MAST

H20.00-32.00F (H440-700F/FS) [E008]

PART NO. 897462 4000 SRM 491

 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!
Mast Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
General ........................................................................................................................................................... 1
Lifting - High Speed ...................................................................................................................................... 1
Lifting - Low Speed........................................................................................................................................ 2
Lowering......................................................................................................................................................... 2
Safety Procedures When Working Near Mast.................................................................................................. 4
Forks Repair....................................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Low Mount Forks ...................................................................................................................................... 5
High Mount Forks ..................................................................................................................................... 5
Install ............................................................................................................................................................. 6
Low Mount Forks ...................................................................................................................................... 6
High Mount Forks ..................................................................................................................................... 6
Carriage Repair.................................................................................................................................................. 7
Remove ........................................................................................................................................................... 7
Disassemble ................................................................................................................................................... 7
Clean and Inspect .......................................................................................................................................... 10
Assemble ........................................................................................................................................................ 10
Install ............................................................................................................................................................. 14
Mast Repair........................................................................................................................................................ 14
Remove ........................................................................................................................................................... 14
Disassemble ................................................................................................................................................... 14
Clean and Inspect .......................................................................................................................................... 15
Assemble ........................................................................................................................................................ 17
Install ............................................................................................................................................................. 18
Lift Cylinders Repair ......................................................................................................................................... 19
Remove ........................................................................................................................................................... 19
Disassemble ................................................................................................................................................... 19
Clean and Inspect .......................................................................................................................................... 20
Assemble ........................................................................................................................................................ 20
Install ............................................................................................................................................................. 20
Sideshift Cylinder Repair .................................................................................................................................. 21
Remove ........................................................................................................................................................... 21
Disassemble ................................................................................................................................................... 21
Clean and Inspect .......................................................................................................................................... 22
Assemble ........................................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Fork Positioner Cylinders Repair ..................................................................................................................... 22
Remove ........................................................................................................................................................... 22
Disassemble ................................................................................................................................................... 22
Clean and Inspect .......................................................................................................................................... 22
Assemble ........................................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Slew Cylinders Repair ....................................................................................................................................... 23
Remove ........................................................................................................................................................... 23
Disassemble ................................................................................................................................................... 23
Assemble ........................................................................................................................................................ 23
Install ............................................................................................................................................................. 23
Attachment Connector....................................................................................................................................... 24
Header Hoses Replacement............................................................................................................................... 24

©2003 HYSTER COMPANY i

Table of Contents Mast

TABLE OF CONTENTS (Continued)

Carriage Side Rollers Adjustment .................................................................................................................... 25
Mast Side Rollers Adjustment .......................................................................................................................... 25
Lift Chains Adjustment ..................................................................................................................................... 26
Tilt Cylinders Adjustment................................................................................................................................. 26
Troubleshooting.................................................................................................................................................. 27

This section is for the following models:

H20.00-32.00F (H440-700F/FS) [E008]

ii
4000 SRM 491 Description and Operation

General
This section has the description and the service procedures for the mast. The parts of the mast include the
forks, carriages, lift cylinders, and the mast weldments.

Description and Operation

GENERAL and side rollers are installed between the moving
parts. The load rollers and side rollers travel along
The vertical frames of a mast are called weldments. the channels within the weldments.
See Figure 1. All of the masts have one or more
telescopic weldments. The outer weldment pivots on The mast can lift at two speeds. With a heavy load,
the frame to let the mast tilt forward and backward. the mast lifts at low speed. With no load or a light
The tilt cylinders and the mast pivot pins connect the load, the mast lifts at a higher speed.
outer weldment of the mast to the frame.
LIFTING - HIGH SPEED
Hydraulic lift cylinders are installed vertically at the
back of each side of the outer weldment. The lift Oil from the control valves flows through the hy-
cylinders and lift chains lift and lower the inner weld- draulic manifold and enters the lift cylinders at the
ment and the carriage. The base of each lift cylinder lowering control valves. See Figure 2. A pilot line is
fits on a mount near the bottom of the outer weld- installed between the accumulator charge valve and
ment. The top of each lift cylinder fits into a support the two-speed spool in the hydraulic manifold. The
at the top of the outer weldment. The cylinder rod pilot line senses the pressure at the base of the lift
of each lift cylinder is attached to the top of the in- cylinders.
ner weldment. Operation of the lift cylinders extends
and retracts the inner weldment. When there is no load or when the load is light, pilot
pressure is too low to move the two-speed spool. The
Two lift chains control the movement of the carriage. return circuit to the hydraulic tank is closed by the
The chains fasten to mounts near the top of the two-speed spool.
outer weldment. The chains go up and over the
chain sheaves and then connect to the carriage. The As the lift cylinders extend, oil from the top of each
chain sheaves are installed near the top of the inner cylinder flows through the external hose to the mani-
weldment. When the lift cylinders extend, the lift fold block. The returning oil must flow past the check
chains transfer the force from the lift cylinders to balls in the manifold block and combine with the oil
the carriage. from the control valves. The additional oil from the
top of the lift cylinders increases the lifting speed.
When the telescopic weldment and the carriage lift
a load, forces are put on the mast assembly. To de-
crease the friction caused by these forces, load rollers

1
Description and Operation 4000 SRM 491

Legend for Figure 1

1. OUTER 5. LIFT CHAIN
WELDMENT 6. LIFT CYLINDER
2. INNER WELDMENT 7. CYLINDER CLAMP
3. LOAD ROLLER 8. CHAIN SHEAVE
4. SIDE ROLLER

LIFTING - LOW SPEED

Oil from the control valve enters the base of the lift
cylinders at the lowering control valves. See Fig-
ure 2. Because of the heavy load on the mast, the
pressure in the base of the lift cylinders is higher
than if there was no load.

The two-speed spool senses the higher pressure in

the pilot line. The pilot pressure moves the two-
speed spool and opens a drain circuit to the hydraulic
tank. (The two-speed spool stays open because the
spring side of the two-speed spool is open to the tank.)

As the lift cylinders extend, oil from the top of

the cylinders flows through the external hoses to
the manifold block. Since the return circuit to the
hydraulic tank is open, the oil flows through the
two-speed spool, control valves and the restriction
valve to the hydraulic tank.

LOWERING
During lowering, the oil from the base of the lift cylin-
ders flows through the lowering control valves and
the hydraulic manifold to the lift spools in the con-
trol valves. See Figure 2. At the spools in the control
valves, the oil can flow in two directions.

The oil can flow to the hydraulic tank and the oil can
also return to the top of each lift cylinder. The restric-
tion valve opens when the pressure in the circuit is
138 to 207 kPa (20 to 30 psi). The restriction valve
gives a back pressure at high idle speed of 1380 kPa
(200 psi) minimum that is used to force some of the oil
to fill the rod ends of the lift cylinders. The rod ends
of the lift cylinders must be filled with oil so that the
two-speed lifting function will operate.

Figure 1. Mast

2
4000 SRM 491 Description and Operation

Figure 2. Lift and Lower Circuit Schematic

3
Safety Procedures When Working Near Mast 4000 SRM 491

Legend for Figure 2

1. LIFT CYLINDER 11. TILT SPOOL
2. LOWERING CONTROL VALVE 12. LIFT/LOWER SPOOL
3. HYDRAULIC MANIFOLD 13. SINGLE-SPOOL CONTROL VALVE
4. TWO-SPEED CARTRIDGE 14. CHECK PORT 17.2 MPa (2500 psi)
5. TO TILT CYLINDERS 15. CHECK PORT 17.2 MPa (2500 psi)
6. LIFT/LOWER CONTROL LEVER 16. FROM ACCUMULATOR CHARGE VALVE
7. TILT CONTROL LEVER 17. TO ACCUMULATOR
8. REMOTE CONTROL VALVE 18. CHECK VALVE
9. FROM 2.1 MPa (300 psi) PRESSURE 19. RESTRICTION VALVE
REDUCTION VALVE 20. FROM STEERING SYSTEM
10. TWO-SPOOL CONTROL VALVE

Safety Procedures When Working Near Mast

The following procedures must be used when inspect- 2. If parts of the mast must be in raised position,
ing or working near the mast. Additional precautions install a safety chain to restrain the moving parts
and procedures can be required when repairing or re- of the mast. Connect moving parts to a part that
moving the mast. Follow the repair procedures in does not move. Follow these procedures:
this section.
a. Put the mast in a vertical position.
WARNING b. Raise the mast to align the bottom cross-
Mast parts are heavy and can move. Distances member of the inner weldment with a cross-
between parts are small. Serious injury or member on the outer weldment. See Fig-
death can result if part of the body is hit by ure 3.
parts of the mast or the carriage.
• Never put any part of the body into or under c. Use a 1/2 inch minimum safety chain with
the mast or carriage unless all parts are com- a hook to fasten the crossmembers together
pletely lowered or a safety chain is installed. so that the movable member cannot lower.
Also make sure that the power is OFF and the Put the chain around the crossmembers
key is removed. Put a "DO NOT OPERATE" twice, the put the hook on the back side of
tag in the operator’s compartment. the mast. Make sure the hook is completely
• Be careful of the forks. When the mast is engaged with a link in the chain. Make sure
raised, the forks can be at a height to cause the safety chain does not touch lift chains or
an injury. chain sheaves, tubes, hoses, fittings, or other
• Do NOT climb on the mast or lift truck at any parts on the mast.
time. Use a ladder or personnel lift to work
d. Lower the mast until there is tension in the
on the mast.
safety chain. If running, stop the engine. Ap-
• Do NOT use blocks to support the mast weld-
ply the parking brake. Install a "DO NOT
ments nor to restrain their movement.
REMOVE" tag on the safety chain(s).
• Mast repairs can require disassembly and re-
moval of parts or removal of the mast or car- e. Install another safety chain (1/2 inch mini-
riage. Follow the repair procedures in this mum) between the top or bottom crossmem-
section. ber of the carriage and a crossmember on the
outer weldment. Put the chain around the
WHEN WORKING NEAR THE MAST ALWAYS:
crossmembers twice, then put the hook on
1. Lower the mast and carriage completely. Push the back side of the mast.
the lift/lower control lever forward and make
3. Apply the parking brake. After lowering or re-
sure there is no movement in the mast. Make
straining the mast, shut off the power and re-
sure that all parts of the mast that move are
move the key. Put a "DO NOT OPERATE" tag
fully lowered.
in the operator’s compartment.
OR

4
4000 SRM 491 Forks Repair

1. INNER WELDMENT 3. HOOK

2. OUTER WELDMENT 4. CROSSMEMBER

Figure 3. Mast

Forks Repair
The identification of a fork is determined by how it pins are free from the hooks, back the lift truck away
is connected to the carriage. See Figure 4. These lift from the forks. For pin forks remove the retainers
trucks can have pin forks or hook forks. These forks for the fork pins and push the pins from the carriage.
can be Low Mount Forks or High Mount Forks. Move the lift truck away from the forks.

REMOVE High Mount Forks

Low Mount Forks 1. Remove retaining bolts and spacers.

Put the lift truck on a level surface and lower the 2. Move the forks toward the center of the carriage.
forks. Tilt the mast so that the forks have stability. Make sure the hooks are free of the carriage.
If the forks have hooks, remove the retaining bolts
3. Use a lifting device to remove the forks from the
and spacers. Disconnect the fork positioner cylin-
fork pins. See Table 1 for the weight of the forks.
ders. Lower the carriage and tilt forward. When the

5
Forks Repair 4000 SRM 491

3. For forks with hooks, tilt the mast forward and

lower the carriage completely. Move the lift truck
toward the forks. Carefully raise the carriage un-
til the fork pins fit into the hooks of the forks.
Make sure the forks are completely engaged with
the fork pins. Install the retaining bolts and
spacers.

4. Connect the fork positioner cylinders to the fork

guides.

High Mount Forks

1. HIGH MOUNT 2. LOW MOUNT 1. Make sure the fork guides are on the fork pins.
FORKS FORKS
2. Use a lifting device to install the forks on the
Figure 4. Forks fork pins. See Table 1 for the weight of the forks.
Make sure the fork is completely engaged with
INSTALL the fork pin and bottom hook.

Low Mount Forks 3. Move the fork into position on the carriage so
that the fork retainer can be installed. Also make
1. Put the forks approximately 1 m (3 ft) in front of sure the hook at the bottom of the fork is engaged
the carriage. with the carriage.
2. For pin forks, slowly move the lift truck toward
the forks until the fork pins can be installed. In-
stall the fork pins, fork guides, and the retainers.

Table 1. Weights of Components

Item Weight
Mast (No Carriage or Forks) Lift Height
H20.00-25.00F (H440-550F/FS) 3048 mm (120 in.) 3942 kg (7808 lb)
6096 mm (240 in.) 4907 kg (10,817 lb)
9144 mm (360 in.) 6161 kg (13,582 lb)
H28.00-32.00F (H620-700F/FS) 3048 mm (120 in.) 5009 kg (11,174 lb)
6096 mm (240 in.) 6063 kg (14,698 lb)
9144 mm (360 in.) 8213 kg (18,106 lb)
Carriage (Without Sideshift)
H20.00-25.00F (H440-550F/FS) 1724 kg (3800 lb)
H28.00-32.00F (H620-700F/FS) 2254 kg (4970 lb)
Sideshift Carriage
H20.00-25.00F (H440-550F/FS) 3107 kg (6850 lb)
H28.00-32.00F (H620-700F/FS) 3679 kg (8110 lb)
Forks
10 × 280 × 2438 mm (4 × 11 × 96 in.) 805 kg (1775 lb)
114 × 305 × 2438 mm (4.5 × 12 × 96 in.) 1171 kg (2580 lb)
High Mount Container Fork

6
4000 SRM 491 Carriage Repair

Carriage Repair
REMOVE DISASSEMBLE
The following procedures are for all types of car-
WARNING riages. See Figure 5.
When working on or near the mast, see Safety
Procedures When Working Near Mast. 1. Remove and disassemble the load rollers as fol-
lows:
The forks must be removed before the carriage
can be removed. When removing the carriage, a. Remove the four capscrews that hold the re-
make sure the lifting devices have the correct tainer to the stub shafts. Remove the re-
capacity. See Table 1. tainer.

1. Remove the forks as described in Forks Repair, b. Remove the shims. Make identification
Remove. marks on the shims so that they will be
installed in the same order.
2. Connect a lifting device at each side of the top
crossmember of the carriage. If chains are used c. Remove the load roller from the stub shaft.
to remove the sideshift carriage, do not damage Remove the shields and bearings from the
the top tube. The tube has a machined surface. load roller.
Operate the lifting device until the carriage just
begins to move. 2. Remove and disassemble the side rollers as fol-
lows:
3. Disconnect any header hoses or hydraulic lines
to the cylinders on the carriage. Make sure all a. Remove the capscrews that hold the side
hydraulic lines have identification tags with the roller to the carriage. Make identification
correct information before removal. Put caps on marks on the shims so that they will be
the open lines. installed in the same order.

b. Remove the roll pin from the mount for the

WARNING side roller. Remove the shaft for the side
When disconnecting the lift chains, keep con- roller. Remove the bushings from the side
trol of the ends. Use wire to temporarily con- roller.
nect the ends of the lift chains to a crossmem-
ber on the inner weldment. This procedure will 3. Remove the fork positioner cylinders as follows:
prevent the lift chains from falling and causing
a. Disconnect the hydraulic lines at the cylin-
injury or damage.
ders. Put caps on the open lines.
4. Disconnect the electrical cable at the carriage.
b. Connect a lifting device to the cylinder.
5. Disconnect the lift chains at the carriage. Con- Remove anchor pins from the ends of the
nect the ends of the chain to a crossmember on cylinder. Remove the support bracket for the
the inner weldment. (Do not attach the chains so cylinder shell. Use the lifting device to re-
that they are tight.) Make sure that the lifting move the cylinder. Disassemble the cylinder
device is holding the carriage. as described in the procedures for the Fork
Positioner Cylinders Repair.
6. Operate the lift cylinders to raise the inner weld-
ment. Make sure the lifting mechanism is di- 4. When the carriage is a sideshift carriage, use the
rectly over the carriage. Raise the inner weld- following procedure to disassemble it (see Fig-
ment just past the top load rollers of the carriage. ure 6, Figure 7, and Table 2):

7. Remove the carriage from the lift truck. Lower a. Leave the carriage on the lift truck or remove
the carriage to floor so that the load rollers are the carriage and put it on the surface so that
up. the sliding weldment is up.

7
Carriage Repair 4000 SRM 491

1. LOAD ROLLER 8. BEARING CONE

2. SIDE ROLLER 9. BEARING CUP
3. CHAIN ANCHOR 10. SNAP RING
4. FORK PIN 11. ROLLER
5. RETAINER 12. BUSHING
6. SHIMS 13. PIN
7. SHIELD

Figure 5. Carriage

8
4000 SRM 491 Carriage Repair

Figure 6. Sideshift Carriage

9
Carriage Repair 4000 SRM 491

Legend for Figure 6

1. SLIDING WELDMENT 11. SIDE ROLLER
2. FORK PIN 12. BRACKET
3. SIDESHIFT CYLINDER 13. SHIM
4. CHAIN ANCHOR 14. O-RING
5. CARRIAGE 15. RETAINER
6. BUSHING 16. LOAD ROLLER
7. BEARING CAP 17. BEARING CONE
8. BUSHING 18. BEARING CUP
9. ROLLER 19. SNAP RING
10. PIN 20. SHIELD

b. Disconnect the hydraulic lines at the

sideshift cylinder. Remove the anchor pins
CAUTION
and remove the cylinder. Disassemble the Do not use steam to clean the side rollers and
cylinder as described in the procedures for load rollers. Steam will cause corrosion and
the Sideshift Cylinder Repair. damage to the parts.

c. Move the sliding weldment fully to the left. 2. Inspect the carriage weldments and rollers for
Make sure that the retainers at the bottom wear or damage. Inspect the welds for cracks.
crossmembers of the sliding weldment and
carriage are free of each other. Connect a ASSEMBLE
lifting device to the tube at the top of the
The following procedures are for all types of car-
sliding weldment. If chains are used, make
riages.
sure they do not damage the tube. The tube
has a machined surface. 1. Use the following procedure to assemble and in-
stall the load rollers:
d. Put tension on the lifting device and remove
the bolts for the bearing caps on the sliding a. Install the snap rings in the center of the load
weldment. Remove the bearing caps. roller. Install the bearing cups.
e. Lift the sliding weldment away from the b. Lubricate the bearing cones with multipur-
carriage. Remove the load rollers and side pose grease and install them in the load
rollers as described in Step 1 and Step 2. roller. Install the shields on the bearings.

CLEAN AND INSPECT c. Lubricate the stub shaft with multipurpose

grease and install the load roller on the shaft.
WARNING d. Install the retainer (without shims) and cap-
Cleaning solvents can be flammable and toxic screws on the stub shaft. Tighten the cap-
and can cause skin irritation. When using screws to 47 N•m (35 lbf ft) while rotating
cleaning solvents, always follow the solvent the load roller.
manufacturer’s recommended safety precau-
tions. e. Loosen the capscrews that hold the retainer.

1. Use steam or solvent to clean the parts of the f. Tighten the capscrews for the retainer evenly
carriage. until there is zero clearance in the bearings.
Measure the clearance between the stub
WARNING shaft and the retainer. Measure the clear-
ance through the hole in the retainer.
Get information from your dealer for Hyster
lift trucks before welding on the carriage. g. Remove the retainer. Install shims equal to
the measurement taken in Step f.

h. Install the retainer, shims and capscrews.

Tighten the capscrews to 108 to 115 N•m (80
to 85 lbf ft).

10
4000 SRM 491 Carriage Repair

Figure 7. Sideshift Carriage Arrangement

11
Carriage Repair 4000 SRM 491

Legend for Figure 7

NOTE: FOR HYDRAULIC TUBE AND ELECTRICAL WIRE IDENTIFICATION SEE TABLE 2.
1. CARRIAGE 9. SIDESHIFT SOLENOID 13. EXTEND/RETRACT
2. BEARING CAP 10. LEFT-HAND FORK SOLENOID
3. SIDE ROLLER POSITIONER OR SLEW 14. MAIN CABLE
4. LOAD ROLLER SOLENOID
5. SLIDING WELDMENT 11. RIGHT-HAND FORK
6. ROLLER POSITIONER OR SLEW
7. FORK PIN SOLENOID
8. SIDESHIFT CYLINDER 12. TWIST LOCK SOLENOID

2. Use the following procedure to assemble and in-

stall the side rollers:
CAUTION
There are left-hand and right-hand side rollers.
a. Install the bushing in the side roller. Install Do not install a side roller on the wrong side of
the O-rings on the shaft for the side roller. the carriage.
Use O-ring lubricant on the O-rings.
3. Assemble the fork positioner cylinders as de-
b. Install the side roller on the bracket. Install scribed in the procedures for the Fork Positioner
the shaft. Install the roll pin that holds the Cylinders Repair. Use the following procedure to
shaft to the bracket. install the cylinders (see Figure 8 and Table 2):

c. Install the side roller to the carriage. Do not a. Lubricate the fork pin with multipurpose
tighten the capscrews at this time. Adjust grease. Install the fork pin and fork guide.
the side roller as described in Carriage Side Install the keeper for the fork pin.
Rollers Adjustment.

Figure 8. Carriage with Fork Positioners

12
4000 SRM 491 Carriage Repair

Legend for Figure 8

NOTE: FOR HYDRAULIC TUBE IDENTIFICATION, SEE TABLE 2. ARRANGEMENT FOR SIDESHIFT CARRIAGE
SHOWN.
1. FORK POSITIONER CYLINDER 5. FORK GUIDE
2. MANIFOLD 6. COUPLING
3. PIN 7. SUPPORT BRACKET
4. COTTER PIN

Table 2. Hydraulic Tube and Electric Wire Codes

Tube Wire Function

Codes Codes
G 11 Sideshift Cylinder (Rod Side)
H 11 Sideshift Cylinder (Piston Side)
J 14 Left-Hand Slew Cylinder (Piston Side) or Left-Hand Fork Positioner Cylinder
(Piston Side)
K 14 Left-Hand Slew Cylinder (Rode Side) or Left-Hand Fork Positioner (Rod Side)
L 13 Right-Hand Slew Cylinder (Rod Side) or Right-Hand Fork Positioner Cylinder
(Rod Side)
M 13 Right-Hand Slew Cylinder (Piston Side) or Right-Hand Fork Positioner
Cylinder (Piston Side)
N 12 Extension Cylinder (Rod Side)
P 12 Extension Cylinder (Piston Side)
T 15 Twist Lock (Engage)
U 15 Twist Lock (Disengage)
Y Supply/Return
Z Supply/Return

b. Use a lifting device to install the fork posi- opposite sides of the bearing caps. Also make
tioner cylinders. Install the anchor pins at sure the ends of the bushings are even with
the carriage and fork guides. Install the sup- the ends of the bearing caps. Lubricate the
port bracket for the cylinder shell. Install the bushings with multipurpose grease.
hydraulic tubes and lines as shown in Fig-
ure 8. Make sure the lines have identifica- c. Connect a lifting device to the tube at the top
tion tags and are in the correct sequence on of the sliding weldment. If chains are used,
the bracket. make sure they do not damage the tube. The
tube has a machined surface.
4. If the carriage has a sideshift cylinder, assem-
ble the cylinder as described in the procedure for d. Install the sliding weldment on the carriage.
the Sideshift Cylinder Repair. Use the following Make sure the hooks at the bottom of the
procedure to assemble the sideshift carriage (see sliding weldment are over the bars on the
Figure 6): carriage. Make sure the bushings are in
the correct position and install the bearing
a. Install the rollers on the bottom crossmem- caps. Tighten the nuts on the bearing caps to
ber of the carriage. 500 N•m (310 lbf ft). The pins on the bush-
ings will crush as the bearing caps are tight-
b. Install the bushings in the bearing caps. ened.
Make sure the pins in the bushings are at

13
Mast Repair 4000 SRM 491

e. Install the sideshift cylinder in the carriage. 2. Operate the lift cylinders to raise the inner weld-
Install the anchor pins. Connect the hy- ment of the mast. Raise the inner weldment just
draulic lines at the cylinder. past the top load rollers of the carriage.

INSTALL 3. Operate the lifting device and move the carriage

into position under the inner weldment. Lower
Install the carriage as follows: the inner weldment completely to engage the
rollers of the carriage.
1. Connect a lifting device to the top crossmember.
See Table 1 for the weight of the parts. If chains 4. Raise the carriage and connect the lift chains at
are used, do not damage the tube at the top of the the carriage. Remove the lifting device. Adjust
sideshift carriage. the lift chains as described in Lift Chains Adjust-
ment.

5. Connect the header hoses and electric cables.

Mast Repair
REMOVE WARNING
1. If necessary, remove the carriage as described in When working on or near the mast, see Safety
the procedures for the carriage. Lower the inner Procedures When Working Near Mast.
weldment completely. See Figure 9.
When removing the mast assembly, make sure
2. Disconnect the four hydraulic lines at the lift the lifting devices have the correct capacity.
cylinders. Put caps on the openings. See Table 1.

3. Connect the lifting device to the top crossmem-

bers of the inner and outer weldments of the
mast. Make sure the lifting device is directly
over the mast. Raise the lifting device just
enough to put tension on the mast.

WARNING
Do not use your finger to push the anchor pins.
The tilt cylinder can drop and cause injury.

4. Disconnect the tilt cylinders at the mast. Remove

the capscrews and keeper plates for the anchor
pins. Use a driver to remove the anchor pins. Use
the hydraulic controls to retract the tilt cylinders.

5. Remove the nuts and outer caps from the mast

pivot. Replace the outer caps with spacers,
then install the nuts. Install capscrews in the
threaded holes of the inner caps to pull the pivot
1. MAST 5. THREADED HOLES pins from the frame and mast. Lift the mast
2. FRAME OF LIFT 6. OUTER CAP away from the lift truck. Lower the mast on
TRUCK 7. BOLT blocks so that the lift cylinders are on the top.
3. BUSHING 8. NUT Put blocks under the outer weldment.
4. INNER CAP 9. PIVOT PIN

Figure 9. Mast Mount

DISASSEMBLE
1. Disconnect the lift chains from the outer weld-
ment. Remove the lift chains.

14
4000 SRM 491 Mast Repair

2. Use the following procedure to remove the lift

cylinders (see Figure 10): WARNING
Make sure the lifting devices have the correct
a. Remove the clamp for the lift cylinder at the capacity. See Table 1 for the weights of the
top of the outer weldment. parts of the mast.
b. Remove the capscrew and spacer from the top 5. Connect a lifting device to the top crossmember of
of the lift cylinder. Use a pry bar to extend the inner weldment. Pull the inner weldment ap-
the inner weldment approximately 150 mm proximately half-way out of the outer weldment.
(6 in.). Move the lifting device to the center of the inner
weldment. Remove the inner weldment from the
c. Connect a lifting device to the lift cylinder. outer weldment.
See Table 1 for the weight of the cylinder.
Be careful not to damage the tube on the lift 6. Remove the load rollers and side rollers as nec-
cylinder. Raise the lifting device just enough essary.
to give support to the lift cylinder.
CLEAN AND INSPECT
d. Remove the capscrew and plate at the bottom
of the lift cylinder.
WARNING
e. Use the lifting device to pull the lift cylinder Cleaning solvents can be flammable and toxic
from the outer weldment. and can cause skin irritation. When using
cleaning solvents, always follow the solvent
f. Disassemble the lift cylinder as described in manufacturer’s recommended safety precau-
the procedures for the Lift Cylinders Repair. tions.
3. Use the following procedure to remove and disas-
semble the chain sheaves: CAUTION
Do not use steam to clean the lift chains, side
a. Use a pry bar and extend the inner weldment rollers, or load rollers. Steam will cause corro-
until the chain sheave is clear of the outer sion and damage to the parts.
weldment.
1. Use steam or solvent to clean the parts of the
b. Connect a lifting device to the chain sheave. mast.
Operate the lifting device just enough to give
support to the chain sheave.
CAUTION
c. Remove retainer for the shaft for the chain Get information from your dealer for Hyster
sheave. Remove the shims. lift trucks before welding on the mast.

d. Use a driver to remove the shaft. Remove the 2. Inspect the mast weldments, lift chains, and
chain sheave from the mast. rollers for wear or damage. Inspect the welds for
cracks.
e. Remove the bearings and seals from the
chain sheave.

4. Remove the side rollers at the top of the outer

weldment.

15
Mast Repair 4000 SRM 491

Figure 10. Mast Assembly

16
4000 SRM 491 Mast Repair

Legend for Figure 10

1. OUTER WELDMENT 15. SIDE ROLLER ASSEMBLY
2. BUSHING 16. SPACER
3. PIVOT PIN 17. SHAFT
4. OUTER CAP 18. CHAIN SHEAVE
5. GREASE FITTING 19. CHAIN ANCHOR
6. INNER CAP 20. BOLT
7. SEAL 21. PIN
8. BEARING CONE 22. LIFT CHAIN
9. BEARING CUP 23. BRACKET
10. SNAP RING 24. BUSHING
11. LOAD ROLLER 25. SIDE ROLLER
12. RETAINER 26. O-RING
13. SHIM 27. WASHER
14. LOAD ROLLER ASSEMBLY

ASSEMBLE c. Install the side roller, spacer, and shims on

the inner weldment. Make sure the grease
1. Use the following procedure to install the load fitting in the side roller can be reached
rollers on the inner weldment (see Figure 10): through the hole in the spacer and mast
weldment.
a. Lubricate the bearings. Install the bearings
and shields in the load roller. d. Adjust the side rollers as described in Mast
Side Rollers Adjustment.
b. Install the load roller on the stub shaft. In-
stall the retainer without shims. Tighten the 3. Use the following procedure to install the chain
capscrews to 47 N•m (35 lbf ft) while rotat- sheaves (see Figure 11):
ing the load roller.
a. Lubricate the bearings, then install the bear-
c. Loosen the capscrews for the retainer. ings in the chain sheave. Install the seals in
the chain sheave.
d. Tighten the capscrews for the retainer until
there is zero clearance in the bearings. Mea- b. Connect a lifting device to the chain sheave.
sure the clearance between the stub shaft Install the short spacer in the chain sheave.
and the retainer. Measure the clearance
through the hole in the retainer. c. Install the chain sheave in the inner weld-
ment. The short spacer fits toward the out-
e. Remove the retainer. Install shims equal to side of the mast. Install the long spacer in the
the measurement made in Step d. inner weldment. Install the shaft with the
grease fitting toward the inside of the mast.
f. Install the retainer. Tighten the capscrews
to 108 to 115 N•m (80 to 85 lbf ft). d. Install the retainer on the inner weldment.
(Do not install the shims at this time.)
2. Use the following procedure to install the side
Tighten the capscrews for the retainer until
roller at the bottom of the inner weldment:
rotation of the chain sheave becomes dif-
a. Install the bushings in the side roller. Install ficult. Measure the clearance between the
new O-rings on the shaft. retainer and the inner weldment. Install
enough shims under the retainer to give zero
b. Install the side roller in the mount, then in- clearance in the bearings.
stall the shaft and roll pin.

17
Mast Repair 4000 SRM 491

fitting in the side roller can be reached

through the hole in the spacer and mast
weldment.

b. Move the inner weldment back and forth.

Use shims to adjust the side rollers for zero
clearance at the point of tightest fit in the in-
ner weldment.

5. Use the following procedure to install the lift

cylinders:

a. Connect a lifting device to the lift cylinder.

See Table 1 for the weight of the lift cylinder.

b. Install the lift cylinder in position in the

outer weldment. Retract the inner weld-
ment to engage the top of the lift cylinders.
Install the capscrew, washers, and spacer at
the top of the lift cylinder.

c. Install the clamp and capscrews and washers

at the top of the lift cylinder. Install enough
washers between the clamp and the outer
weldment so that there is a maximum clear-
ance of 12.7 mm (0.50 in.) between the cylin-
der and the clamp.

1. INNER WELDMENT 5. SHIMS d. Install the capscrews and washers at the bot-
(MAST) 6. RETAINER tom mount for the lift cylinder.
2. SPACER 7. SHAFT
3. CHAIN SHEAVE 8. BEARING CONE 6. Install the chain anchors in the outer weldment.
4. SEAL 9. BEARING CUP
Install the lift chains to the chain anchors.
Figure 11. Chain Sheave
INSTALL
WARNING WARNING
Make sure the lifting devices have the correct
Make sure the lifting devices have the correct
capacity. See Table 1 for the weights of the
capacity. See Table 1 for the weights of the
parts of the mast.
parts of the mast.
4. Connect a lifting device to the center of the in-
1. Connect a lifting device to the top crossmembers
ner weldment. Make sure the inner weldment
of the inner and outer weldments. See Figure 9.
has stability. Install the inner weldment into the
outer weldment. 2. Raise the mast assembly and make sure it has
stability. Lubricate the bushings in the mast
When the inner weldment is at least two-thirds
with multipurpose grease. Make sure the frame
installed, install the side roller at the top of the
holes are clean and do not have grease in them.
outer weldment as follows:
Move the mast to the mounts on the frame of the
a. Install the side roller, spacer, and shims on lift truck. Align the holes in the mounts with the
the outer weldment. Make sure the grease holes in the mast.

18
4000 SRM 491 Lift Cylinders Repair

5. Operate the lifting device to move the mast so

WARNING that the tilt cylinders can be connected. Install
Do not put your fingers in the holes for the the pins for the tilt cylinders. Install the keeper
pivot pins. The mast can move and cause in- plates and capscrews for the anchor pins. The tilt
jury. cylinders must be adjusted as described in Tilt
Cylinders Adjustment.
3. Lubricate and install the pivot pins from the in-
side. (Do not lubricate the tapered part of the 6. Disconnect the lifting device from the mast. Con-
pin.) nect the hydraulic lines to the lift cylinders. See
Figure 2.
4. Install the inner cap and bolt for the pivot pin.
Make sure the flange on the inner cap fits be- 7. Install the carriage as described in the proce-
tween the pivot pin and the frame. Install the dures for the Carriage Repair.
outer cap, washer, and nut. Make sure the
grease fitting is toward the front of the lift truck.
Tighten the nut to 285 N•m (210 lbf ft).

Lift Cylinders Repair

REMOVE 2. Install a lifting eye on the end of the cylinder rod.
Pull the rod from the shell.
Remove the lift cylinders as described in Mast Re-
pair, Disassemble. 3. Remove the seals and O-rings from the parts of
the cylinder.
DISASSEMBLE
4. Remove the lowering control valve and fittings
1. Remove the retainer from the cylinder shell. See from the base of the cylinder.
Figure 12.

1. SHELL 5. BACKUP RING 9. PISTON SEAL

2. ROD 6. ROD SEAL 10. WEAR RING
3. RETAINER 7. ROD WIPER
4. O-RING 8. NYLON PLUG

Figure 12. Lift Cylinder

19
Lift Cylinders Repair 4000 SRM 491

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.

Clean all the parts of the lift cylinder in solvent. In-

spect the bore of the cylinder and the cylinder rod for
scratches or grooves.

ASSEMBLE
1. Install the lowering control valve in the base of
the cylinder (see Figure 13 and Figure 12).

NOTE: The seal can be installed on the piston with

the use of a cone. Make a cone (wood) that is ap-
proximately 250 mm (10 in.) in length. Make the
small end of the cone approximately 6 mm (0.25 in.)
smaller than the inside diameter of the seal. Make
the large end of the cone approximately 6 mm
(0.25 in.) larger than the piston. Put the seal on the
cone. Use a wood or plastic drift to push the seal
onto the cone and piston.

2. Use the following procedure to install the seal on

the piston:
A. LIFTING B. LOWERING
a. Install part of the seal in the groove of the
piston. Have a helper hold the seal in the 1. LIFT CYLINDER 4. SPRING
groove. 2. FITTING 5. WASHER
3. O-RING
b. Use two bars [approximately 460 mm (18 in.)
in length and approximately 10 mm (0.38 in.) Figure 13. Lowering Control Valve
in diameter] that have a tapered end. Make
3. Install the wear rings, rod seal, and rod wiper
sure the bars are smooth so that the seal is
in the retainer. Install the O-rings, backup ring,
not damaged.
and nylon plug on the retainer. Lubricate the
c. With the tapered end of the bars toward the seals in the retainer with packing lubricant and
piston, use the bars to pull the seal into the install the retainer. It is necessary to make a spe-
groove. It will take several minutes for the cial tool to tighten the retainer. The dimensions
seal to increase in size to fit over the piston. of the retainer are shown in Figure 14. Tighten
After installation, it will take several min- the retainer to 880 N•m (650 lbf ft).
utes for the seal to decrease to its original
size. INSTALL

d. Install the backup rings on both sides of the Install the lift cylinder as described in Mast Repair,
piston seal. Assemble.

e. Install the wear rings on the piston.

f. Use packing lubricant on the piston and in-

stall the rod in the shell.

20
4000 SRM 491 Sideshift Cylinder Repair

Figure 14. Retainer Dimensions

Sideshift Cylinder Repair

REMOVE DISASSEMBLE
1. Put tags for identification on the hydraulic lines. 1. If used, remove the setscrew(s) from the collar.
Disconnect the hydraulic lines at the cylinder. See Figure 15. Install the special tool in the hole
Put caps on the open lines. for the setscrew and remove the collar.

2. Remove the sideshift cylinder as described in

Carriage Repair, Disassemble.

1. ROD 5. O-RING 9. PISTON

2. COLLAR 6. RETAINER 10. NUT
3. ROD WIPER 7. PISTON SEAL 11. SHELL
4. ROD SEAL 8. WEAR RING 12. SETSCREW

Figure 15. Sideshift and Fork Positioner Cylinder

21
Fork Positioner Cylinders Repair 4000 SRM 491

2. Pull the piston and rod assembly from the shell. ASSEMBLE
3. Remove the retainer and bushing from the rod. 1. Install the piston and O-ring on the cylinder rod.
Remove the nut and piston from the rod. See Figure 15. Tighten the nut on the rod to 678
to 746 N•m (500 to 550 lbf ft). Install the wear
4. Remove the seals from the parts of the cylinder. ring, piston seal, and O-ring on the piston.

CLEAN AND INSPECT 2. Lubricate the shell with hydraulic oil and pack-
ing lubricant, then install the piston and rod as-
WARNING sembly.
Cleaning solvents can be flammable and toxic 3. Install the rod seal and rod wiper in the retainer.
and can cause skin irritation. When using Install the with O-ring on the outside of the re-
cleaning solvents, always follow the solvent tainer.
manufacturer’s recommended safety precau-
tions. 4. Lubricate the seals on the retainer with packing
lubricant and install the retainer in the shell. In-
Clean all the parts of the cylinder in solvent. In- stall the collar and tighten it against the retainer.
spect the shell, piston and rod for scratches, grooves Tighten the setscrew(s).
or cracks.
INSTALL
Install the sideshift cylinder as described in Carriage
Repair.

Fork Positioner Cylinders Repair

REMOVE cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
1. Put tags for identification on the hydraulic lines. tions.
Disconnect the hydraulic lines at the cylinder.
Put caps on the open lines. Clean all the parts of the cylinder in solvent. In-
spect the shell, piston rod and retainer for scratches,
2. Remove the fork positioner cylinders as de- grooves or cracks.
scribed in Carriage Repair, Disassemble.
ASSEMBLE
DISASSEMBLE
Use the same assembly procedures as described for
Use the same disassembly procedures as described the sideshift cylinder. See Sideshift Cylinder Repair,
in Sideshift Cylinder Repair, Disassemble. See Fig- Disassemble. Tighten the nut to 305 to 373 N•m (225
ure 15. to 275 lbf ft).

CLEAN AND INSPECT INSTALL

WARNING Install the fork positioner cylinders as described in

Carriage Repair, Assemble.
Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using

22
4000 SRM 491 Slew Cylinders Repair

Slew Cylinders Repair

REMOVE 2. Lubricate the seal ring and wear ring with pack-
ing lubricant and install them on the piston. In-
1. Put tags for identification on the hydraulic lines. stall the piston and rod in the shell.
Disconnect the hydraulic lines at the cylinder.
Put caps on the open lines. 3. Install the seal ring and O-ring on the retainer.
Install the rod seal and rod wiper in the retainer.
2. Remove the retainer pins and anchor pins from
the ends of the cylinder. 4. Install the retainer in the shell. Tighten the re-
tainer to 475 to 542 N•m (350 to 400 lbf ft). It can
DISASSEMBLE be necessary to make a special tool to tighten the
retainer.
1. Remove the retainer from the cylinder shell. See
Figure 16. Pull the rod and piston from the shell. INSTALL
2. Remove the seals from the retainer and piston. 1. Put the slew cylinder in position and install the
anchor pins. Install the retainer pins. Make sure
ASSEMBLE the rod end of the cylinder is connected to the
container attachment.
1. Install the O-ring in the piston. Install the piston
on the rod. Tighten the nut for the piston to 407 2. Connect the hydraulic lines to the cylinder.
to 441 N•m (300 to 325 lbf ft).

1. ROD 6. O-RING
2. RETAINER 7. PISTON RING
3. ROD WIPER 8. GUIDE RING
4. ROD SEAL 9. NUT
5. BACKUP RING 10. PISTON

Figure 16. Slew Cylinder

23
Header Hoses Replacement 4000 SRM 491

Attachment Connector
The two attachment connectors attach at the top of
the carriage, between the carriage and the container
attachment. See Figure 17. These connectors are
non-hydraulic and are used on container attach-
ments that are not equipped with slew cylinders.
The connectors help give the load stability, and are
used where slewing function is not required.

1. ROD END 3. BUSHING

2. CYLINDER 4. PIN

Figure 17. Attachment Connector

Header Hoses Replacement

The header hoses are the hydraulic lines that connect 1. Connect the hoses to the fittings on the carriage.
the cylinders on the carriage and/or attachment to Run the hoses over the sheaves.
the hydraulic system of the lift truck. The header
hoses move on hose sheaves that are installed at the 2. Fasten the hoses to the mast and lift cylinder
top of the outer weldment. An electrical cable (wires using the clamps. Do not tighten the clamps at
inside a hose) is used to connect the selector valves the top of the outer weldment.
on the carriage to the electrical system on the lift
3. Put tension on the hoses and electrical cable by
truck. Another electrical cable is used for lights on
pulling on them with 155 N (30 lb) of force and
the attachment.
then tightening the clamps at the top of the outer
When removing or installing the header hoses, make weldment (just below hose sheave). After tight-
sure they are connected to the correct fittings as ening the clamps for the hoses, make sure the
shown in Figure 18. Use the following procedure to wires move freely inside the hose.
install the hoses:

24
4000 SRM 491 Mast Side Rollers Adjustment

Legend for Figure 18

NOTE: Y AND Z - SUPPLY AND RETURN LINES

FROM CONTROL VALVE FOR CARRIAGE AND AT-
TACHMENTS.
1. ELECTRICAL CABLE

Figure 18. Header Hoses Arrangement

Carriage Side Rollers Adjustment

Use shims to adjust the side rollers for zero clearance at the point of tightest fit in the inner weldment.

Mast Side Rollers Adjustment

Use shims to adjust the side rollers. punch to make a mark that will keep the screws
from turning.
1. Adjust the side rollers at the bottom of the inner
weldment for zero clearance at the point of tight- 2. Adjust the side rollers at the top of the outer
est fit in the outer weldment. When the adjust- weldment for zero clearance at the point of tight-
ments are complete, lock each screw in position est fit against the inner weldment.
with the use of a thread locking adhesive. Use a

25
Tilt Cylinders Adjustment 4000 SRM 491

Lift Chains Adjustment

1. Adjust the chain anchors on the carriage so that at the top of the inner weldment. There must
when the mast is fully lowered, the forks just be a minimum of 6.4 mm (0.25 in.) between the
touch the floor. Make sure the lift chains have carriage and the top of the inner weldment.
equal tension.

2. Extend the mast fully. Make sure the carriage

(top side rollers) do not touch the inside surface

Tilt Cylinders Adjustment

1. Put the lift truck on a horizontal surface. Lower on the lower tilt cylinders so that there is zero
the mast completely. See Figure 19. clearance between the end of the tilt cylinder and
the rod end. Tighten the setscrews to hold the ad-
justment. Turn each setscrew one complete turn
WARNING
after it touches the threads of the spacer.
Do not use your finger to push the anchor pins.
The tilt cylinder can drop and cause injury.

2. Disconnect the lower tilt cylinders at the mast.

Remove the capscrews and keeper plates for the
anchor pins. Use a driver to remove the anchor
pins. Put a block of wood under each tilt cylinder.

3. Use the hydraulic controls to completely retract

the tilt cylinders. Adjust the rod ends of the up-
per tilt cylinders for 10 back tilt. Loosen the
clamp bolts at the rod ends and rotate the rod(s)
to change the adjustment. Tilt the mast forward
and backward several times to make sure the up-
per tilt cylinders are adjusted equally. Tighten
the clamp bolts to 65 N•m (48 lbf ft).

4. Tilt the mast forward so that both tilt cylinders

are fully extended. Adjust the rod ends of the 1. MAST 6. ANCHOR PIN
2. UPPER TILT 7. KEEPER PLATE
lower tilt cylinders so that the anchor pins fit eas- CYLINDER 8. CLAMP BOLT
ily into the holes in the mast. Install the anchor 3. LOWER TILT 9. CYLINDER ROD
pins and keeper plates in the rod ends. Tighten CYLINDER 10. SPACER
the clamp bolts to 65 N•m (48 lbf ft). 4. RELIEF VALVE 11. SETSCREW
5. ROD END
5. Tilt the mast backward until the upper tilt cylin-
ders are fully retracted. Adjust each tilt spacer Figure 19. Tilt Cylinder Adjustment

26
4000 SRM 491 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No movement of the lift Load is more than the capacity of the

cylinders. lift truck.

Check valve(s) do not operate cor-

rectly.

No oil or not enough oil to the lift

cylinders.

Relief valve(s) adjustment is not cor-

rect.

Pilot line(s) is damaged.

Pilot pressure is not correct.

Spool(s) in control valve(s) does not

operate correctly.

Slow action of the lift cylin- No oil or not enough oil to the lift
ders. cylinders.

Lift cylinder seals are damaged.

Lift cylinders have internal or exter-

nal leaks.

Relief valve(s) adjustment is not cor-

rect.

Two-speed cartridge does not oper-

ate.

Spool(s) in control valve(s) does not

operate correctly.

Lowering control valve(s) does not

operate correctly.

Check valve(s) in hydraulic manifold

does not operate correctly.

Return line(s) from top of the lift

cylinder is damaged.

27
Troubleshooting 4000 SRM 491

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Rough movement of the mast Lift cylinders have internal or exter-

assembly. nal leaks.

Relief pressure at control valve(s) is

not correct.

Two-speed cartridge does not oper-

ate.

Air is in the hydraulic system.

Damaged cylinder rod(s), bent lift

cylinders.

Mast assembly is damaged or not in

alignment.

The tilt cylinder movement No oil or not enough oil to the tilt
is slow or is not smooth. cylinders.

The seals in the tilt cylinders are

damaged.

The relief valve(s) at the tilt cylinder

do not operate correctly.

The tilt cylinders permit the There is air in the hydraulic system.
mast to move when the lever
is in the NEUTRAL position.

The tilt cylinders have internal dam-

age.

There is leakage in the hydraulic

lines of the tilt system.

The seals in the tilt cylinders are

damaged.

The control valve does not operate

correctly.

28
4000 SRM 491 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The tilt cylinders tilt the The control valve does not operate
mast forward or backward correctly.
too slowly.

There is a leak in the hydraulic sys-

tem.

The relief pressure at the tilt cylin-

der(s) is not correct.

The pilot pressure is not correct.

29
 NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

30
 TECHNICAL PUBLICATIONS

4000 SRM 491 4/92 Printed in U.S.A.