Hyster G005 Operating instructions

Hyster G005 (H70XL, H80XL, H90XL, H100XL,
H110XL, H90XLS) Forklift

VISTA®MASTS
DESCRIPTION AND REPAIRS FOR LIFT
TRUCKS WITH 3,500 TO 6,000 KG
(7,000 TO 12,000 LB) CAPACITIES
H3.50-5.00XL (H70-110XL) [G005];
S3.50-5.50XL (S70-120XL) [D004];
E3.50-5.50XL (E70-120XL) [C098]
PART NO. 897122 4000 SRM 340

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!

Vista®Masts Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Carriages........................................................................................................................................................ 1
Two-Stage Mast With Limited Free-Lift ...................................................................................................... 1
Two-Stage Mast With Full Free-Lift Mast ................................................................................................... 2
Three-Stage Mast With Full Free-Lift ......................................................................................................... 3
Safety Procedures When Working Near Mast.................................................................................................. 5
Forks Replacement ............................................................................................................................................ 7
Remove and Install........................................................................................................................................ 7
Hook Fork .................................................................................................................................................. 7
Remove .................................................................................................................................................. 7
Install..................................................................................................................................................... 7
Pin Fork ..................................................................................................................................................... 8
Remove .................................................................................................................................................. 8
Install..................................................................................................................................................... 8
Carriage Repair.................................................................................................................................................. 8
Remove ........................................................................................................................................................... 8
Sideshift Carriage Repair.................................................................................................................................. 10
Sideshift Carriage (Earlier Designs) ............................................................................................................ 10
Disassemble............................................................................................................................................... 10
Assemble.................................................................................................................................................... 11
Install......................................................................................................................................................... 14
Sideshift Carriage (1993 and Later Design) ................................................................................................ 14
Remove....................................................................................................................................................... 14
Repairs ....................................................................................................................................................... 14
Install......................................................................................................................................................... 14
Weight of Mast Parts ......................................................................................................................................... 17
Two-Stage Mast With Limited Free-Lift Repair .............................................................................................. 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 17
Clean and Inspect.......................................................................................................................................... 19
Assemble ........................................................................................................................................................ 19
Install ............................................................................................................................................................. 21
Two-Stage Mast With Full Free-Lift Repair..................................................................................................... 21
Remove ........................................................................................................................................................... 21
Disassemble ................................................................................................................................................... 21
Clean and Inspect.......................................................................................................................................... 23
Assemble ........................................................................................................................................................ 23
Install ............................................................................................................................................................. 23
Three-Stage Mast With Full Free-Lift.............................................................................................................. 24
Remove ........................................................................................................................................................... 24
Disassemble ................................................................................................................................................... 24
Clean and Inspect.......................................................................................................................................... 24
Assemble ........................................................................................................................................................ 24
Install ............................................................................................................................................................. 26
Mast Operation Check....................................................................................................................................... 28
Lift and Tilt System Leak Check ...................................................................................................................... 29
Lift System..................................................................................................................................................... 29
Tilt System..................................................................................................................................................... 29
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment............................................................................ 30
Lift Chain Adjustments ..................................................................................................................................... 30
©2002 HYSTER COMPANY i

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Table of Contents Vista®Masts
TABLE OF CONTENTS (Continued)
Mast Adjustments.............................................................................................................................................. 31
Carriage Adjustment ......................................................................................................................................... 33
Troubleshooting.................................................................................................................................................. 34
This section is for the following models:
H3.50-5.00XL (H70-110XL) [G005];
S3.50-5.50XL (S70-120XL) [D004];
E3.50-5.50XL (E70-120XL) [C098]
ii

4000 SRM 340 Description and Operation
General
This section has the description, operation, and repair procedures for the Vista®masts for the 3,500 to 6,000 kg
(7,000 to 12,000 lb) capacity lift trucks. Information on the different types of sideshift carriages is also in-
cluded. The lift cylinders and the lowering control valves are described in the section Lift Cylinders 4000
SRM 1354000 YRM 135. The tilt cylinders are described in the section Tilt Cylinders 2100 SRM 103 .
Description and Operation
The vertical frames of a mast are called weldments.
See Figure 1. Channels, load rollers and crossmem-
bers are parts of the weldments. The channels on
each side of the weldment are the support members
of the mast and the tracks for the load rollers. Dur-
ing lifting and lowering a load, large forces are put
on the mast assembly. The load rollers reduce the
friction between the channels when the weldments
move vertically.
Each mast can tilt forward and backward. Tilt
cylinders are installed between the frame of the lift
truck and the outer weldment of the mast. The pivot
mounts at the bottom of the outer weldment connect
the mast to the lift truck. During the tilt operation,
the mast rotates on the pivot pins in the frame.
1. FORKS
2. CARRIAGE
3. LOAD BACKREST
EXTENSION
4. OUTER
WELDMENT
5. INNER WELDMENT
6. LIFT CYLINDER
Figure 1. Mast Components
CARRIAGES
The carriage is a separate section that moves on load
rollers within the vertical channels of the inner weld-
ment. Forks or other types of load handling equip-
ment are attached to the carriage. A load backrest
extension is installed on the carriage.
A sideshift carriage permits the operator to hydrauli-
cally change the lateral position of the load handling
device on the carriage.
TWO-STAGE MAST WITH LIMITED
FREE-LIFT
The Vista Two-Stage mast has two weldments, an
outer weldment and an inner weldment. See Fig-
ure 2. The outer weldment is connected to the lift
truck by the pivot mounts and the tilt cylinders. The
top of the outer weldment has one load roller on each
side. The base of the inner weldment has one load
roller on each side. These load rollers travel along
the channels of the weldments. The angle of the load
rollers permits them to control the forces from the
front, back and sides of the mast. The shims on the
load rollers control the lateral clearance between the
weldments and the load rollers. Strip bearings are
installed at the top of each side of the outer weld-
ment. The strip bearings keep the correct clearance
(forward and backward) between the outer weldment
and the inner weldment.
The two-stage mast has two single stage lift cylin-
ders. The lift cylinders are installed at the back of the
outer weldment. The base of each lift cylinder sits in
a mount at the bottom of the outer weldment. The
hydraulic fitting for each lift cylinder goes through a
hole in the mount. The top of each lift cylinder (cylin-
der rod) fits into a guide at the top of the inner weld-
ment. A bracket on the cylinder shell holds the lift
cylinder in position on the outer weldment. Opera-
tion of the lift cylinders extends and retracts the in-
ner weldment.
1

Description and Operation 4000 SRM 340
1. LIFT CYLINDER (2)
2. LIFT CHAIN
3. OUTER WELDMENT
4. CHAIN SHEAVE
5. INNER WELDMENT
6. CARRIAGE
7. FROM MAIN CONTROL VALVE
8. EXTERNAL LOWERING CONTROL VALVE
9. INTERNAL LOWERING CONTROL VALVE
Figure 2. Two-Stage Mast With Limited
Free-Lift
Two lift chains control the movement of the carriage.
The chains are fastened to mounts near the top of
the lift cylinder shells. The chains go up and over
the chain sheaves on the inner weldment and then
connect to the carriage. When the lift cylinders ex-
tend, the lift chains transfer the force from the lift
cylinders to the carriage.
When the lift cylinders retract, the weight of the
load, carriage and inner weldment push the oil
from the lift cylinders. The oil flows from the lift
cylinders, through the lowering control valves, main
control valve and then to the hydraulic tank.
TWO-STAGE MAST WITH FULL FREE-LIFT
MAST
The Vista Free-Lift mast has an inner weldment, an
outer weldment and three single stage lift cylinders.
See Figure 3. It is called a free-lift mast because the
carriage can travel to the top of the inner weldment
without increasing mast height. The free-lift mast
has load roller and strip bearing arrangements sim-
ilar to the two-stage mast.
The two main lift cylinders are installed at the back
of the outer weldment. The base of each lift cylin-
der sits in a mount at the bottom of the outer weld-
ment. The hydraulic fitting for each lift cylinder goes
through a hole in the mount. The top of each lift
cylinder (cylinder rod) fits into guides at the top of
the inner weldment.
The free-lift cylinder is installed in the inner weld-
ment. The main lift cylinder on the right side of the
mast and the free-lift cylinder each have an inter-
nal lowering control valve. A single external lower-
ing control valve is connected by tubing to all of the
lift cylinders. Two chain sheaves are installed on the
cylinder rod of the free-lift cylinder. The lift chains
are connected to a mount behind the free-lift cylin-
der. The chains then go over the sheaves and are
connected to the carriage.
The three lift cylinders are connected by hoses and
tubing. To extend the mast, oil from the main control
valve flows to all of the lift cylinders at the same time.
The free-lift cylinder raises first because it lifts the
least amount of weight. The free-lift cylinder raises
the carriage to the top of the inner weldment. After
the free-lift cylinder reaches the end of its stroke, the
main lift cylinders begin to extend and raise the inner
weldment.
2

4000 SRM 340 Description and Operation
1. MAIN LIFT CYLINDER (2)
2. OUTER WELDMENT
3. FREE-LIFT CYLINDER
4. INNER WELDMENT
5. CHAIN SHEAVE
6. LIFT CHAIN
7. CARRIAGE
8. FROM MAIN CONTROL VALVE
9. EXTERNAL LOWERING CONTROL VALVE
10. INTERNAL LOWERING CONTROL VALVE
Figure 3. Two-Stage Mast With Full Free-Lift
During lowering, the main lift cylinders lower first
because they have a greater load. After the main lift
cylinders have retracted, the free-lift cylinder lowers.
All of the oil from the lift cylinders flows through the
lowering control valves to the hydraulic tank.
THREE-STAGE MAST WITH FULL
FREE-LIFT
The Vista Three-Stage mast has an outer, an inter-
mediate and an inner weldment. See Figure 4. Three
single stage lift cylinders are used on the mast to
raise the carriage and extend the weldments. The
weldments are telescopic and have load roller and
strip bearing arrangements similar to the two-stage
mast. The two main lift cylinders are installed at
the back of the outer weldment. The base of each lift
cylinder is held on a mount at the bottom of the outer
weldment. The hydraulic fittings for the lift cylin-
ders go through holes in the mounts. The top of each
main lift cylinder (cylinder rod) fits into a guide at
the top of the intermediate weldment. The free-lift
cylinder is installed in the inner weldment.
The two main lift chains fasten at one end near the
top of the outer weldment. The lift chains then go
over sheaves at the top of the intermediate weldment
and fasten at the bottom of the inner weldment. The
free-lift chains are connected to a mount behind the
free-lift cylinder. The chains then go over the sheaves
and connect to the carriage.
3

Description and Operation 4000 SRM 340
A. PHASE 2
1. MAIN LIFT CYLINDER (2)
2. OUTER LIFT CHAIN
3. FREE-LIFT CYLINDER
4. INNER LIFT CHAIN
5. INNER WELDMENT
6. INTERMEDIATE WELDMENT
7. OUTER WELDMENT
8. FROM MAIN CONTROL VALVE
9. EXTERNAL LOWERING CONTROL VALVE
10. INTERNAL LOWERING CONTROL VALVE
Figure 4. Three-Stage Mast With Full Free-Lift
4

4000 SRM 340 Safety Procedures When Working Near Mast
The three lift cylinders are connected by hoses and
tubing. To extend the mast, oil from the main con-
trol valve flows to all cylinders at the same time.
The free-lift cylinder raises first because it lifts the
least amount of weight. The free-lift cylinder raises
the carriage to the top of the inner weldment. After
the free-lift cylinder reaches the end of its stroke, the
main lift cylinders begin to extend. As the main lift
cylinders extend the intermediate weldment, the in-
ner weldment is extended by the lift chains.
During lowering, the main lift cylinders lower first
because they have a greater load. After the main lift
cylinders have retracted, the free-lift cylinder lowers.
All oil from the lift cylinders flows through the low-
ering control valves to the hydraulic tank.
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. Usealadderorpersonnellifttowork
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.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely.
Push the lift/lower control lever toward 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. Putmastinverticalposition.
2. Raise mast to align bottom crossmember of weld-
ment 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 weldment. See Figure 5.
3. Use a 3/8 inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able member cannot lower. Put the hook on the
backsideofthemast.Makesurethehookiscom-
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.
4. Lower mast until there is tension in the safety
chain and the free-lift cylinder (free-lift, three-
stage, and four-stage masts only) is completely
retracted. If running, stop the engine. Apply
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 parking brake. After lowering or re-
straining the mast, shut off power and remove key.
Put a DO NOT OPERATE tag in the operator’s com-
partment. Disconnect battery on electric lift trucks
and put a tag or lock on battery connector.
5

Safety Procedures When Working Near Mast 4000 SRM 340
A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CROSSMEMBER
7. CROSSMEMBER
Figure 5. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts
6

4000 SRM 340 Forks Replacement
Forks Replacement
The identification of a fork describes how the fork is
connected to the carriage. The series of lift trucks
that use this mast normally have hook forks. See
Figure 6. Pin forks are available on the larger capac-
ity lift trucks in this series as an option. Pin forks
are fastened to the carriage with large fork pins. See
Figure 8.
Hook forks are connected to the carriage by hooks
and lock pins. These lock pins are installed through
the top fork hooks and fit into slots in the top carriage
bar. Separate the forks as much as possible for maxi-
mum support of the load. Hook forks will slide along
thecarriagebarstoadjustfortheloadtobelifted.
Raisethelockpinineachforktoslidetheforkon
thecarriagebar. Makesurethelockpinisengaged
in the carriage bar to lock the fork in position after
the width adjustment is made.
REMOVE AND INSTALL
WARNING
Do not try to move a fork without a lifting de-
vice. Each fork for these lift trucks can weigh
[66 to 183 kg (145 to 402 lb) for a hook fork] and
[128 to 226 kg (281 to 498 lb) for a pin fork].
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance.
Hook Fork
Remove
Slide a hook fork to the fork removal notch on the car-
riage. See Figure 6. Lower fork on to blocks so bot-
tom hook of fork moves through fork removal notch.
See Figure 7. Lower carriage further so top hook of
fork is disengaged from top carriage bar. Move car-
riage away from fork, or use lifting device to move
fork away from carriage.
Install
Move fork and carriage so top hook on fork can
engage upper carriage bar. Raise carriage to move
lower hook through fork removal notch. Slide fork
on carriage so both upper and lower hooks engage
carriage. Engage lock pin with a notch in the upper
carriage bar.
1. FORK REMOVAL NOTCH
2. FORK
3. HOOK
4. LOCKING PIN ASSEMBLY
5. CARRIAGE
Figure 6. Hook Fork
7

Carriage Repair 4000 SRM 340
1. CARRIAGE BARS
2. HOOK FORK 3. BLOCKS
Figure 7. Hook Fork Removal
Pin Fork
Remove
Put blocks under forks and lower carriage. When
weight of forks have been removed from fork pin, re-
move load backrest extension. The load backrest ex-
tension holds the fork pin in the carriage. Slide fork
pin from its mount in the carriage and through the
eye of the fork. See Figure 8. Use lifting device to lift
fork away from carriage.
Install
Install fork pin in carriage. Align eyes of forks so
forks will be installed on fork pin. When fork pin
is installed in carriage so it holds forks, install load
backrest extension. Engage fork with lock pin.
1. CARRIAGE
2. FORK 3. FORK PIN 4. LOCK PIN 5. LOAD BACKREST EXTENSION
Figure 8. Pin Forks
Carriage Repair
REMOVE
WARNING
Do not work under a raised carriage. Lower
the carriage or use a chain or blocks to prevent
the carriage and inner weldment from lower-
ing.
NOTE: If the mast is equipped with a sideshift car-
riage, see the paragraphs under Sideshift Carriage
Repair.
8

4000 SRM 340 Carriage Repair
1. Lower carriage and forks on blocks so lift chains
becomeloose.SeeFigure9andFigure12.
WARNING
When disconnecting the lift chains, keep
control of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling and causing an injury or damage.
2. Removepinfromeachchainanchoratthecar-
riage. Disconnect lift chains from carriage.
3. Put weight on forks so carriage has stability and
will not fall when it is disconnected from mast.
WARNING
Make sure that the carriage has stability and
will not fall over when the inner weldment is
raised above the load rollers of the carriage.
4. Use lift cylinders to raise inner weldment until
it is above load rollers of carriage. If the hy-
draulic system cannot be used, connect lifting de-
vice to top of inner weldment. Carefully raise in-
ner weldment until it is above load rollers of car-
riage.
5. Move lift truck from carriage. Connect lifting de-
vice to carriage. Make sure carriage has stability.
Remove load backrest, fork pins, and forks. Put
carriage on floor so load rollers are up.
6. If any of the load rollers must be replaced, make
anoteofthearrangement of the shims.
1. CARRIAGE
2. LOAD ROLLER
3. SHIMS
4. SNAP RING
5. SIDE ROLLER
6. CHAIN ANCHOR (TWO-STAGE MAST)
7. CHAIN ANCHOR (FREE-LIFT AND
THREE-STAGE MAST)
Figure 9. Carriage
9

Sideshift Carriage Repair 4000 SRM 340
Sideshift Carriage Repair
SIDESHIFT CARRIAGE (EARLIER
DESIGNS)
The earlier Hyster Company designs of sideshift car-
riages for this mast are shown in Figure 12 and Fig-
ure 13. These designs are used on lift trucks man-
ufactured through 1993. During the second half of
1993, a second design shown in Figure 14 was in-
stalled on lift trucks. The operation of the designs
are similar, but the components are different.
NOTE: See the section, Main Control Valve 2000
SRM 77 for information about the control valve link-
age for the sideshift carriage.
Disassemble
WARNING
Make sure any lifting devices have the correct
capacity for the parts being moved. See Weight
of Mast Parts.
1. Disconnect hydraulic lines at sideshift cylinder.
Disconnect sideshift cylinder at carriage and at
apron. Remove sideshift cylinder. See Figure 10,
Figure 11, Figure 12, and Figure 13.
2. Remove keeper plates or carriage hooks at bot-
tom of carriage. Use lifting device and lift apron
from carriage. Remove rollers and bearing seg-
ments as necessary.
3. Disassemble sideshift cylinder (see Figure 10)
and Figure 11 as follows:
a. Remove retaining ring, then remove retainer
from cylinder shell. Pull rod and piston from
shell.
b. Remove nut from rod, and remove piston and
retainer.
c. Remove seals and O-rings.
Figure 10. Sideshift Cylinders for Earlier Design Carriages (Old Style)
10

4000 SRM 340 Sideshift Carriage Repair
Legend for Figure 10
1. RETAINER
2. COVER
3. WIPER
4. ROD SEAL
5. SNAP RING
6. CAPSCREW
7. RETAINING RING
8. BACKUP RING
9. O-RING
10. ROD
11. PISTON
12. PISTON SEAL
13. NUT
14. SHELL
1. CYLINDER SHELL
2. GLAND
3. WIPER
4. O-RING
5. BACKUP RING
6. ROD SEAL
7. "T" SEAL (INCLUDES BACKUP RING)
8. PISTON
9. NUT
10. ROD
Figure 11. Sideshift Cylinders for Earlier Design Carriages (New Style)
Assemble
NOTE: Several different types of carriages are used
on these lift trucks. Not all procedures are neces-
sary for some carriages. See Figure 12 and Figure 13
when assembling the carriage.
1. Assemble sideshift cylinder (see Figure 10) and
Figure 11 as follows:
a. Lubricate seals and O-rings with clean hy-
draulic oil. Install rod seal and wiper in re-
tainer. Install retainer on rod. Install O-ring
andbackupringingrooveofretainer.
b. Install piston on rod. Tighten nut for rod to
122 to 149 N•m (90 to 110 lbf ft).
c. Install piston seal and backup ring on piston.
Install rod and piston in shell. Install gland
into cylinder tube. Tighten gland to 140 to
160 N•m (103 to 118 lbf ft).
2. Install guide rollers on brackets at carriage.
When used, install bearing segments as shown
in Figure 12 and Figure 13. Make sure to lubri-
cate bearing segments and sliding surfaces with
multipurpose grease.
3. Install load rollers on apron. Install thrust
rollers on carriage.
4. Use a lifting device and install apron on car-
riage. Install keeper plate or carriage hooks on
carriage. Tighten capscrews for keeper plates
to 90 N•m (66 lbf ft). Tighten capscrews for
carriage hooks to 165 N•m (120 lbf ft). For
carriages that have hook-type forks and carriage
hooks, adjust carriage hooks during Install,
Step 5.
5. When used, install mount bracket for sideshift
cylinder. Tighten capscrews that hold bracket to
carriage to 320 N•m (235 lbf ft).
11

Sideshift Carriage Repair 4000 SRM 340
Figure 12. Sideshift Carriages
12

4000 SRM 340 Sideshift Carriage Repair
Legend for Figure 12
A. H3.50-4.00XL-5 (H70-80XL)
B. FACE OF CARRIAGE C. BACK OF CARRIAGE D. H4.00XL-6, H4.50-5.00XL (H90-100XL)
1. CARRIAGE
2. APRON
3. SIDESHIFT CYLINDER
4. LOAD ROLLER
5. GUIDE ROLLER
6. THRUST ROLLER
7. KEEPER PLATE
8. SIDE ROLLER
9. CHAIN ANCHOR (FREE-LIFT AND
THREE-STAGE MAST)
10. FORK PIN
11. SHIMS
12. SNAP RING
13. BEARING SEGMENT
A. S/H3.50-4.50XL (S/H70-110XL)
1. CARRIAGE
2. APRON
3. SIDESHIFT CYLINDER
4. LOAD ROLLER
5. SHIMS
6. SNAP RING
7. CARRIAGE HOOK
8. CYLINDER MOUNT
9. SIDE ROLLER
10. BEARING SEGMENT
11. BEARING BLOCK
Figure 13. Sideshift Carriages
6. Install sideshift cylinder in carriage. Install an-
chor pins or nuts at both ends of the cylinder. Af-
ter the nut at the apron is just tight, loosen nut
1/4 turn. Connect hydraulic lines to cylinders.
7. Install side rollers and load rollers on carriage.
Tighten capscrews for side rollers to 65 N•m
(50 lbf ft).
13

Sideshift Carriage Repair 4000 SRM 340
Install
1. Use hydraulic system of lift truck or a lifting de-
vice to raise inner weldment. Raise inner weld-
ment until it is above the load rollers of the car-
riage. Carefully lower inner weldment until it
engages all load rollers.
2. Check clearance of load rollers and side rollers.
See Mast Adjustments and Carriage Adjustment
in this section. When installing the side rollers,
make sure grease fittings are toward front of
lift truck. Tighten capscrews for side rollers to
65 N•m (50 lbf ft).
3. Connect lift chains. Install pins using new cotter
pins.
4. Install forks and fork pins. Install load backrest.
5. Adjustcarriagehooks(seeFigure12andFig-
ure 13) as follows:
a. Check clearance between carriage hook and
bottom carriage bar. The maximum clear-
ance is 4 mm (0.16 in.).
b. There are two sets of mount holes for the
carriage hooks. Install carriage hooks in
mount holes so clearance measured in Step a
is 4 mm (0.16 in.) or less. Tighten capscrews
for carriage hooks to 165 N•m (120 lbf ft).
6. Connect any hydraulic lines as necessary. Check
lift chains as described in Lift Chain Adjust-
ments.
SIDESHIFT CARRIAGE (1993 AND LATER
DESIGN)
Remove
1. Lower carriage completely and remove forks. See
Figure 14.
2. Connect lifting device to lifting eye on sideshift
carriage.
3. Remove two upper capscrews from bottom car-
riage bar. Slowly loosen two bottom capscrews,
but do not remove them. The holes have slots
that will permit the bottom carriage bar to move
down so the sideshift carriage can be removed.
Carefully lift sideshift carriage from standard
carriage. The sideshift cylinder mounting
bracket and cylinder will stay on the standard
carriage. Remove bushings.
4. Disconnect hydraulic lines at sideshift cylinder.
Put caps on open lines. Remove cylinder mount
bracket from carriage. If necessary, remove
threaded rods and shims to remove sideshift
cylinder.
Repairs
1. Do the following procedure to repair the sideshift
cylinder (see Figure 15 and Figure 16):
a. Remove retainers from shell. Pull rod from
shell.
b. Replace seals, O-rings, or backup rings as
necessary.
c. Lubricate all internal parts with clean hy-
draulic oil.
d. Install piston and rod in shell. Apply Loctite®
242 to threads of retainers. Install retainers
and tighten them to 25 to 30 N•m (223 to
267 lbf in).
2. Use new bushings if the old bushings are worn or
damaged.
Install
1. Install sideshift cylinder in bracket. Use an
equal number of shims on both sides of the
cylinder to limit side-to-side movement within
the bracket. Maximum movement is 0.6 mm
(0.024 in.). Install threaded rods to hold cylinder
in position.
2. Install cylinder mount bracket on standard car-
riage, and make sure it is engaged in the notch in
the top carriage bar. Connect hydraulic lines to
sideshift cylinder. Put grease on ends of cylinder
rod.
3. Install top bushing on mounting bracket. Lubri-
cate outer surface of bushing with multipurpose
grease.
4. Connect top and bottom carriage bars by in-
stalling two bottom capscrews. Do not tighten
capscrews. Lubricate outer surface of bottom
bushing with multipurpose grease. Install bot-
tom bushing in bottom bar of sideshift carriage.
14