See Figure 41

and Table 7.

49
Three-Stage Mast With Full Free-Lift Repair 4000 YRM 1773

1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE

Figure 41. Header Hose Measurement for Three-Stage Full Free-Lift Mast

50
4000 YRM 1773
Table 7. Standard Three-Stage Hose Dimensions
Channel
Lift Height Length (Ref- Dimension "D"
erence)
mm in. mm mm
5035 198.2 2149 340
3. 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.
NOTE: These marks will be used to pretension the
header hose during installation.
4. Place a mark on hoses (2) at dimensions E and G
(all measurements are made from the carriage
end of the hose [the smaller fitting]). See
Figure 40 and Table 7.
5. Attach the hoses to the carriage bracket with
clamps. Apply spray lubricant to the surface of the
hose guide that contacts the hoses.
6. Place the hoses over the top of the free-lift chains
and under the hose guard bracket. Attach the
hose guard to left and right hose guard brackets,
tighten the capscrews to 18 N•m (13 lbf ft).
Make sure the right and left hose guard brackets
are secured properly to the free lift cylinder. If
necessary tighten capscrews to 66 N•m (49 lbf ft).
Also ensure the hoses are routed to the outside of
the roller located on the inside (mast side) of the
free lift cylinder assembly. See Figure 40.
NOTE: The header hose configuration on this model
lift truck is composed of two hoses, the free lift header
hose and the main lift header hose.
7. Hang hoses over hose sheave on free-lift cylinder
crosshead with dimension D in front. Align mark D
with bottom of clamp and using two capscrews
attach to carriage bracket. Tighten capscrews to
8 N•m (71 lbf in). See Figure 40.
8. Connect hoses to sideshift cylinder bracket. Using
two capscrews, attach carriage bracket to
carriage assembly. tighten capscrews to
18 N•m (13 lbf ft). See Figure 40.
Three-Stage Mast With Full Free-Lift Repair
Dimension "E" Dimension "G"
in. mm in. mm in.
13.4 150 5.9 2645 104.1
9. Preassemble hoses onto upper sheave and
stubshaft weldment with spacer, washer and
capscrew. Position hose so female end of hoses
are toward back of the mast.
10. Using a nut, install sheave assembly onto mast in
upper corner. Tighten to 53 N•m (39 lbf ft). See
Figure 40.
11. Route male end of hoses (2) through hose guide
and up the back of the free-lift cylinder.
12. Align mark E with bottom of clamp located on
mounting plate on the inside of the mast. Using
two capscrews, install clamp to plate. Tighten
capscrews to 8 N•m (71 lbf in).
13. Connect hoses (1) and (2) at back of free-lift
cylinder.
14. Install strap clamp 75 mm (3.0 in.) above fittings
on back side of free-lift cylinder.
15. Route hoses (2) over bracket in upper corner of
mast. Secure hoses using clamp and two
capscrews. Align mark G at bottom of clamp.
Tighten capscrews to 8 N•m (71 lbf in).
16. Install upper and lower clamps to main lift
cylinder.
17. Connect header hoses to cowl hoses.
18. Use the rubber clamps and strap clamps to attach
the hoses to the main lift cylinders. Make sure the
hoses do not stretch or fold while tilting the mast
fully forward and backward.
51
Main Lift Cylinder Repair 4000 YRM 1773

Adjust hoses are too tight) on header hoses so they

1. If the tension of the header hoses is correct
between the carriage and the clamp at the free-lift
bracket, go to Step 2. If the tension of the header
hoses is wrong, loosen the clamps and pull (if
hoses are loose) or push (if hoses are tight) on
the hoses so they move 15 mm (0.6 in.). Tighten
the hardware to 8 N•m (71 lbf in). See Figure 40.
2. If the tension of the header hoses is correct
between the clamp at the upper bracket and the
clamp at the free-lift bracket, go to Step 3. If the
tension of the header hoses is wrong, loosen the
clamps and pull (if hoses are too loose) or push (if
move 15 mm (0.6 in.), plus the amount the
header hoses were moved in Step 1. Tighten the
hardware to 8 N•m (71 lbf in).
3. With no load on the forks, check the header hose
adjustment by operating the mast through the full
lift cycle two times. When properly adjusted, the
header hoses will not be so tight that they
compress when they pass over the sheaves nor
will they be so loose that they touch the load
backrest or any crossmember that is next to a
sheave. If necessary, repeat Step 1 and Step 2
until the header hoses are properly adjusted.

Main Lift Cylinder Repair

To repair the main lift cylinders, see Cylinder Repair
(Mast S/N A698 and A699) 2100YRM1770 for
procedures.

Lift and Tilt System Leak Check

See service manual Cylinder Repair (Mast S/N A698
and A699) 2100YRM1770 for procedures to check the
main lift cylinders and tilt cylinders for leaks.

Tilt Cylinders Adjustment

For procedures to adjust the tilt cylinders, see service
manual Cylinder Repair (Mast S/N A698 and A699)
2100YRM1770.

Lift Chain Adjustment

WARNING
When working on or near the mast, see
Safety Procedures When Working Near Mast in
this section.
During test procedures for the hydraulic system,
fasten the load to the carriage with chains to
prevent it from falling. Keep all personnel away
from the lift truck during the tests.
Never allow anyone under a raised carriage. DO
NOT put any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
the skin.
When the lift chains are correctly adjusted:
• The tension will be the same on each chain of
the chain set. Check tension by pushing on both
chains at the same time.
• The chain length will be correct.
• The chains must travel freely through the
complete cycle.

52
4000 YRM 1773 Lift Chain Adjustment

1. When adjusting the lift chains, go to Step 3. If the

forklift truck is normally equipped with a hook-type
carriage and has an attachment without forks, go
to Step 4.

2. Install new cotter pins and chain anchor pins.

Both legs of cotter pin must be bent against chain
anchor pin.

NOTE: Prior to performing adjustment procedures,

make sure the forklift truck is parked on a level surface
and the mast is in the vertical position.
3. Adjust the chain anchors that support the
carriage, until the bottom of the fork heel is above
the floor level. See Figure 42.

4. Adjust the chain anchors that support the

carriage, until the bottom of the lower carriage bar
1. MAST
is 88.5 +3.0/−6.0 mm (3.50 +0.12/−0.24 in.) 2. CARRIAGE
above the floor level. See Figure 43. 3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Table 8. Hook-Type Carriage Chain Adjustment
Figure 43. Lift Chain Adjustment, Hook-Type
Class II and III 88.5 +3.0/−6.0 mm (3.50 Carriage
+0.12/−0.24 in.)

1. MAST
2. CARRIAGE
3. FORK
4. HEEL OF FORK IS
12.0 +3.0/−6.0 mm (0.47 +0.12/−0.24 in.) ABOVE
FLOOR LEVEL

Figure 42. Lift Chain Adjustment, Forks

53
Mast Adjustments 4000 YRM 1773

Mast Adjustments
LOAD ROLLER ADJUSTMENT
NOTE: Shims are installed on both sides of the load
rollers. Do not add or remove shims from the stub
shafts. To change the position of the roller on the stub
shaft, move the shims from one side of the load roller
to the other.
During assembly, the shim arrangement will be
approximately the same as before disassembly. Check
the clearance and adjust shims after repairs have
been completed.
1. The load rollers control the alignment of the mast
uprights. See Figure 44. The alignment conditions
are given on a list below with the most important
condition first.

54
4000 YRM 1773 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 44. Mast Adjustments

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

55
Mast Adjustments
a. Use a crowbar to move mast uprights from
side to side to measure movement. Measure
movement in a minimum of three different
positions of each mast upright.
b. Separate mast uprights and change shim
arrangements as required. Assemble uprights.
Slide upright all the way to the top and bottom
to find the tightest fit.
c. Repeat Step a and Step b until there is zero
clearance at the point of the tightest fit.
1. STRIP BEARING
2. LOAD ROLLER
3. MAST UPRIGHT
Figure 45. Strip Bearings Arrangement
MAST SIDE KICKING ADJUSTMENT
To adjust the mast for side kicking, do the following:
1. Place the lift truck on a level surface and apply
the parking brake.
2. Raise the mast and visually inspect it as it
reaches its full height.
3. If the mast is moving to the left, shims will need to
either be added or removed from the top of the
right main lift cylinder. If mast moves to the right,
56
4000 YRM 1773
d. Measure distance between channels of mast
uprights on top and bottom. Change shims to
keep distance equal between top and bottom
so mast uprights are parallel. Also make sure
the mast uprights are parallel within
1.5 mm (0.060 in.).
3. Adjust strip bearings. See Figure 45. Insert shims
under strip bearing. Adjust clearance until there is
less than 0.8 mm (0.030 in.) at the tightest fit. See
Figure 44.
4. SHIMS
5. O-RING
shims will need to either be added or removed
from the top of the left main lift cylinder. For main
lift cylinder shim locations see Figure 45 .
4. If shims are to be added, use the smallest shim
size available on the cylinder being adjusted. See
the Parts Manual for shim sizes and part
numbers.
4000 YRM 1773 Carriage Adjustment

Carriage Adjustment
1. Install the load rollers on the carriage. Install the 3. Remove the carriage from the mast. Adjust the
shims for the rollers in the same sequence on the shim arrangement for each load roller for
stub shaft as before disassembly. clearance between the load roller and the inner
mast weldment. Repeat Step 1 and Step 2 until
there is zero clearance at the point of tightest fit.
WARNING
The mast is heavy. The mast can weigh 4. Keep the shim arrangement between the middle
approximately 907 kg (2000 lb). Make sure all and bottom load rollers on the same side of the
lifting devices (hoists, cables, chains, slings, etc.) carriage approximately equal. Also keep the shim
are suitable and of adequate capacity to lift the arrangement on each side of the carriage
motor. approximately equal. The carriage must be
parallel with the inner mast weldment within
2. Use a crane to raise the carriage up the inner ±1.50 mm (±0.06 in.).
mast weldment. Find the tightest fit between the
load rollers and the inner mast weldment.

57
 NOTES

58
4000 YRM 1773 2/18 (12/17)(11/16)(12/14)