MASTS AND

CARRIAGES
STARTING 2003
H8.00-12.00XM (H170-280HD) [F007, G007];
H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]

PART NO. 1553599 4000 SRM 1062

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance 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 HYSTER 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
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Masts and Carriages Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Operation............................................................................................................................................................ 2
Two-Stage Mast ............................................................................................................................................. 2
Three-Stage Mast .......................................................................................................................................... 2
Safety Procedures When Working Near Mast.................................................................................................. 4
Forks Repair....................................................................................................................................................... 6
Remove ........................................................................................................................................................... 6
Inspect and Adjust......................................................................................................................................... 6
Install ............................................................................................................................................................. 7
Carriage Repair.................................................................................................................................................. 7
Description ..................................................................................................................................................... 7
Three Function .......................................................................................................................................... 7
Four to Six Function ................................................................................................................................. 7
Remove ........................................................................................................................................................... 7
Disassemble ................................................................................................................................................... 10
Clean and Inspect .......................................................................................................................................... 10
Assemble ........................................................................................................................................................ 10
Install ............................................................................................................................................................. 11
Sideshift Cylinder Repair .................................................................................................................................. 11
Remove ........................................................................................................................................................... 11
Disassemble ................................................................................................................................................... 11
Clean and Inspect .......................................................................................................................................... 14
Assemble ........................................................................................................................................................ 14
Install ............................................................................................................................................................. 15
Fork Positioner Cylinders Repair ..................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Disassemble ................................................................................................................................................... 15
Clean and Inspect .......................................................................................................................................... 15
Assemble ........................................................................................................................................................ 15
Install ............................................................................................................................................................. 15
Directional Control Valve Repair ...................................................................................................................... 21
Remove ........................................................................................................................................................... 21
Disassemble ................................................................................................................................................... 22
Clean and Inspect .......................................................................................................................................... 22
Assemble ........................................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Mast Repair........................................................................................................................................................ 23
Two- and Three-Stage Mast .......................................................................................................................... 23
Remove....................................................................................................................................................... 23
Disassemble ............................................................................................................................................... 28
Clean and Inspect...................................................................................................................................... 28
Assemble .................................................................................................................................................... 30
Install ......................................................................................................................................................... 31
Three-Stage Mast (Four Cylinders).............................................................................................................. 32
Remove....................................................................................................................................................... 32
Disassemble ............................................................................................................................................... 34
Clean and Inspect...................................................................................................................................... 34
Assemble .................................................................................................................................................... 34
Install ......................................................................................................................................................... 36
Fork Carriage Chains.................................................................................................................................... 38

©2004 HYSTER COMPANY i

Table of Contents Masts and Carriages

TABLE OF CONTENTS (Continued)

Adjust ......................................................................................................................................................... 38
Bearing Rollers .............................................................................................................................................. 40
Description................................................................................................................................................. 40
Lubrication ................................................................................................................................................ 40
Clearance ................................................................................................................................................... 40
Remove and Disassemble.......................................................................................................................... 40
Assemble .................................................................................................................................................... 40
Mast Profile.................................................................................................................................................... 41
Lift Cylinders Description ................................................................................................................................. 41
Piston-Type Cylinders ................................................................................................................................... 41
Displacement-Type Cylinders ....................................................................................................................... 41
Lift Cylinders Repair ......................................................................................................................................... 42
Remove ........................................................................................................................................................... 42
Disassemble ................................................................................................................................................... 44
Clean and Inspect .......................................................................................................................................... 44
Assemble ........................................................................................................................................................ 44
Install ............................................................................................................................................................. 45
Mast Operation Check ....................................................................................................................................... 45
Lift and Tilt System Leak Checks..................................................................................................................... 46
Lift System..................................................................................................................................................... 46
Tilt System ..................................................................................................................................................... 46
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment............................................................................ 47
Lift Chain Adjustments ..................................................................................................................................... 47
Mast Adjustments.............................................................................................................................................. 48
Bearing Blocks, Two Stage Masts................................................................................................................. 48
Wear Plates .................................................................................................................................................... 48
Carriage Adjustment ......................................................................................................................................... 48
Troubleshooting.................................................................................................................................................. 50

This section is for the following models:

H8.00-12.00XM (H170-280HD) [F007, G007];

H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]

ii
4000 SRM 1062 Description

General
This section has the description, operation, and re- Three-stage masts, full free lift:
pair procedures for the two- or three-stage masts and • H10.00-12.00XM (H230-280HD) [F007, G007]
carriages on the following lift trucks: • H13.00-16.00XM (H300-360HD) [E019, F019]

Two-stage mast: Information on the lift cylinders, lowering control

• H8.00-12.00XM (H170-280HD) [F007, G007] valves, and sideshift carriage is also described in this
• H13.00-16.00XM (H300-360HD) [E019, F019] section. The tilt cylinders are described in the section
• H10.00-12.00XM-12EC (H360HD-EC) [E019, Tilt Cylinders 2100 SRM 103.
F019]

Description
The vertical frames of a mast are made of chan-
nels and crossmembers. Load rollers and side
rollers/bearing blocks are installed on the inner and
outer masts. The channels are the vertical parts of
the mast that have the tracks for the load rollers
and side rollers/bearing blocks. During lifting and
lowering a load, large forces are put on the mast as-
sembly. The load rollers reduce the friction between
the channels when the mast lifts and lowers. See
Figure 1 and Figure 4.

The mast can tilt forward and backward. Tilt cylin-

ders are installed between the frame of the lift truck
and the outer mast. The pivots at the bottom of the
outer mast connect the mast to the lift truck. During
the tilt operation, the mast rotates on the pivot pins
in the frame.

The mast is equipped with a carriage. This carriage

is a separate section that moves within the vertical
channels of the inner mast on load rollers and side
rollers/bearing blocks. In later versions, the bearing
block function may be incorporated in the load roller.
The truck may have three, four, five, or six functions.
The truck may be equipped with an optional sideshift
system which allows the carriage to move from side
to side. Forks or other types of load handling equip-
ment are attached to the carriage. The carriage may
also be equipped with an optional fork positioner sys-
tem which allows the forks to move side to side.

Figure 1. Mast

1
Operation 4000 SRM 1062

Operation
TWO-STAGE MAST
The two-stage mast has an outer mast and an in-
ner mast. See Figure 2. The outer mast is con-
nected to the lift truck by the pivot mounts and the
tilt cylinders. The top of the outer mast has one
side roller/bearing block on each side. The lower end
of the inner mast has two load rollers on each side
and one side roller/bearing block on each side directly
above the lowest load roller. In later versions the side
roller/bearing block function may be incorporated in
the load rollers. These load rollers travel along the
channels and control the front-to-back movement be-
tween the inner and outer masts. The side roller/
bearing blocks control the side-to-side movement be-
tween the inner and outer masts. A wear plate and
shims are installed at the top of both channels of the
outer mast.

The two-stage mast has two single-stage lift cylin-

ders. The lift cylinders are installed at the back of
each channel of the inner mast. The base of each lift
cylinder is held by a mount plate at the bottom of the
outer mast. Capscrews and washers fasten the cylin-
ders at the bottom to the mount plate. The top of each
lift cylinder (rod end) fits into guides at the top of the
inner mast and is fastened with a capscrew.

Two lift chains control the movement of the carriage.

The chains are fastened to mounts on the underside
of the top crossmember of the outer mast. The chains
go up and over the chain sheaves on the inner mast
and connect to the carriage. When a load on the car-
riage is raised by the lift cylinders, the weight of the
load and carriage is transferred from the carriage
through the chains to the outer mast.

When the carriage is lowered, the weight of the load,

the carriage, and inner mast pushes the oil from the 1. LIFT CYLINDER (2) 7. FROM MAIN
lift cylinders. The oil flows from the lift cylinders, 2. LIFT CHAIN (2) CONTROL VALVE
through the lowering control valves and main control 3. OUTER MAST 8. EXTERNAL
4. CHAIN SHEAVE LOWERING
valve to the hydraulic tank. 5. INNER MAST CONTROL VALVE
6. CARRIAGE
THREE-STAGE MAST
Figure 2. Two-Stage Mast
The three-stage mast has an outer, intermediate, and
an inner mast. See Figure 3. The outer mast is con- of the intermediate and inner masts has two load
nected to the lift truck by the pivot mounts and the rollers on each side and one side roller/bearing block
tilt cylinders. The top of the outer mast has one side on each side directly above the lowest load roller.
roller/bearing block on each side. The lower end These load rollers travel along the channels. The

2
4000 SRM 1062 Operation

load rollers control the front to back movement be-
tween the masts. The side roller/bearing blocks con-
trol the side-to-side movement between the masts.
Wear plates and shims are installed at the top of both
channels of the outer mast and intermediate mast.
In later versions, the bearing block function may be
incorporated in the load rollers.
The three-stage mast may have three or four single-
stage lift cylinders.
mast and the third free-lift cylinder is installed in the
inner mast. The base of each lift cylinder is held by a
mount plate at the bottom of the outer mast. The top
of each lift cylinder (rod end) fits into guides at the
top of the intermediate mast and is fastened with a
capscrew.
With four single-stage lift cylinders, two free-lift
cylinders have been installed. They are mounted on
each side of the inner mast.

With three single-stage lift cylinders, the two main

lift cylinders are installed at the back of the outer

1. LIFT CYLINDER (2) 6. FREE-LIFT CYLINDERS

2. LIFT CHAIN 7. CARRIAGE
3. OUTER MAST 8. FROM MAIN CONTROL VALVE
4. INTERMEDIATE MAST 9. EXTERNAL LOWERING CONTROL VALVE
5. INNER MAST 10. INTERNAL LOWERING CONTROL VALVE

Figure 3. Three-Stage Mast

3
Safety Procedures When Working Near Mast
The two main lift chains fasten to the top of the outer
mast. The lift chains then go up and over the chain
sheaves at the top of the intermediate mast and fas-
ten at the bottom of the inner mast. The free-lift
chains are connected to the shell of the free-lift cylin-
der. The chains then go over the sheave and connect
to the carriage.
With four single-stage lift cylinders, the two free-lift
cylinders each have a chain connected to the shell
and go over a sheave connected to the carriage.
The lift cylinders are connected by hydraulic hoses
and tubing. To extend the mast, oil from the main
control valve flows to all cylinders at the same time.
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast. See the correct Service
Manual section for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery on electric lift trucks and put a
tag or lock on the battery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• DO NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
the mast.
4
4000 SRM 1062
The free-lift cylinder(s) raises first because of its
larger cylinder diameter and it lifts the least amount
of weight. The free-lift cylinder(s) raises the car-
riage to the top of the inner mast. After the free-lift
cylinder(s) reaches the end of its stroke, the main lift
cylinders begin to extend. As the main lift cylinders
extend, the intermediate and inner masts extend
because of the lift chains. During lowering, the main
lift cylinders lower first because they have a greater
load. The weight of the load, carriage, and inner
mast pushes the oil from the lift cylinders. The oil
flows from the lift cylinders through the lowering
control valves and the main control valve to the
hydraulic tank.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely.
Push the lift/lower control lever forward and
make sure there is no movement in the mast.
Make sure that all parts of the mast that
move are fully lowered.
OR
• If parts of the mast must be in a raised po-
sition, 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 the mast in a vertical position.
2. Raise the mast to align the bottom crossmem-
ber of the weldment that moves in the outer
weldment with a crossmember on the outer
weldment. On the two-stage and free-lift mast,
the moving part is the inner weldment. On the
three-stage mast, it is the intermediate weld-
ment. See Figure 4.
3. Use a 1/2 inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able member cannot lower. Put the hook on the
back side of the mast. Make sure the hook is com-
pletely engaged with a link in the chain. Make
sure the safety chain does not touch lift chains
or chain sheaves, tubes, hoses, fittings, or other
parts on the mast.
4000 SRM 1062 Safety Procedures When Working Near Mast

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

1. OUTER WELDMENT 4. CHAIN 7. CROSSMEMBER
2. INNER WELDMENT 5. FREE-LIFT CYLINDER
3. INTERMEDIATE WELDMENT 6. CROSSMEMBER

Figure 4. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts

5
Forks Repair 4000 SRM 1062

4. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (two-stage,
full free-lift, and three-stage masts only) is com-
pletely retracted. If running, stop the engine.
Apply the parking brake. Install a DO NOT
REMOVE tag on the safety chain(s).
5. Install another safety chain (3/8 inch minimum)
between the top or bottom crossmember of the
carriage and a crossmember on the outer weld-
ment.
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power and remove
the key. Put a DO NOT OPERATE tag in the oper-
ator’s compartment. Disconnect the battery on elec-
tric lift trucks and put a tag or lock on the battery
connector.

Forks Repair
REMOVE Never repair damaged forks by heating or
welding. Forks are made of special steel using
WARNING special procedures. Replace damaged forks.
The mast assembly and its components are 1. Inspect forks for cracks and wear. Check that the
heavy. To avoid causing damage or an injury, fork tips are aligned within 3% of the length of
a lifting device must be used during all service the forks. Check that bottom of the fork is not
procedures. worn. See Figure 5.
1. Place truck on level surface.

2. Lower the carriage completely.

3. Tilt the mast in a manner to increase fork stabil-

ity.

4. Apply the parking brake.

5. Shut down the engine.

6. Remove the capscrews, washers, and keeper

plate. See Figure 6.

7. Carefully remove the pin that holds the fork in

the carriage.

WARNING Fork Tip Alignment

Verify the lifting device has the rated capacity
of 1000 kg (2205 lb) Length of Forks 3% Dimension
1220 mm (48 in.) 37 mm (1.5 in.)
8. Use a lifting device to move the fork.
1830 mm (72 in.) 55 mm (2.2 in.)
9. Reinstall pin, keeper plate, capscrews, and wash-
2440 mm (96 in.) 73 mm (2.9 in.)
ers.

INSPECT AND ADJUST 1. TIP ALIGNMENT 3. FORK PIN

(MUST BE WITHIN DAMAGE
3% OF FORK 4. MUST BE 90% OF
WARNING LENGTH) DIMENSION X
2. CRACKS 5. FORK WEAR
Do not try to correct the alignment of the fork
tips by bending the forks or adding shims. Re- Figure 5. Check the Forks
place damaged forks.

6
4000 SRM 1062
2. Replace any damaged or broken parts that are
used to keep forks locked in position.
INSTALL
1. Remove capscrews, washers, and keeper plate.
2. Carefully remove the pin from the carriage.
Carriage Repair
DESCRIPTION
NOTE: For carriage layout details, see Figure 6,Fig-
ure 8,Figure 13, andFigure 15.
For valve section details, see Figure 7,Figure 9,Fig-
ure 14, andFigure 16.
Three Function
The directional control valve of the lift truck is be-
ing used to give altering P & T (alternate hydraulic
configuration) to the carriage for the operation of the
third function/auxiliary. Possible configurations are:
• Standard carriage (no sideshift) with lift, tilt, and
simultaneous fork positioning or one auxiliary (ad-
ditional function).
• Sideshift carriage with lift, tilt and sideshift.
Four to Six Function
Fixed P & T is supplied to a valve section mounted
on the carriage. This valve section is being used for
the third, fourth, fifth, and sixth function/auxiliary.
Possible configurations are:
• Standard carriage (no sideshift) with lift, tilt, and
up to four additional functions/auxiliaries.
• Sideshift carriage with lift, tilt, sideshift, and up to
three additional functions/auxiliaries.
REMOVE
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
1. Place truck on flat surface.
2. Apply parking brake.
Carriage Repair
3. Use a lifting device to move the fork to the lift
truck and position the fork in the carriage.
4. Reinstall pin, keeper plate, washers, and cap-
screws. See Figure 6.
3. Put mast in vertical position.
4. Center the carriage.
NOTE: The following Step 5 is for three-stage mast
only.
5. Remove the four socket head capscrews on the
inner sides of the carriage.
6. Lower the carriage and forks on blocks so that
the lift chains are loose.
7. Shut down the engine.
NOTE: Use Step 8, Step 9, and Step 10 if a sideshift
carriage, fork movement, or other auxiliary function
is installed.
8. Disconnect the hydraulic lines at the carriage.
9. Tag hydraulic lines.
10. Put screw type metal caps or plugs on open hy-
draulic lines/connections.
WARNING
Maintain control of the lift chains when discon-
necting them from the carriage. Use wire to
temporarily connect the ends of the lift chains
to the mast. This procedure will prevent the lift
chains from falling and causing injury or dam-
age.
11. Remove the pin from each chain anchor at the
carriage and disconnect lift chains from the car-
riage.
12. Reinstall pins.
7
Carriage Repair 4000 SRM 1062

WARNING WARNING
When the carriage is not connected to the mast, Verify the lifting device has the rated capacity
it can fall and cause injury or damage. Ver- of 2500 kg (5512 lb).
ify the carriage is stable and will not fall over
when the inner mast is raised above the car- 17. Connect a lifting device to the carriage and verify
riage. the carriage is stable.

13. Put weight on the forks so the carriage is stable 18. Remove the weight from the forks.
and will not fall when it is disconnected from the
19. Remove the load backrest (if fitted), fork pins,
mast.
and forks.
14. Start engine.
CAUTION
15. Carefully lift the inner mast until it is above the
Do not allow the load rollers to touch the
bearing blocks of the carriage.
ground.
16. Move truck away from carriage.
20. Lay the carriage on blocks.

1. BEARING WELDMENT 7. SHIM

2. KEEPER PLATE 8. BEARING BRACKET
3. FORK PIN 9. BEARING BLOCK
4. SNAP RING 10. CAPSCREW/WASHER
5. LOAD ROLLER 11. SPACER
6. BEARING BLOCK ASSEMBLY

Figure 6. Standard Carriage, Front and Top Views

8
4000 SRM 1062 Carriage Repair

A. 4 FUNCTION (2 AUXILIARY FUNCTIONS) C. 6 FUNCTION (4 AUXILIARY FUNCTIONS)

B. 5 FUNCTION (3 AUXILIARY FUNCTIONS) D. 3 FUNCTION W/HOSE GROUP

Figure 7. Standard Carriage, Valve Configurations (Rear View)

9
Carriage Repair
DISASSEMBLE
1. Disconnect the hydraulic lines at the sideshift
cylinder. See Figure 8.
2. Tag hydraulic lines.
3. Place caps and plugs on open lines and at the
sideshift cylinder.
NOTE: To remove the lock nut from the cylinder rod
end, use a wrench on the flats of the rod so the rod
will not turn in the cylinder.
4. Remove the lock nuts from both ends of the cylin-
der.
WARNING
Verify the lifting device has the rated capacity
of 500 kg (1102 lb).
5. Remove cylinder using a lifting device.
6. Disconnect hydraulic lines from, when fitted, the
fork positioning cylinders. See Figure 13.
7. Place caps and plugs on open lines and at the
positioning cylinder.
8. Remove the cotter and mounting pins at each end
of the cylinders.
9. Remove cylinders using a lifting device.
NOTE: For H8.00-12.00XM (H170-280HD) models,
remove the slider bars, one at a time, to the inner
side.
NOTE: For 13.00-16.00XM (H300-360HD) models,
remove the right hand slider bar to the outer side
through the hole in the side plate. Remove the left
hand slider bar to the inner side just enough to clear
the hanger casting on the apron.
10. Remove the keeper plates from the slider bar.
WARNING
Use caution when removing or installing the
snap rings used to fasten the load rollers to
the stub shafts. The snap rings can come loose
with force if not properly removed or installed.
Wear eye and face protection when the snap
rings are removed or installed.
10
4000 SRM 1062
11. Use a lifting device to lift the apron from the car-
riage.
12. Remove load rollers and bearing blocks as neces-
sary.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
CAUTION
Do not use steam to clean the side rollers and
load rollers. Steam will cause corrosion and
damage to the parts.
Use steam or solvent to clean the parts of the car-
riage.
Inspect the carriage weldments and rollers for wear
or damage. Inspect the welds for cracks.
ASSEMBLE
1. Install the load rollers on the carriage.
2. Install the correct shims between the bearing
brackets and the carriage surface.
3. Install, with curved surface of bearing bracket
facing the load roller(s), the bearing block as-
semblies on the vertical members of the carriage.
Tighten to 44 N•m (32 lbf ft).
4. Fasten the bearing block bracket with the cap-
screw and a washer.
CAUTION
Do not exceed the torque value listed.
5. Tighten the capscrew to 9 N•m (80 lbf in).
WARNING
Verify the lifting device has the rated capacity
of 500 kg (1102 lb).
6. Using a lifting device, install the apron on the
carriage.
4000 SRM 1062
7. Assemble the slider bars and the sideshift move-
ment in the reverse order of Disassemble.
8. Install the keeper plates securing the slider bars.
9. Install the fork positioning cylinders onto the
mounting brackets using the cotter pins at each
end.
10. Connect the hydraulic lines to the fork position-
ing cylinders.
11. Install the sideshift cylinder in the carriage and
fasten with the self-locking nuts at each end.
12. Tighten nuts fully; then loosen one-quarter turn.
13. Connect hydraulic lines to the cylinders.
INSTALL
WARNING
Verify the lifting device has the rated capacity
of 5000 kg (11,023 lb).
1. Raise the inner mast, using a lifting device or the
hydraulic system of the lift truck, until it is above
the top of the carriage.
Sideshift Cylinder Repair
REMOVE
SeeCarriage Repair, Disassemble, Figure 8 and Fig-
ure 9.
DISASSEMBLE
1. Remove the outer snap ring on the retainer. See
Figure 10.
2. Push retainer into the shell until the retainer
ring is exposed.
3. Remove the retainer ring.
Sideshift Cylinder Repair
2. Use lifting device to position the carriage under-
neath the inner mast.
3. Lower the inner mast until it engages the bear-
ing blocks and all of the load rollers.
4. Check the clearance of the load rollers and bear-
ing blocks.
5. Connect lift chains to the carriage using pins.
6. Adjust chain. See Figure 22.
7. Secure lift chains using new cotter pins in the
pins of the lift chains.
NOTE: The following Step 8 is model dependent.
8. Install four socket-head capscrews on inner sides
of the carriage.
9. Install forks and fork pins.
10. Connect hydraulic lines as necessary.
4. Pull rod assembly and retainer from the cylinder
shell.
5. Remove retainer from rod.
6. Remove and discard wiper, seal, backup ring, and
O-ring from the retainer.
7. Remove lock nut from the rod and remove piston.
8. Remove and discard seal and backup ring from
the piston.
11
Sideshift Cylinder Repair 4000 SRM 1062

1. SNAP RING 5. KEEPER PLATE

2. BUSHING 6. BEARING BLOCK
3. LUBE FITTING 7. LOCK NUT/WASHER
4. SLIDER BAR 8. SIDESHIFT CYLINDER

Figure 8. Sideshift Carriage, Front View

12
4000 SRM 1062 Sideshift Cylinder Repair

A. 4 FUNCTION (2 AUXILIARY FUNCTIONS) C. 6 FUNCTION (4 AUXILIARY FUNCTIONS)

B. 5 FUNCTION (3 AUXILIARY FUNCTIONS) D. 3 FUNCTION (W/HOSE GROUP)

Figure 9. Sideshift Carriage, Rear View, Valve Configurations

13
Sideshift Cylinder Repair 4000 SRM 1062

1. SNAP RING 8. BACKUP RING

2. RETAINER RING 9. O-RING
3. ROD 10. LOCK NUT
4. RETAINER 11. PISTON
5. CYLINDER SHELL 12. SEAL
6. WIPER 13. BACKUP RING
7. SEAL

Figure 10. Sideshift Cylinder

CLEAN AND INSPECT ASSEMBLE

1. Install new seal and backup ring on the piston.
WARNING
Cleaning solvents can be flammable and toxic 2. Install piston rod.
and can cause skin irritation. When using
cleaning solvents, always follow the solvent 3. Install and tighten lock nut on rod to 678 N•m
manufacturer’s recommended safety precau- (500 lbf ft).
tions.
4. Install rod and piston in the shell.
Clean all the parts of the cylinder in solvent. In-
5. Install new O-ring and backup ring in the groove
spect the shell, piston halves, rod, and bushing for
of the retainer.
scratches or grooves.

14
4000 SRM 1062
6. Install new rod seal and wiper in bore of the re-
tainer.
7. Install retainer on the rod.
8. Push the retainer into the shell until the retainer
ring groove is exposed.
9. Install retainer ring into groove in the shell.
Fork Positioner Cylinders Repair
REMOVE
SeeCarriage Repair, Disassemble, and Figure 13.
DISASSEMBLE
1. Remove nut, lockwasher, and capscrew from the
rod end. See Figure 11.
NOTE: With later versions of the fork positioner
cylinder, the rod end cannot be removed from the
rod. See Figure 12 and Figure 13.
NOTE: For various configurations of the fork posi-
tioner cylinder, see Figure 14, Figure 15, and Fig-
ure 16.
2. Remove rod end from the rod.
3. Remove gland from the rod and remove the rod
from the cylinder shell.
4. Remove and discard rod wiper, backup ring,
O-ring, and rod seal from gland.
5. Remove lock nut and piston from the rod.
6. Remove and discard the O-ring and seal from the
piston.
Fork Positioner Cylinders Repair
10. Pull rod and piston out of shell until the retainer
stops on the retainer ring and the snap ring
groove is exposed.
11. Install the snap ring on the retainer.
INSTALL
SeeCarriage Repair, Assemble, Install.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
Use steam or solvent to clean the parts of the fork
positioning cylinder.
ASSEMBLE
1. Install new seal and O-ring onto piston.
2. Install piston onto rod.
3. Install lock nut onto rod and tighten to 95 N•m
(70 lbf ft).
4. Install new seal, O-ring, backup ring, and wiper
onto gland.
5. Install rod into the cylinder shell.
INSTALL
See Carriage Repair, Assemble, Install.
15
Fork Positioner Cylinders Repair 4000 SRM 1062

1. NUT 9. O-RING
2. LOCKWASHER 10. ROD SEAL
3. CAPSCREW 11. LOCK NUT
4. ROD END 12. PISTON
5. ROD 13. SEAL
6. GLAND 14. O-RING
7. WIPER ROD 15. SHELL
8. BACKUP RING

Figure 11. Fork Positioner Cylinder

16
4000 SRM 1062 Fork Positioner Cylinders Repair

1. SHELL ASSEMBLY 7. RING

2. ROD ASSEMBLY 8. O-RING
3. PISTON 9. SPACER
4. RETAINER 10. ROD SEAL
5. NUT 11. WIPER
6. PISTON SEAL

Figure 12. Fork Positioner Cylinder, Later Models

17
Fork Positioner Cylinders Repair 4000 SRM 1062

1. PIN 4. PIN WITH SPLIT PIN

2. FORK GUIDE 5. FORK POSITIONER CYLINDER
3. SPLIT PIN

Figure 13. Standard Carriage With Fork Positioning, Front View

18
4000 SRM 1062 Fork Positioner Cylinders Repair

A. CARRIAGE WITH INDIVIDUAL POSITIONING

B. CARRIAGE WITH SIMULTANEOUS POSITIONING

Figure 14. Standard Carriage With Fork Positioning, Rear View, Valve Configurations

19
Fork Positioner Cylinders Repair 4000 SRM 1062

Figure 15. Sideshift Carriage With Fork Positioning, Front and Top Views

20
4000 SRM 1062 Directional Control Valve Repair

A. CARRIAGE WITH INDIVIDUAL POSITIONING

B. CARRIAGE WITH SIMULTANEOUS POSITIONING

Figure 16. Sideshift Carriage With Fork Positioning, Top and Rear Views, Valve Configurations

Directional Control Valve Repair

REMOVE 7. Put caps on open lines.

1. Tilt mast. 8. Tag hydraulic lines.

2. Lower carriage. 9. Mark for identification and disconnect electrical

plugs.
3. Switch off engine.
10. Loosen bolts holding valve section bracket if
4. Apply parking brake. present.
5. Apply brake pedal 8-10 times to remove hy- 11. Loosen bolts and remove valve section from
draulic pressure. bracket.
6. Disconnect hydraulic lines.

21
Directional Control Valve Repair 4000 SRM 1062

DISASSEMBLE ASSEMBLE
1. Carefully disassemble valve sections. See Fig- NOTE: Lubricate all parts using hydraulic oil before
ure 17. assembly.

2. Discard O-rings. Use only new O-rings and seals.

CLEAN AND INSPECT 1. Assemble in reverse order of Disassemble.

2. Torque bolts/nuts to values specified. See Fig-

WARNING ure 17.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using INSTALL
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau- 1. Install valve section using reverse procedure of
tions. Remove.

1. Clean all parts in solvent. 2. Operate truck.

NOTE: Replace any damaged parts. 3. Check functions.

2. Check components for damage. 4. Check for leaks.

Figure 17. Directional Control Valve

22
4000 SRM 1062
Mast Repair
TWO- AND THREE-STAGE MAST
Remove
WARNING
Lower the lift mechanism completely. Never
allow anyone under a raised carriage. Do not
put any part of your body in or through the
lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
Before making any repairs, use blocks and
chains on the inner mast and carriage so that
they cannot move. Make sure the moving parts
are attached to a part that does not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
NOTE: If the mast must be disassembled, remove the
forks and carriage. If the carriage is not removed, it
must be fastened to a cross member on the mast. Use
a chain or straps to keep the carriage from moving
when the mast is removed.
1. Place truck on flat surface.
2. Apply parking brake.
3. Fully lower the mast.
4. Tilt mast forward.
5. Shut down the engine.
6. Clean area around the hydraulic fittings for the
lift cylinders.
7. Disconnect hydraulic lines at the bottom of the
lift cylinders.
Mast Repair
8. Put metal caps on open lines and metal plugs on
cylinders.
9. Tag hydraulic lines.
10. Disconnect header hoses. See Figure 18.
11. Put metal caps/plugs on open lines.
12. Start engine.
WARNING
Verify the lifting device has the rated capacity
of 5000 kg (11,023 lb).
13. Connect a lifting device to the top cross members
on the inner, outer, and (if equipped) intermedi-
ate masts. See Figure 19.
14. Tilt the mast backward to the vertical position;
maintain stability using the lifting device.
15. Shut down the engine.
16. Remove capscrews from the bottom of the mast
mounting pins. See Figure 20.
17. Raise the mast slightly using the lifting device,
and put small blocks under the tilt cylinders be-
tween the cylinders and the fenders.
18. Remove the anchor pins for the tilt cylinders at
the mast.
19. Using the lifting device, lift the mast from the
truck.
20. Place the mast in a position so that the cross
members are on the floor.
23
Mast Repair 4000 SRM 1062

Figure 18. Header Hoses, Two-Stage Mast (Fixed P and T Shown)

24
4000 SRM 1062 Mast Repair

Legend for Figure 18

1. CLAMP 28. COVER
2. CLAMP 29. CAPSCREW
3. BRACKET 30. LOCKWASHER
4. ADAPTER FITTING 31. NUT
5. ADAPTER NUT 32. FITTING
6. ADAPTER NUT 33. NUT
7. NUT 34. CLAMP
8. LOCKWASHER 35. CAPSCREW
9. CAPSCREW 36. CLAMP
10. IDENTIFICATION BAND 37. NUT
11. NUT 38. WASHER
12. CLAMP 39. CAPSCREW
13. SHEAVE 40. PLATE
14. SPACER 41. CLAMP
15. SPACER 42. CLAMP
16. CAPSCREW 43. NUT
17. NUT 44. IDENTIFICATION BAND
18. IDENTIFICATION BAND 45. BRACKET
19. LOCKWASHER 46. PLATE
20. NUT 47. CAPSCREW
21. CAPSCREW 48. SPACER
22. LOCKWASHER 49. CAPSCREW
23. NUT 50. SPACER
24. BRACKET 51. HOSE PRESSURE
25. PLATE 52. HOSE RETURN
26. SPACER 53. WIRE HARNESS
27. CLAMP

25
Mast Repair 4000 SRM 1062

Figure 19. Two-Stage Mast Assembly

26
4000 SRM 1062 Mast Repair

Legend for Figure 19

1. OUTER MAST 10. PIN 19. NOTE: DIRECTION OF THE
2. INNER MAST 11. CAPSCREW AND WASHER CAPSCREW IS IMPORTANT
3. LIFT CYLINDER 12. SHIMS FOR CORRECT CLEARANCE
4. CHAIN ANCHOR 13. WEAR PLATE WITH THE INNER MAST.
5. LIFT CHAIN 14. SNAP RING 20. NOTE: APPLY GREASE ON
6. SPACER 15. LOAD ROLLER SURFACE OF THE CHANNEL
7. SHEAVE 16. MOUNT TO FRAME FOR THE ENTIRE LENGTH.
8. BEARING 17. MOUNT TO TILT CYLINDER
9. KEEPER 18. BEARING BLOCK

A. 33.0 mm (1.30 in.) FLATS ON B. 60.0 mm (2.36 in.) FLATS ON

57.1 mm (2.25 in.) DIA. ROD 47.6 mm (1.87 in.) DIA. ROD
1. MOUNTING PIN 8. TILT CYLINDER
2. CAPSCREW (2) 9. PIN
3. MAST MOUNT 10. BUSHING
4. LIFT TRUCK FRAME 11. PIN ANCHOR
5. MAST 12. ROD END
6. LIFT CYLINDER 13. GREASE FITTING
7. TILT CYLINDER ROD

Figure 20. Mast Installation

27
Mast Repair
Disassemble
1. Remove the capscrew and washers from the top
of each lift cylinder. See Figure 19.
2. Remove the capscrew and washers at the bottom
mount for each lift cylinder.
3. Put small blocks under the lift cylinders.
4. Slide out inner mast to disengage the lift cylin-
ders. See Figure 21.
WARNING
Verify the lifting device has the rated capacity
of 500 kg (1102 lb).
5. Put a lifting sling on the lift cylinder and remove
cylinder.
6. Repeat Step 5 for other cylinder.
7. Remove the bearing block assemblies from the
top of the outer mast.
8. Partly slide out inner mast and remove cotter pin
and pin from chain anchor.
9. Remove chains.
10. Slide the inner mast half way out of the outer
mast.
WARNING
Verify the lifting device has the rated capacity
of 5000 kg (11,023 lb).
11. Connect a lifting device to the center of the inner
mast.
12. Remove inner mast from outer mast.
NOTE: Write down the shim arrangement for re-
placement in the same order.
13. Remove the wear plate and shims.
WARNING
The snap rings used to fasten the load rollers
are large and can come loose with force if not
properly removed or installed. Wear eye and
face protection when the snap rings for the
load rollers are removed or installed.
28
4000 SRM 1062
14. Remove the load rollers as necessary for cleaning
and repair.
15. Remove the bearing blocks.
16. Remove and disassemble the pulleys as neces-
sary for cleaning and repair.
Clean and Inspect
1. Inspect the pulleys and load rollers for wear or
damage.
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
NOTE: Do not use steam to clean the lift chains, pul-
leys, or load rollers. The bearings in the load rollers
are sealed and lubricated. The bearings in the pul-
leys must be packed with multipurpose grease before
installation. The parts of the chain pulleys can be re-
placed. The load rollers must be replaced as complete
units.
2. Clean the lift chains with solvent.
3. Inspect the lift chains for wear or damage.
4. Use a chain scale to measure the chains. See
Figure 22.
WARNING
Never replace the worn section on a chain. Re-
place the complete chain. Always replace both
chains.
5. Replace lift chain if chain is 3% longer than a new
chain.
NOTE: The best procedure for lubricating the chains
is to remove the chains and soak in engine oil.
6. Lubricate the chains using engine oil.
NOTE: Replace parts that are worn or damaged.
7. Inspect the chain anchors and pins.
8. Clean the mast with steam or solvents.
4000 SRM 1062 Mast Repair

1. OUTER MAST 7. BEARING BLOCK

2. INNER MAST 8. SNAP RING
3. SHIMS 9. LOAD ROLLER
4. WEAR PLATE 10. MOUNTING PIN
5. SHIM 11. BUSHING
6. BEARING BRACKET

Figure 21. Two-Stage Mast

29
Mast Repair 4000 SRM 1062

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE.

Pitch
Wear Limit
Total Length of 20 Links
The Maximum Length of
(Pitch) of New Chain
20 Links

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

15.9 mm (0.626 in.)
19.1 mm (0.75 in.)
25.4 mm (1.00 in.)
31.8 mm (1.25 in.)
44.5 mm (1.75 in.)
50.8 mm (2.00 in.)
317.5 mm (12.5 in.)
381.0 mm (15.0 in.)
508.0 mm (20.0 in.)
635.0 mm (25.0 in.)
889.0 mm (35.0 in.)
1016.0 mm (40.0 in.)
326.9 mm (12.87 in.)
392.4 mm (15.45 in.)
523.2 mm (20.6 in.)
654.1 mm (25.75 in.)
915.7 mm (36.05 in.)
1046.5 mm (41.2 in.)

1. WORN PIN 5. LOOSE LEAVES

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

Figure 22. Lift Chains Check

9. Inspect the sliding and rolling surfaces for dam- Assemble

age.
WARNING
Do not weld any part of the mast assembly, car-
riage, or forks. Contact your dealer for Hyster®
lift trucks before welding on the mast.
NOTE: The shims for the bearing blocks keep the in-
ner and outer masts parallel and give correct clear-
ance. Assemble shim set as found during disassem-
bly. Check clearance and adjust shim set as required.
1. Install wear plate and shims on the outer mast.

10. Inspect all welds for cracks. 2. Apply multipurpose grease to the wear plate sur-
face.

30
4000 SRM 1062
WARNING
The snap rings used to fasten the load rollers
are large and can come loose with force if not
properly removed or installed. Wear eye and
face protection when the snap rings for the
load rollers are removed or installed.
3. Install load rollers on the inner mast.
4. Install bearing blocks and shims on inner mast.
CAUTION
Do not over tighten capscrews for the bearing
blocks.
5. Tighten capscrews for the bearing blocks to
9 N•m (7 lbf ft).
6. Tighten capscrews that hold the bearing block
assemblies to 44 N•m (32 lbf ft).
7. Apply multipurpose grease to the rear surface of
the inner channel.
WARNING
Verify the lifting device has the rated capacity
of 5000 kg (11,023 lb).
8. Connect lifting device to center of inner mast.
9. Put load rollers into end of outer mast.
10. Slide inner mast into outer mast.
11. Check clearances of bearing blocks and wear
plates.
12. Install bearing blocks to outer mast.
NOTE: Verify the roller bearings are installed with
the seals facing outward.
13. Assemble and install chain pulleys.
14. Connect lift chains to the outer mast using chain
anchors.
WARNING
Verify the lifting device has the rated capacity
of 500 kg (1102 lb) to lift the lift cylinders.
15. Position lift cylinders using a lifting device and
install the washers and capscrews at the bottom
of the lift cylinders.
Mast Repair
16. Push inner mast to engage the rods of the lift
cylinders.
17. Check that both cylinder rods fit evenly against
the inner mast. Use shims to align if necessary.
18. Install washers and capscrews to hold the top of
the cylinder rods in position.
19. Verify the lowering control valves are installed at
the bottom of both lift cylinders.
20. Attach, using wire, the ends of the lift chains to
the cross member on the inner mast.
Install
1. Fasten mast elements together using chain with
hooks.
WARNING
Verify the lifting device has the rated capacity
of 500 kg (1102 lb) to lift the lift cylinders.
2. Connect lifting device capable of lifting to the top
of mast.
3. Verify chains will not damage hydraulic lines or
other parts of the mast.
4. Raise the mast assembly to the vertical position,
and position on the lift truck.
5. Lubricate mast mounting pins and bushings.
6. Install the mast mounting pins with grease fit-
ting towards the center of the lift truck.
7. Install shims on mounting pins to restrict lateral
movement of mast to 2.85 to 3.15 mm (0.11 to
0.12 in.).
8. Install the capscrews for the mounting pins.
9. Tighten capscrews to the following:
• 435 N•m (321 lbf ft) for H8.00-12.00XM (H190-
280HD) units.
• 522 N•m (385 lbf ft) for H13.00-16.00XM-12EC
(H300-360HD-EC) units.
NOTE: The capscrews on the rod end must be towards
the floor, with the nuts toward the center of the truck.
10. Connect the tilt cylinders to the outer mast.
11. Install mast tilt pin and bushings.
31
Mast Repair 4000 SRM 1062

12. Install pin anchor and torque to 165 N•m 3. Fully lower the mast.
(122 lbf ft).
4. Tilt mast forward.
13. Tighten capscrews clamping the tilt cylinder rod
end to 66 N•m (49 lbf ft). 5. Shut down the engine.

14. Install connection hoses and header hoses. 6. Clean area around the hydraulic fittings for the
lift cylinders.
15. Install the carriage. See Carriage Repair.
7. Disconnect hydraulic lines at the bottom of the
16. Connect hydraulic supply hoses to the mast as- lift cylinders.
sembly.
8. Tag hydraulic lines.
17. Start engine.
9. Put metal caps on open lines and metal plugs on
18. Check all functions. cylinders.

19. Check for leaks. 10. Disconnect header hoses. See Figure 23.

20. Adjust lift chains, carriage, and tilt cylinders. 11. Tag header hoses.

THREE-STAGE MAST (FOUR CYLINDERS) 12. Put metal caps on open lines.

Remove 13. Start engine.

WARNING
Lower the lift mechanism completely. Never
allow anyone under a raised carriage. Do not
put any part of your body in or through the
lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
Before making any repairs, use blocks and
chains on the inner mast and carriage so that
they cannot move. Make sure the moving parts
are attached to a part that does not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
NOTE: If the mast must be disassembled, remove the
forks and carriage. If the carriage is not removed it
must be fastened to a cross member on the mast. Use
a chain or straps to keep the carriage from moving
when the mast is removed.
1. Place truck on flat surface.
2. Apply parking brake.
WARNING
Verify the lifting device has the rated capacity
of 5000 kg (11,023 lb).
14. Connect a lifting device to the top cross members
on the inner, outer, and, if equipped, intermedi-
ate masts.
15. Tilt the mast backward to the vertical position;
maintain stability using the lifting device.
16. Shut down the engine.
17. Remove capscrews from the bottom of the mast
mounting pins.
18. Raise the mast slightly using the lifting device,
and put small blocks under the tilt cylinders be-
tween the cylinders and the fenders.
19. Remove the anchor pins for the tilt cylinders at
the mast.
20. Using the lifting device, lift the mast from the
truck.
21. Place the mast in a position so that the cross
members are on the floor.

32
4000 SRM 1062 Mast Repair

1. HOSE PULLEY 13. LH PLATE

2. CIRCLIP 14. RH PLATE
3. SCREW 15. SCREW
4. WASHER 16. GUARD
5. SHAFT/HOSE PULLEY 17. FITTING
6. GUIDE 18. HOSE (TWO)
7. SUPPORT 19. HOSE (NOT PRESENT ON 3-FUNCTION HOSE
8. SCREW GROUP)
9. WASHER 20. WIRE HARNESS (NOT PRESENT ON
10. FITTING 3-FUNCTION HOSE GROUP)
11. SCREW 21. NUT
12. WASHER

Figure 23. Header Hoses, Three Stage Mast

33
Mast Repair
Disassemble
1. Disconnect and tag hydraulic lines and remove
from the mast.
2. Put plugs on cylinders.
3. Remove cotter pin and remove chain pin. See
Figure 24.
4. Remove lift chain from the free-lift cylinder and
mast.
5. Remove sheave assembly from the free-lift cylin-
der.
WARNING
Verify the lifting device has the rated capacity
of 500 kg (1102 lb).
6. Attach lifting device to the free-lift cylinder.
7. Remove lock nut and two screws holding the free-
lift cylinder.
8. Using the lifting device, remove the free-lift
cylinder.
9. Repeat Step 8 for other free-lift cylinder.
10. Remove the pin for the lift chain at the chain
anchor on top of the outer mast.
11. Remove the pin for the lift chain at the chain
anchor on the bottom of the inner mast.
12. Repeat Step 10 and Step 11 for the other lift
chain.
13. Remove lift chains.
14. Support lift cylinders with small blocks.
15. Remove ring and split ring from bottom of cylin-
der.
16. Remove screws and washers holding cylinder
support.
17. Remove screw (8) and washer (9) on top of cylin-
der. See Figure 23.
34
4000 SRM 1062
WARNING
Verify the lifting device has the rated capacity
of 500 kg (1102 lb).
18. Attach a lifting device and remove lift cylinder.
19. Repeat Step 18 for the other lift cylinder.
20. Slide inner mast halfway out towards the top of
the mast, and connect a lifting device to the cen-
ter of the inner mast.
21. Slide inner mast further towards the top of the
mast, and remove through notches in the inter-
mediate mast.
22. Remove load rollers, as necessary for cleaning
and/or repair.
23. Slide intermediate mast halfway out of the outer
mast; connect a lifting device to the center of the
intermediate mast.
NOTE: The head end of the outer mast has two
notches. These notches provide a passage way for
the load rollers when the inner mast is removed.
24. Slide intermediate mast towards the top end, and
remove through notches in outer mast.
25. Remove load rollers, as necessary for cleaning
and/or repair.
26. Remove and disassemble the pulleys as neces-
sary for cleaning and/or repair.
Clean and Inspect
NOTE: See Two- and Three-Stage Mast, Clean and
Inspect.
Assemble
NOTE: Follow reverse procedure as listed in Three-
Stage Mast (Four Cylinders), Disassemble.
4000 SRM 1062 Mast Repair

Figure 24. Three Stage Mast, Full Free Lift

35
Mast Repair 4000 SRM 1062

Legend for Figure 24

1. ROLLER 19. CHAIN PIN
2. SCREW 20. CHAIN ANCHOR
3. FITTING 21. LOCK NUT
4. CHAIN PULLEY 22. COTTER PIN
5. PULLEY PIN 23. DRAINAGE HOSE
6. WASHER 24. HOSE
7. TUBE 25. FREE-LIFT CYLINDER
8. RING 26. HOSE
9. SCREW 27. RING
10. FITTING 28. CIRCLIP
11. SCREW 29. LOCK NUT
12. WASHER 30. FITTING
13. CYLINDER SUPPORT 31. VALVE BLOCK
14. CHAIN 32. FITTING
15. LIGHT BRACKET 33. VALVE
16. PULLEY SUPPORT 34. FITTING
17. PULLEY ASSEMBLY 35. CLAMP
18. COTTER PIN

Install
1. Using a lifting device, lift the mast to the truck.
2. Install the anchor pins for the tilt cylinders at the
mast.
3. Lower the mast slightly using the lifting device,
and remove the small blocks under the tilt cylin-
ders between the cylinders and the fenders.
4. Install capscrews to the bottom of the mast
mounting pins.
5. Start engine.
6. Tilt the mast forward to the vertical position,
maintain stability using the lifting device.
13. Connect an oil filling tube to the oil filling con-
nection. See Figure 25.
NOTE: The drainage tube must not be immersed in
the reservoir below the oil level. IT MUST ALWAYS
BE ABOVE THE SURFACE.
The drainage tube should also form a bend before en-
tering the reservoir in which there should be a small
quantity of oil to act as a syphon. This helps to keep
the internal surface of the cylinder case wet when it
is closed.
14. Connect a drainage tube to the oil drain connec-
tion. See Figure 25.
15. Test the tilt movement to verify that there are no
obstructions between the truck and mast.

WARNING NOTE: Use graphite grease, avoiding if possible,

Verify the lifting device has the rated capacity
of 5000 kg (11,023 lb).
7. Remove lifting device from the top cross members
on the inner, outer, and, if equipped, intermedi-
ate masts.
8. Shutdown engine.
9. Remove metal caps on open lines.
10. Connect header hoses. See Figure 23.
11. Remove metal caps on open lines and metal plugs
on cylinders.
12. Connect hydraulic lines at the bottom of the lift
cylinders.
spray greases.
16. Grease roller surfaces for mast and carriages.
17. Operate mast three to four times to circulate the
oil through the system.
18. Lift forks approximately 500 mm (20 in.).
NOTE: At first sign of oil flow, tighten the screw. See
Figure 26.
19. Loosen screw(s) located below top cap.
20. Put load on forks, 30% of nominal load, and lower
forks. Verify descent is normal. If found not to be
normal, check cylinder(s) for damage.

36
4000 SRM 1062 Mast Repair

1. OIL FILLING CONNECTION 2. OIL DRAIN CONNECTION

Figure 25. Mast Oil Filling

Figure 26. Air Bleeder Screw

37
Mast Repair 4000 SRM 1062

FORK CARRIAGE CHAINS

Adjust
The chains must be adjusted so that the upper and
lower blocks of the end-of-run stops never make con-
tact.

The construction of the mast allows, when the chain

is correctly regulated, a clearance of about 5 mm
(0.197 in.) between the upper and lower carriage
stops. See Figure 27.

To adjust, remove the forks and adjust the chains so

that between the lower stop of the carriage and the
one located on the internal mast, there is a play of
about 5 mm (0.197 in.).

Operate the free lift cylinder to the end-of-stroke and

verify that the upper stop also has a minimum clear-
ance of 1 mm (0.039 in.) with no load. If this oper-
ation is not carried out and the stops are allowed to
bind, these will warp and the lower bearing of the
carriage plate will come out of the mast. If too much
clearance is allowed between the lower stops, the
upper ones could bind causing large loads on them-
selves, the chain, and in the cylinder. See Figure 28.

Verify the chains that work in a parallel way always

have the same tension. If not, adjust using the chain
tensioner. See Figure 29.

Figure 27. Chain Clearance

38
4000 SRM 1062 Mast Repair

Figure 28. Lower Bearing

Figure 29. Chain Tensioner

39
Mast Repair 4000 SRM 1062

BEARING ROLLERS
Description
The bearing rollers used for the three-stage masts
provide both radial and lateral support. Two types
of rollers are available, standard and oversized, and
are being used dependent upon the mast profile. See
Figure 30.

Figure 31. Roller Clearance

Remove and Disassemble

1. Remove, disassemble, and/or operate mast to
1. MAIN ROLLER 7. ROLLERS gain access to bearing roller.
2. SIDE ROLLER 8. SEAL
3. CAP 9. STUB SHAFT 2. Loosen two/four screws, and remove cap. See
4. PIVOT 10. LUBRICATION Figure 32.
5. SEAL DUCT
6. ROLLERS 3. Remove external roller.
Figure 30. Bearing Roller 4. Remove pin and side roller.

Lubrication 5. Inspect, clean, and replace if found to be faulty.

NOTE: Standard Lubrication frequency is 500 hours, Assemble

but frequency may have to be increased when work-
ing in dusty, corrosive surroundings, and/or high NOTE: The pin has profiled ends enabling it to corre-
temperatures. spond with the surface of the pivot.

1. Remove plug in lubrication duct, lubricate, and 1. Assemble roller in reverse order of Remove and
replace plug. See Figure 30. Disassemble.

Clearance 2. Check operation of mast.

When the clearance value has become 2 mm (.08 in.),

it is advisable to remove the roller. As wear will
mainly occur on the mast profile, it is advisable to re-
place the standard roller with the oversized version.
See Figure 31.

40
4000 SRM 1062
1. EXTERNAL 4. STUB SHAFT
ROLLER 5. CAP
2. SCREWS 6. SIDE ROLLER
3. PIN
Figure 32. Roller Assembly
Lift Cylinders Description
There are two types of lift cylinders used on these
lift trucks. The H8.00-12XM (H170-280HD) and
H13.00-16.00XM (H300-360HD) units use pis-
ton-type cylinders. The H10.00-12.00XM-12EC
(H330-360HD-EC) units use displacement-type lift
cylinders. The two-stage masts have two main lift
cylinders. The three-stage masts have two main lift
cylinders and two free-lift cylinder. All lift cylin-
ders for these lift trucks are single-action hydraulic
cylinders. When hydraulic oil enters one end of the
cylinder, the hydraulic force extends the rod. When
the oil is allowed to drain from the cylinder, the
weight of the carriage and inner mast causes the
cylinder rods to retract.
PISTON-TYPE CYLINDERS
During lifting, oil from the main control valve flows
to the bottom of the lift cylinders. See Figure 34. The
cylinder rods extend because the area on the bottom
side of the piston is greater than the area on top of
the piston. As the cylinder rods extend, the oil on top
of the pistons is forced through the check valves in
the bottom of the pistons.
Lift Cylinders Description
MAST PROFILE
NOTE: Profiles on which the forks carriage runs will
always wear out the most, in particular, the lower
section compared to the middle and upper sections.
Wear of the mast profile should be checked on a reg-
ular basis. When the thickness of the wing has been
reduced by about 15% of its initial value, mast re-
placement should be considered to ensure safe oper-
ating conditions.
The lift cylinders have a single lip seal on the piston
to prevent hydraulic oil leaks past the piston and re-
tainer. During operation, some hydraulic oil can leak
past the piston area to the rod end of the lift cylin-
der. Small internal leaks are permitted if the inter-
nal leak rate of the hydraulic system is not greater
than the specification.
DISPLACEMENT-TYPE CYLINDERS
The displacement-type cylinders do not have a pis-
ton or piston seal. See Figure 34. A cast iron guide
replaces the piston assembly. The guide keeps the
cylinder rod aligned with the shell. The seal arrange-
ment at the top of the lift cylinder is the same as for
the piston-type cylinders.
During lifting, oil from the main control valve flows
to the bottom of the lift cylinders. The cylinder rods
extend because the area on the bottom side of the rod
and guide is greater than the area on top of the guide.
As the cylinder rods extend, the oil on top of the guide
is forced between the guide and the cylinder shell to
the bottom side of the pistons.
41
Lift Cylinders Repair
Lift Cylinders Repair
A lowering control valve is installed in the base of
the lift cylinders. See Figure 33, Figure 34, and Fig-
ure 35. The lowering control valve permits easy en-
try of hydraulic oil into the cylinders, but gives a re-
striction when the rods retract. This restriction con-
trols the maximum speed at which a load on the forks
can be lowered.
The lowering control valve is shown in Figure 33.
The position of the orifice sleeve is controlled by oil
flow. The position of the plunger is controlled by oil
pressure and spring tension. During lifting, oil enter-
ing the cylinder goes through the center of the main
sleeve to the large holes. The oil continues between
the plunger and bore to move the orifice sleeve to the
end of the plunger. The flange of the orifice sleeve
is then aligned with the large part of the bore in the
body. This alignment lets the oil flow around the ori-
fice sleeve to the inlet port of the cylinder.
During the lowering operation, oil from the cylinder
moves the orifice sleeve. The sleeve moves away from
the larger area of the bore in the valve body. This
movement makes a restriction to the oil flow. When
A. FREE FLOW
B. RESTRICTED FLOW
1. VALVE BODY
2. SPRING
3. WASHER
4. CYLINDER
Figure 33. Lowering Control Valve
42
4000 SRM 1062
the pressure increases, the plunger begins to move
against the spring. The movement begins to close the
openings of the large holes in the main sleeve. Ad-
ditional pressure will push the plunger against the
main sleeve to close the large holes completely. All
the oil must go through the small holes to the center
of the main sleeve. This restriction limits cylinder
rod lowering to a maximum controlled speed.
Spacers are used in some cylinders to limit the stroke
of the rod. Worn spacers must be replaced with the
same size spacer.
The most common maintenance problem is the repair
of oil leaks. If the bore of the shell of the lift cylinder
is damaged and cannot be repaired, the lift cylinder
must be replaced.
REMOVE
Remove the lift cylinders while disassembling the
mast. See the procedures in Two- and Three-Stage
Mast, Disassemble orThree-Stage Mast (Four Cylin-
ders), Disassemble.
C. LIFTING
D. LOWERING
5. ORIFICE SLEEVE
6. PLUNGER
7. MAIN SLEEVE
4000 SRM 1062 Lift Cylinders Repair

A. FOR STANDARD LIFT TRUCKS (PISTON-TYPE B. FOR LIFT TRUCKS WITH EMPTY CONTAINER
CYLINDERS) ATTACHMENT (DISPLACEMENT-TYPE
CYLINDERS)
1. ROD AND PISTON ASSEMBLY 9. CHECK VALVE
2. WIPER RING 10. O-RING
3. RETAINER 11. WASHER
4. ROD SEAL 12. SNAP RING
5. O-RING 13. CYLINDER SHELL
6. SPACER 14. GUIDE
7. BACKUP RING 15. SCREW
8. WEAR RING

Figure 34. Lift Cylinders

43
Lift Cylinders Repair 4000 SRM 1062

DISASSEMBLE Packing lubricant (Part No. 186061) is also avail-

able.
WARNING • Make sure the single-lip seal assemblies are in-
stalled with the O-ring toward the base of the cylin-
The lift cylinders are very heavy. Use slings
der. See Figure 35.
and a lifting device to handle and disassem-
ble the lift cylinders. Make sure that the lift-
ing device and slings have the rated capacity
of 500 kg (1102 lb).

CAUTION
Carefully disassemble and assemble the lift
cylinders so the rods and sliding surfaces are
not damaged.

1. Loosen the retainer with a spanner. Remove the

retainer from the shell. See Figure 34.

2. Remove the protective cap from the inlet and

slide the rod and piston or guide assembly from
the shell. Drain the hydraulic oil into a container.

3. Remove the retainer from the rod. Remove and

discard the O-rings, seals, wiper ring, and wear
ring.

4. Remove the internal check valve (if used) from

the base of the piston. The check valve is fas-
tened by a snap ring. On displacement-type
cylinders, remove the lower snap ring and the
guide.
1. PISTON 6. O-RING
CLEAN AND INSPECT 2. ROD 7. CHECK VALVE
3. BACKUP RING 8. WASHER
4. SINGLE-LIP SEAL 9. SNAP RING
WARNING 5. O-RING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using Figure 35. Internal Check Valve and Single-Lip
cleaning solvents, always follow the recom- Seal
mendations of the manufacturer.
1. Install the internal check valve and O-ring.
Clean all the parts in solvent. Check the sliding sur- Make sure the arrow on the internal check valve
faces for damage. Repair or replace any damaged is toward the base of the piston. Install the
parts. washer and snap ring.

2. Install the wear ring, single-lip seal, and backup

ASSEMBLE
ring onto the piston assembly. If a spacer sleeve
NOTE: is used, install it. Use shim material and a clamp
• Lubricate all internal parts of the cylinder with as a guide to move the single-lip seal over the
clean hydraulic oil during assembly. See Figure 34. threads of the shell.
• Use new O-rings, seals, and wear rings. Apply
clean lubricant (hydraulic oil) during assembly.

44
4000 SRM 1062
WARNING
Be careful. The snap rings are large and can
come loose with force if not properly removed
or installed. Wear eye and face protection
when the snap rings are removed or installed.
3. On displacement-type cylinders, install the guide
and the snap ring.
4. Carefully push the piston and rod assembly into
the shell. Release the clamp on the seal when the
seal travels past the threads of the shell.
5. Install the seal, O-ring, and wiper ring in the re-
tainer. If the wiper seal has a spring for a backup
ring, the spring must be toward the base of the
cylinder.
Mast Operation Check
WARNING
Lower the lift mechanism completely. Never
allow anyone under a raised carriage. Do not
put any part of your body in or through the
lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
Before making any repairs, use blocks and
chains on the inner and outer masts and car-
riage so that they cannot move. Make sure the
moving parts are attached to a part that does
not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
Mast Operation Check
6. Carefully install the retainer on the rod.
7. Engage the threads and tighten the retainer in
the shell. The correct torque is 550 to 625 N•m
(406 to 461 lbf ft). Use a correct spanner. Do not
hit the retainer with a hammer and driver.
8. Install the lowering control valves. Make sure
the special washer and the spring are installed
correctly in the base of the cylinders. A wrong
installation can cause the load to lower too fast.
INSTALL
Install the lift cylinders while assembling the mast.
See the procedures inTwo- and Three-Stage Mast,
Assemble orThree-Stage Mast (Four Cylinders), As-
semble.
1. Check for leaks in the hydraulic system. Check
the condition of the hydraulic hoses and tubes.
2. Slowly raise and lower the mast several times
without a load. The mast components must raise
and lower smoothly in the correct sequence.
NOTE: Some parts of the mast move at different
speeds during raising and lowering.
3. The inner mast and the carriage must lower com-
pletely.
4. Check that the controls for the attachment oper-
ate the functions of the attachment. (See symbols
by each of the controls.) Make sure all of the hy-
draulic lines are connected correctly and do not
leak.
45
Lift and Tilt System Leak Checks 4000 SRM 1062

Lift and Tilt System Leak Checks

LIFT SYSTEM
1. Slowly raise and lower the mast several times
without a load. Put a capacity load on the forks
and raise and lower the load several times.
Lower the load and tilt the mast forward and
backward several times. Check for leaks and
repair as necessary.
2. Raise the carriage and the capacity load 1 m
(3 ft). If the carriage lowers slowly with the con-
trol valve in a neutral position, there are leaks
inside the hydraulic system.
3. Check the lift cylinder for internal leaks. Remove
the load from the forks. Install a gate valve in
each of the supply lines between the main control
valve and the mast. Put a capacity load on the
forks again. Raise the carriage 1 m (3 ft). Close
both gate valves. If the carriage or inner mast
lowers slowly, the seals in the lift cylinders have
leaks.
4. If the carriage does not move, open both gate
valves and check the movement again. If the car-
riage lowers when the gate valves are open, check
for leaks in the hydraulic lines and fittings. If no
leaks are found, the main control valve can have
a defect. Remove the load from the forks.
TILT SYSTEM
1. Put a capacity load on the forks and raise the
forks approximately 30 cm (12 in.). Slowly tilt
the mast forward. If the mast continues to slowly
tilt forward when the control valve is in a neu-
tral position, there are leaks inside the hydraulic
system. The maximum speed that the mast is al-
lowed to tilt forward is shown in Table 1. For
example, the maximum speed that the mast is
allowed to tilt forward is 29 mm (1.1 in.) per 10
minutes when the hydraulic oil is 30 C (86 F).
2. If the leak rate is greater than specified, remove
the load from the forks. Install a gate valve be-
tween the port at the front of each tilt cylinder
and the hydraulic line. Put the load on the forks
again. Close one valve. If the mast tilts slowly
forward, the cylinder connected to the closed gate
valve has leaking seals. Check the other cylinder
using the same procedure.
3. If the mast does not move, open one of the gate
valves and check for movement again. If the
mast moves forward with the valve open, check
for leaks in the hydraulic lines or fittings. Check
the other tilt cylinder using the same procedure.
If no leaks are found, the main control valve can
have a defect. Remove the load from the forks.

Table 1. Allowable Mast Movement from Internal Leakage

Maximum Horizontal Movement at

Hydraulic Oil Maximum Vertical Movement Tilt Cylinder
Temperature at Carriage
Tilt Cylinder Stoke
deg C deg F mm/10 min in./10 min deg/10 min mm/10 min in./10 min
20 68 22 0.9 1.1 18.6 0.73
30 86 33 1.3 1.7 28.8 1.1
40 104 63 2.5 3.1 52.6 2.1
50 122 100 3.9 5.0 84.8 3.3
60 140 146 5.7 7.3 123.7 4.9

46
4000 SRM 1062
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment
For lift trucks without back tilt spacers, adjust the
tilt cylinders as follows:
1. Slowly tilt the mast backward until one rod is
against its stop. On the opposite tilt cylinder,
loosen the capscrews on the rod end and turn the
cylinder rod out of the rod end until both rods
stop at the same time. If necessary, loosen a fit-
ting on the tilt cylinder to release hydraulic pres-
sure in the cylinder.
2. Repeat the procedure to make sure the cylin-
der rods stop at the same time within 1.0 mm
(0.04 in.). Check that the tilt angles are correct
as specified on the nameplate of the lift truck.
When the adjustments are complete, tighten the
capscrews on the rod end to 66 N•m (49 lbf ft).
For lift trucks with back tilt spacers, adjust the tilt
cylinders as follows:
1. Slowly tilt the mast forward until one rod is
against its stop. On the opposite tilt cylinder,
loosen the capscrews on the rod end and turn the
cylinder rod into the rod end until both rods stop
Lift Chain Adjustments
The following conditions will exist 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.
1. Put the lift truck on a flat, level surface. Put the
mast in a vertical position. Lower the carriage
and check the clearance between the heel of the
fork and the surface (floor). Adjust the lift chains
so that the clearance is 6.0 mm (0.24 in.).
Lift Chain Adjustments
at the same time. If necessary, loosen a fitting
on the tilt cylinder to release hydraulic pressure
in the cylinder.
2. Repeat the procedure to make sure the cylin-
der rods stop at the same time within 1.0 mm
(0.04 in.). Check that the tilt angles are correct
as specified on the nameplate of the lift truck.
3. Slowly tilt the mast backward until one of the rod
ends touches its spacer. Measure the clearance
between the opposite cylinder spacer and the rod
end. Remove this rod end and add shims to fill
the clearance between the spacer and the rod end
to within 1.0 mm (0.04 in.). Install the rod end to
its original position and tighten the capscrews on
the rod end.
4. Tilt the mast forward and backward to make sure
both tilt cylinders stop within 1.0 mm (0.04 in.) of
each other. Repeat the above procedures if more
adjustment is necessary. When the adjustments
are complete, tighten the capscrews on the rod
end to 66 N•m (49 lbf ft).
2. Check the clearance of the carriage when the
mast is fully extended. The carriage stops must
not touch the stop on the top crossmember of the
inner mast. The chains are too tight if the car-
riage touches the crossmember. If the chains are
too tight, adjust the chain anchors. Make sure
each anchor is adjusted the same amount.
NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain
anchors are completely engaged. Make sure that the
lock nuts on the chain anchors are drawn up tight
against the mount plate.
47
Carriage Adjustment 4000 SRM 1062

Mast Adjustments
BEARING BLOCKS, TWO STAGE MASTS
1. The bearing blocks control the alignment of the
inner, and outer masts. The vertical channels
must be parallel to each other to decrease wear.
See Figure 36.

2. The maximum side clearance between the bear-

ing blocks and the channels at the tightest fit
is 0.5 to 1.3 mm (0.020 to 0.051 in.). When in-
stalling the bearing blocks, be sure to lubricate
the face of the bearing block with multipurpose
grease. Adjust the bearing blocks as follows:

a. Use a crowbar to move the inner mast from

side to side to measure the amount of move-
ment. Repeat in a minimum of three differ-
ent positions of the inner and outer masts. A. 6 mm (0.24 in.) MAXIMUM

b. Change the shim arrangements as needed. 1. MAST OR 4. SPACER

CARRIAGE 5. BEARING BLOCK
Slide the inner mast all the way to the top WELDMENT 6. CAPSCREW AND
and bottom to find the tightest fit. Maximum 2. SHIMS WASHER
clearance at the point of the tightest fit is 3. BEARING
0.5 to 1.3 mm (0.020 to 0.051 in.). If neces- BRACKET
sary, a maximum of five shims can be added
Figure 36. Bearing Block
between the bearing block and the bracket.
If more than five shims are required, replace
the bearing block. Also check the distance
WEAR PLATES
that the bearing block extends from the Adjust the wear plates as follows:
bracket. The maximum distance that the
bearing block can extend from the bracket is 1. Adjust the wear plates so the maximum clear-
6.0 mm (0.24 in.). ance at the point of tightest fit is 0.5 to 1.5 mm
(0.020 to 0.059 in.).

2. Insert shims between the wear plate and the top

crossmember on the outer mast as necessary.

Carriage Adjustment
WARNING
Verify the lifting device has the rated capacity
of 2500 kg (5512 lb) to raise the carriage.
3. Adjust the shim arrangement for each bearing
1. Use a lifting device to raise the carriage. Find
the tightest fit between the bearing blocks and
the channels of the inner mast. See Figure 36
and Figure 37.
2. The maximum clearance between the bearing
block and the inner channel is 0.5 to 1.3 mm
(0.020 to 0.051 in.) at the point of the tightest
fit. When installing the bearing blocks, be sure
to lubricate the face of the bearing block with
multipurpose grease.
block. If necessary, a maximum of five shims
can be added between the bearing block and the
bracket. If more than five shims are required, re-
place the bearing block. Also check the distance
that the bearing block extend from the bracket.
The maximum distance that the bearing block
can extend from the bracket is 6.0 mm (0.24 in.).

48
4000 SRM 1062 Carriage Adjustment

Figure 37. Lift Chain and Mast Adjustments

49
Troubleshooting 4000 SRM 1062

Legend for Figure 37

1. OUTER MAST 7. 1/3 OF CARRIAGE ROLLER
2. INNER MAST 8. LOCK NUT
3. LIFT CYLINDER 9. BEARING BLOCK
4. CARRIAGE 10. BEARING BRACKET
5. LIFT CHAIN 11. SHIMS
6. CHAIN ANCHOR 12. EMPTY CONTAINER ATTACHMENT

4. Keep the shim arrangement on each side of 5. After adjustment, lubricate the surface of the
the carriage approximately equal. The carriage channels that touch the bearing blocks with a
must be parallel with the inner channel within thin layer of grease. Do not lubricate the sur-
±1.5 mm (0.059 in.). faces for the load rollers.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No movement of the lift or Pilot line(s) to the control valve are Tighten or connect fittings.
tilt cylinders. disconnected or leaking.

No oil or not enough oil in the hy- Fill tank. Check for leaks.
draulic tank.

Relief valve(s) not set correctly. Adjust or install new relief valve.

Hydraulic pump does not operate or Repair or install new pump.

has damage.

Remote control valve does not oper- Check and repair valve.
ate.

Slow movement of the lift or No oil or not enough oil to the lift or Fill tank. Check for leaks.
tilt cylinders. tilt cylinders.

Cylinders have internal or external Repair leaks. Install new parts.

leaks.

Relief valve is not set correctly. Adjust or install new relief valve.

There is a restriction in a hydraulic Remove restriction. Install new

line. parts.

Load is more than capacity. Reduce load.

50
4000 SRM 1062 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Rough movement of the mast There is air in the hydraulic system. Remove air. Check for loose connec-
assembly. tions or breaks in lines.

Lift cylinder(s) is damaged. Repair or install new lift cylinder.

Mast weldments are damaged or not Align weldments. Install new parts.
aligned.

Mast weldments are not lubricated Lubricate correctly.

correctly.

Load rollers or bearing blocks are Repair or adjust the parts.

damaged or not adjusted correctly.

Lift chains are damaged. Replace lift chains.

Lift or tilt cylinders extend Load check valves and spools have Repair or install new load check
or retract when the control damage. valve and spool.
valve lever (spool) is in the
Neutral position.

Cylinder seals have leaks. Install new seals.

Hydraulic lines have leaks. Repair leaks. Install new parts. Re-
move air from the system.

Leaks between the spool and the Install new spool and O-ring seals.
bore.

Cylinders at carriage do not Header hoses are damaged. Replace header hoses.
operate correctly.

Hydraulic lines at selector valve are Check connections or install new

damaged or not connected correctly. lines.

Wire harness or wires at selector Check connections or install new

valve are damaged or not connected wires.
correctly.

Solenoid at directional control valve Replace solenoid.

does not operate.

51
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 TECHNICAL PUBLICATIONS

4000 SRM 1062 2/04 (10/03)(9/03) Printed in U.S.A.