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HM170082
• 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.
• 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.
• 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!
Lift Cylinders Table of Contents
TABLE OF CONTENTS
HYSTER
APPROVED
PARTS
4000 SRM 135 Safety Procedures When Working Near Mast
1
Safety Procedures When Working Near Mast 4000 SRM 135
HM170086
Figure 1. Mast
2
4000 SRM 135 Safety Procedures When Working Near Mast
YM170000
Figure 2. Mast
3
Safety Procedures When Working Near Mast 4000 SRM 135
4
4000 SRM 135 Description
General
This section has the description for lift cylinders used lift cylinders. All of the variations in lift cylinders
in masts and the instructions for their repair. There used in lift trucks are not shown. A section for Lift
are many different sizes of lift cylinders used in Hys- Cylinders for VISTA® Masts is included later in this
ter Company lift trucks. The operation and repair section.
procedures for the different lift cylinders are simi-
lar. The illustrations in this section are for typical
Description
All lift cylinders are single-acting cylinders. See Fig- The most common type of lowering control valve uses
ure 4. The hydraulic force is applied only in one di- these parts: (1) a special fitting for the valve body, (2)
rection. When hydraulic oil enters one end of the lift a spring, and (3) a special washer. There is a varia-
cylinder, the hydraulic force extends the piston rod. tion in the shapes of the special washer. Different
When the force is removed, the weight of the carriage lift cylinders use different shapes of special washers.
and inner mast retracts the piston rod. The volume of the hydraulic oil flowing through the
inlet port controls the shape of the special washer.
A common maintenance problem is the repair of oil (A typical shape of a special washer is shown in Fig-
leaks from the seals and wiper around the piston rod. ure 5.) When the piston rod is lowered, the oil flow
If the bore of the shell of the lift cylinder is damaged pushes against the special washer and spring. When
and cannot be repaired, the lift cylinder must be re- the oil flow reaches the limit, the special washer is
placed. moved against the special fitting. The oil then flows
only through the hole in the center of the special
LOWERING CONTROL VALVE washer. This restriction permits the piston rod to
lower only at a maximum controlled speed.
A lowering control valve is installed in the inlet port.
See Figure 5. It permits easy entry of hydraulic oil The other type of lowering control valve uses these
into the cylinder, but gives a restriction when the rod basic parts: (1) valve body, (2) spring, (3) washer, (4)
is retracted. This restriction gives limits to the speed cylinder, (5) orifice sleeve, (6) plunger, and (7) main
that a load on the forks can be lowered. sleeve. The orifice sleeve position is controlled com-
pletely by oil flow. The plunger position is controlled
There are two types of lowering control valves. Both
by oil pressure and spring tension. During lifting,
types have the same function and similar operation.
oil entering the lift cylinder goes through the center
The most common type of valve has a design that
of the main sleeve to the large holes. The oil flow
has good operation using large flows and lower pres-
through the plunger and bore moves the orifice sleeve
sures. Some lift trucks have a lift system design us-
to the end of the plunger. The flange of the orifice
ing higher pressures and a lower flow. These systems
sleeve is then aligned with the large part of the bore
need a different type of lowering control valve.
in the body. This alignment lets the oil flow past the
orifice sleeve to the cylinder.
5
Description 4000 SRM 135
HM170088
During lowering, oil from the lift cylinder moves the sleeve. Additional pressure will push the plunger
orifice sleeve. The orifice sleeve moves away from the against the main sleeve to close the large holes com-
larger inner diameter area of the bore in the valve pletely. All the oil must then go through the small
body. This movement makes a restriction to the oil holes to the center of the main sleeve. This restric-
flow. As the pressure increases, the plunger begins tion permits the piston rod to lower only at a maxi-
to move against the spring. The movement begins mum controlled speed.
to close the openings of the large holes in the main
6
4000 SRM 135 Description
HM170089
7
Description 4000 SRM 135
CYLINDERS (GENERAL) the piston of many of the lift cylinders. When the rod
extends, the pressure increases more quickly on any
Standard masts use a single-stage lift cylinder. oil in the rod end of the cylinder. The hydraulic oil
Most three-stage and four-stage masts use two sin- transfers through the check valve to the piston end of
gle-stage lift cylinders. A single-stage lift cylinder the cylinder. This action prevents hydraulic damage
has one piston rod. See Figure 6. to the wiper seal. See Figure 8. Lift cylinders that
do not have an internal check valve have a drain line
Most full free-lift masts and some three-stage masts
on the outside of the cylinder shell.
use a two-stage lift cylinder. A two-stage lift cylin-
der has two telescopic piston rods. See Figure 7. The
CYLINDERS (H520-620B, H700-800A)
two-stage lift cylinder operates similar to a one-stage
lift cylinder. Hydraulic pressure pushes the primary The rod side of the lift cylinder is used for the storage
(larger) piston rod from the cylinder first because of hydraulic oil on the H520-620B and H700-800A lift
it has a larger diameter. The secondary piston rod trucks. This storage decreases the required size of
moves with the primary piston rod. When the pri- the hydraulic tank. When the piston raises in the
mary piston rod reaches the limit of its stroke, the cylinder, the oil on the rod side of the piston trans-
secondary piston rod extends from the primary pis- fers to the hydraulic tank. When the piston lowers
ton rod. in the cylinder, some of the oil transfers to the rod
side of the cylinder. Approximately one half of the oil
Spacers are used in some cylinders to give a limit to
in the bottom of the cylinder goes through the main
the stroke of the piston rod. Worn spacers must be
control valve to the rod side of the cylinder. See the
replaced with the same size spacer.
Main Control Valve of Service Manual for more
Most of the lift cylinders use a single-lip seal assem- information. See Figure 9.
bly to prevent hydraulic oil leaks past the piston
and past the retainer. See Figure 4. There are Retainer, Install
many lift cylinders in use that have an older design 1. Install the retainer over the piston and into the
chevron-style packing. The chevron-style packing cylinder. Make sure the single-lip seal assembly,
can be replaced with a seal kit that has the newer the O-ring, and the backup ring are not damaged.
single lip seal and an adaptor. There are no replace- See Figure 9.
ments of single lip seals for chevron-style packing
for lift trucks over 7,000 kg (15,000 lb) capacity. 2. Turn the retainer ring into the threads in the
cylinder. Turn the retainer ring until it is even
Lift cylinders and other hydraulic parts can have in- with the top of the cylinder.
ternal leaks. Internal leakage will increase as the
temperature of the hydraulic oil increases. The in- 3. Install the capscrews loosely.
ternal leak rate of the hydraulic system is normally
checked after every 1000 hours of operation. See Lift 4. The stroke of the cylinder rod can be adjusted by
System Leak Check for test procedures and leakage turning the retainer ring one-half turn in either
rates within the specifications. direction.
During operation, some leakage of hydraulic oil can 5. Install and tighten the setscrew.
move past the piston seal to the rod side of the pis-
ton. A small leakage is permitted if the internal leak 6. Tighten the capscrews to 36 to 46 N•m (27 to
rate of the hydraulic system is not greater than the 34 lbf ft).
specification. An internal check valve is installed in
8
4000 SRM 135 Description
HM170090
9
Description 4000 SRM 135
CYLINDERS (H360-460B)
The lift cylinders used in the H360-460B lift trucks
are displacement cylinders. The design and repairs
for these cylinders are similar to the other lift cylin-
der in this section. A displacement cylinder does not
have a piston or piston seal. The rod diameter is al-
most the same as the inside diameter of the cylin-
der. There are wear rings on the rod that are the
bearings between the rod and the walls of the cylin-
der. The wiper seal at the top of the cylinder is also
the high-pressure seal for these cylinders. The wiper
seal has chevron-style packing. See Figure 10.
;„tg . -
HM170091
10
4000 SRM 135 Description
HM170093
11
Description 4000 SRM 135
CYLINDERS (TWO-SPEED)
Two-speed lift cylinders are single-stage lift cylinders
with a special valve and path for the hydraulic oil.
The lift cylinder is filled with oil on both sides of the
piston. For loads less than 45% of the rated capacity,
the cylinder rod can be extended at high speed. When
the cylinder rod extends, the oil on the rod side of the
piston transfers to the bottom of the piston. When
the oil transfers, the increase almost doubles the flow
of oil to the base of the cylinder. The pump pressure
is applied to both sides of the piston. The area on the
bottom of the piston is greater than the rod side of
the piston. The difference in force pushes the piston
up the cylinder. See Figure 11.
S60-80B H150-250E
Figure 10. Displacement Cylinders S125-150A H150-275H
H60-80C H250-300A
H300-350B P125-180A
H110-150F P150-200B
12
4000 SRM 135 Description
HM170095
Model Load
S60-100B 1589 to 2043 kg (3500-4500 lb)
H60-80C 1589 to 2043 kg (3500 to 4500 lb)
H110-150F 1589 to 2043 kg (3500 to 4500 lb)
S125-150A 2270 to 2724 kg (5000 to 6000 lb)
H150-200ES, Standard Masts 2270 to 3087 kg (5000 to 6800 lb)
P125-180A, Standard Masts 2270 to 3087 kg (5000 to 6800 lb)
H150-250E, Heavy Duty Masts 3133 to 4041 kg (6900 to 8900 lb)
P125-180A, Heavy Duty Masts 3133 to 4041 kg (6900 to 8900 lb)
H250-300A 4540 to 4994 kg (10,000 to 11,000 lb)
This table shows the approximate maximum load that the mast will lift at high speed. Loads greater than
those shown will cause the mast to lift at normal speed. These loads will have a variation because of the
different attachments that can be installed on the lift truck.
13
Lift Cylinder Repair 4000 SRM 135
Remove the carriage before the lift cylinder. See the 8. Raise the cylinder and move it away from the
procedure described in the Masts section. If the mast mast. Move the lift cylinder to a position where
must be removed for repairs, then remove the lift it can be disassembled.
cylinder when the mast is disassembled. Remove the
lift cylinder from the mast as described in the follow- Standard and Full Free-Lift Masts With Lift
ing paragraphs. Cylinder Fastened to Crosshead
Standard Masts With Main Lift Cylinder 1. Remove the lift chains and chain anchors from
the mast and the lift cylinder. Connect a sling
Fastened to Crossmember of Inner Mast
to the upper area of the lift cylinder. Raise the
1. Fully lower the mast. Loosen, but do not discon- lifting mechanism until the sling is tight. See
nect the capscrew that fastens the cylinder rod to Figure 12 and Figure 13.
the crossmember of the inner mast.
2. Remove the capscrews that connect the piston
2. Clean the area next to the fittings that connect rod to the crosshead.
the hydraulic lines to the lift cylinder. Put a
3. Disconnect and remove the crosshead assembly
drain pan under the area where the hydraulic
from the mast. Make a note of the shim arrange-
lines will be disconnected. Disconnect the hy-
ment on the crosshead guide.
draulic lines and put a cap on each open fitting.
4. Clean the area next to the fittings that connect
WARNING the hydraulic lines to the lift cylinder. Put a
Make sure the lifting mechanism has enough drain pan under the area where the hydraulic
capacity to lift the loads. See the Weight Guide lines will be disconnected. Disconnect the hy-
for lift cylinders in Table 2. draulic lines and put a cap on each open fitting.
3. Connect a lifting mechanism to the inner mast. 5. Remove the snap ring that connects the bottom
Lift the inner mast approximately 300 mm of the lift cylinder to the outer mast.
(12 in.). Fasten the inner and outer masts to-
6. Raise the lift cylinder and move it away from the
gether at the crossmembers with a heavy chain.
mast. Move the lift cylinder to a position where
Make sure that the inner mast cannot move.
it can be disassembled.
Remove the lifting mechanism.
4. Connect a heavy-duty sling to the upper part of Masts That Have Two Cylinders, Main Lift
the cylinder. Raise the lifting mechanism until Cylinder and Free-Lift Cylinder
the sling is tight. Make sure the sling will not
slide. 1. Remove the free-lift cylinder as described in
the section above for removing a lift cylinder
5. Remove the capscrew and washer connecting the fastened to a crosshead.
piston rod to the inner mast. Remove the spacer.
2. Remove the main lift cylinder as described in
the section above for removing a lift cylinder fas-
CAUTION tened to an inner mast.
Oil can come out of the cylinder fittings with
pressure when retracting the rod.
14
4000 SRM 135 Lift Cylinder Repair
HM170097
1. CHAIN GUARD 6. CHAIN ANCHOR Figure 13. Free-Lift Cylinder and Crosshead
2. CROSSHEAD 7. SPECIAL WASHER
ASSEMBLY 8. LOCK NUT
3. SNAP RING 9. SPACER
4. SHEAVE 10. WEAR PLATE
5. BEARING 11. PAD
15
Lift Cylinder Repair 4000 SRM 135
CAUTION
CAUTION
A difficult and important step in assembling
Carefully disassemble and assemble the lift
cylinders is the correct installation of the seals
cylinders so that the rods and sliding surfaces
without damage. Most cylinder maintenance is
are not damaged.
caused by seal leakage.
NOTE: Disassembly of single-stage and two-stage lift
2. Install the seal and bearing (and spacer if
cylinders is the same except the two-stage lift cylin-
equipped) on the rod piston. Use shim material
der has a second piston rod assembly. The disassem-
and a band clamp as a guide to move the sin-
bly of the secondary piston rod assembly is similar to
gle-lip seal past the threads of the shell.
the disassembly of the primary piston rod assembly.
3. Carefully push piston and piston rod into the
1. Loosen the retainer with a spanner. Disconnect
shell. Release the band clamp on the seal when
the retainer from the shell. See Figure 14 and
the seal travels past the threads of the shell.
Figure 15.
4. Install the seals, O-rings, and bearings (when
2. Remove the cap from the inlet and slide the pis-
used) in the retainer. If the wiper seal has a
ton rod assembly from the shell. Use drain pans
spring backup ring, the spring must be toward
for the hydraulic oil.
the base of the lift cylinder.
3. Remove the retainer from the piston rod. Re-
5. Carefully install the retainer on the piston rod.
move and discard the O-rings, seals, and bear-
ings. 6. Engage the threads and tighten the retainer in
the shell to the correct torque. Use a correct
4. Remove the internal check valve.
spanner. Do not hit the retainer with a hammer
5. Remove the lowering control valve. and driver.
16
4000 SRM 135 Lift Cylinder Repair
1413
7 6 5
HM170098
17
Lift Cylinder Repair 4000 SRM 135
LIFT CYLINDER INSTALLATION IN MAST 2. Install the crosshead assembly in the mast.
Align the holes in the piston rod and the
Standard Masts With Main Lift Cylinder crosshead.
Fastened to Crossmember of Inner Mast
3. Fasten the crosshead to the piston rod with cap-
1. Put the lift cylinder into position in the mast. screws.
Make sure the base of the lift cylinder is aligned
correctly on its mount. 4. Fasten the base of the lift cylinder to its mount
with a snap ring.
2. Connect a chain to the upper section of the lift
cylinder and the overhead guard. Make sure the 5. Connect the hydraulic lines.
chain will hold the lift cylinder in position until 6. Install the chain anchors.
it can be fastened to the mast.
7. Install the lifting chains.
3. Connect a lifting mechanism to the inner mast.
8. Install the carriage. See masts section for checks
CAUTION and adjustments.
Do not connect a wrench to the sliding surface CHEVRON-STYLE PACKING
of the piston rod. Any damage to the sliding
surface will cause leaks. The replacement seal kits for chevron-style packing
have a single-lip seal and an aluminum spacer. The
4. Disconnect the inner mast from the outer mast. seal kits also have one or two backup rings. If one
Lower the inner mast until it touches the piston backup ring is in the seal kit, install it as shown in
rod. Align the holes of the inner mast and the B of Figure 16. Two backup rings are installed as
piston rod. shown in C of Figure 16. Make sure the single-lip
5. Install capscrews, washer, and spacer to fasten seal is always installed correctly against the direc-
the lift cylinder to the crossmember of the inner tion of pressure.
mast. The installation of chevron-style packing on a pis-
6. Fasten the base of the lift cylinder to the cross- ton is shown in Chevron-Style Packing Installation
member of the outer mast with a capscrew and on Piston. The installation of chevron-style packing
plate. in a packing gland nut used at the top of the cylin-
der is shown in Chevron-Style Packing Installation
7. Connect the hydraulic lines. in Packing Gland. There will be some variation in
the design of the different lift cylinders. The prin-
8. Install the carriage. ciples of installation of the chevron-style packing is
similar.
Standard and Full Free-Lift Masts With Lift
Cylinder Fastened to Crosshead Lubricate the parts with hydraulic oil or packing lu-
bricant (Part No. 186061) before assembly.
1. Put the lift cylinder into position in the mast.
Align the guide pin with the hole in the bottom
crossmember.
18
4000 SRM 135 Lift Cylinder Repair
HM170099
A. MANY EARLIER PRODUCTION LIFT TRUCKS WITH LESS THAN 7000 kg (15,000 lb) CAPACITY THAT
HAVE CHEVRON-STYLE PACKING CAN BE CHANGED TO SINGLE-LIP SEALS.
B. THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN.
C. IF TWO BACKUP RINGS ARE IN THE SEAL KIT, THE PARTS ARE INSTALLED IN THE ARRANGEMENT
SHOWN.
1. CHEVRON-STYLE PACKING 3. BACKUP RING 5. DIRECTION OF OIL
2. ALUMINUM SPACER 4. SINGLE-LIP SEAL ASSEMBLY PRESSURE
STEP 2.
Install a new packing assembly on the piston half.
The packing must extend approximately 3 mm
(1/8 in.) beyond the end of the piston half.
HM170101
19
Lift Cylinder Repair 4000 SRM 135
STEP 3.
Install the piston half and snap ring.
HM170102
STEP 4.
Install the nylon spacer.
HM170103
STEP 5.
Install the piston in the lift cylinder. Carefully push the piston and piston rod into the lift cylinder. Release
the clamp on the packing when the packing moves past the threads of the cylinder.
HM170104
1. PISTON
2. SPECIAL TOOL OR BAND CLAMP TO INSTALL PACKING
20
4000 SRM 135 Lift Cylinder Repair
HM170105
STEP 2.
Assemble the gland nut using a new O-ring, backup
ring, and inner seal.
STEP 3.
Install the bushing assembly and gland nut assembly
in the rod.
HM170107
21
Lift Cylinders for VISTA® Masts 4000 SRM 135
STEP 4.
Install a new wiper ring and spring on the retainer. Install the retainer against the packing gland nut. Lightly
hit the retainer to move against the internal threads in the cylinder shell. Use a spanner to tighten the retainer.
r
j
0
HM170108
1. O-RING
22
4000 SRM 135 Lift Cylinders for VISTA® Masts
maximum speed at which a load on the forks can be on the forks from freely falling if a hydraulic hose
lowered. The lowering control valve prevents a load breaks.
23
Lift Cylinders for VISTA® Masts 4000 SRM 135
HM170111
The lowering control valve includes the following holes completely. All the oil must go through the
parts: (1) valve body, (2) spring, (3) washer, (4) small holes to the center of the main sleeve. This
cylinder, (5) orifice sleeve, (6) plunger, and (7) main restriction permits the piston rod to lower only at a
sleeve. The orifice sleeve position is controlled by oil maximum controlled speed.
flow. The plunger position is controlled by oil pres-
sure and spring tension. During lifting, oil entering REMOVE
the lift cylinder goes through the center of the main
sleeve to the large holes. The oil continues between NOTE: Remove the carriage before removing the lift
the plunger and bore to move the orifice sleeve to the cylinder. See the procedure described in the Masts
end of the plunger. The flange of the orifice sleeve section. If the mast assembly must be removed for re-
is then aligned with the large part of the bore in the pairs, then remove the lift cylinders when the mast
body. This alignment lets the oil flow around the assembly is disassembled. When only the lift cylin-
orifice sleeve to the inlet port of the lift cylinder. ders must be removed for repairs, then remove the
lift cylinders from the mast as described in the fol-
During the lowering operation, oil from the lift lowing paragraphs.
cylinder moves the orifice sleeve. The sleeve moves
away from the larger area of the bore in the valve 1. Clean the area around the hydraulic fittings for
body. This movement makes a restriction to the the lift cylinders. Disconnect the fittings at the
oil flow. When the pressure increases, the plunger lift cylinders and put caps on the open lines.
begins to move against the spring. The movement
2. On the free-lift mast, remove the capscrews,
begins to close the openings of the large holes in
washers, and cylinder clamp from the mount
the main sleeve. Additional pressure will push the
for the free-lift cylinder. Remove the free-lift
plunger against the main sleeve to close the large
cylinder.
24
4000 SRM 135 Lift Cylinders for VISTA® Masts
3. Remove the snap rings and washers from the top DISASSEMBLE
of each main lift cylinder. Remove the cylinder
clamps near the top of each lift cylinder. Each WARNING
cylinder clamp is fastened to the top crossmem-
Use slings and a crane to handle and disassem-
ber of the inner mast by two capscrews and wash-
ble the lift cylinders of most lift trucks. Make
ers.
sure that the crane and slings can lift the load
4. Support the cylinder. Connect a crane to the top correctly. See Table 2 for weight guide.
of the inner mast using chains. Raise the inner
mast from the outer mast approximately 30 cm CAUTION
(12 in.). Disengage the piston rod ends of lift Carefully disassemble and assemble the lift
cylinders from the top crossmember of the inner cylinders so that the piston rods and sliding
mast. Remove the lift cylinders from the mount surfaces are not damaged.
plates at the bottom of the outer mast.
NOTE: Disassembly of the main lift cylinders and the
free-lift cylinder is similar. All of the lift cylinders are
disassembled from the rod end of the cylinder shell.
25
Lift Cylinders for VISTA® Masts 4000 SRM 135
ASSEMBLE 2. Install the wear ring, single lip seal, and backup
ring onto the piston assembly. If a spacer sleeve
NOTE: is used, install it. Use shim material and a clamp
• Lubricate all internal parts of the lift cylinder with as a guide to move the single-lip seal over the
hydraulic oil during assembly. threads of the shell.
• Use new O-rings, seals, and bearings. Apply lubri-
cant (hydraulic oil) during assembly. Packing lu- 3. Carefully push the piston and rod assembly into
bricant (Part No. 186061) is also available. the shell. Release the clamp on the seal when the
• Make sure the single-lip seal assemblies are in- seal travels past the threads of the shell.
stalled with the O-ring toward the base of the lift
cylinder. (See Figure 19.) NOTE: When a main lift cylinder of the type shown in
Figure 18 is assembled, use the following procedure:
CAUTION a. Install the seal ring and wiper ring into the
A difficult and important step in assembling retainer. Assemble the retainer onto the pis-
lift cylinders is the correct installation of the ton rod.
seals. Most lift cylinder maintenance is caused
b. Install the piston to the threaded part of the
by seal leaks.
piston rod. Use a round bar through the hole
1. Install the internal check valve, if installed. in the piston and tighten the piston to the
Make sure the arrow on the internal check valve piston rod. Hold the piston rod in a vise or
is toward the base of the piston. clamp by the two flats on the top end of the
piston rod.
26
4000 SRM 135 Lift Cylinders for VISTA® Masts
NOTE: Do not use an adhesive on the threads of the of the inner mast. Install the washers and snap
piston rod and piston. rings, or other locking device, at the top of the lift
cylinders. Install the cylinder clamps near the
4. Install the seal, O-ring, wear ring, and wiper ring top of each cylinder. Fasten the clamps, if used,
in the retainer. If the wiper seal has a spring for a to the top crossmember of the outer mast with
backup ring, the spring must be toward the base the capscrews and washers.
of the lift cylinder.
2. Install the lowering control valve on the outer
5. Carefully install the retainer on the piston rod. mast. Connect the hydraulic lines and fittings
between the lowering control valve and the lift
6. Engage the threads and tighten the retainer in
cylinders.
the shell until it is tight. Use a correct span-
ner. Do not hit the retainer with a hammer and 3. Install the chain sheaves and brackets. Connect
driver. the lift chains to the chain anchors on the inner
mast. Fasten wires between the ends of the lift
7. Install the lowering control valve. Make sure the
chains so that they can be controlled during in-
special washer and the spring are installed cor-
stallation of the carriage.
rectly. A wrong installation can cause the load to
lower too fast. 4. Install the carriage. Connect the lift chains.
27
Lift System Leak Check 4000 SRM 135
28
4000 SRM 135 Specifications
Specifications
Table 2. Cylinder Retainer Torque Specifications and Weight Guide
29
Troubleshooting 4000 SRM 135
Troubleshooting
No movement of lift cylin- Pilot line(s) to control valve are dis- Tighten or connect fittings.
ders or tilt cylinders. connected or leaking.
No oil or not enough oil in the hy- Fill tank. Check for leaks.
draulic tank.
Relief valve(s) not set correctly. Adjust or install new relief valve.
Remote control valve does not oper- Check and repair valve.
ate.
Slow movement of lift or tilt No oil or not enough oil to lift or tilt Fill tank. Check for leaks.
cylinders. cylinders.
Relief valve is not set correctly. Adjust or install new relief valve.
Rough movement of the mast There is air in the hydraulic system. Remove air. Check for loose connec-
assembly. tions or breaks in lines.
Mast weldments are damaged or not Align weldments. Install new parts.
aligned.
30
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