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• 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!
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Reach Carriages Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Description ......................................................................................................................................................... 3
Reach Assemblies .......................................................................................................................................... 3
Repair - General................................................................................................................................................. 5
Load Backrest Removal and Installation ......................................................................................................... 5
Fork Replacement .............................................................................................................................................. 6
Hook Forks ..................................................................................................................................................... 6
Reach Assembly Removal and Installation ...................................................................................................... 7
Carriage Load Rollers Removal and Installation............................................................................................. 8
Side Rollers Disassembly and Assembly .......................................................................................................... 9
Reach Assembly Repair ..................................................................................................................................... 9
Reach Assembly Outer Frame........................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Disassemble ................................................................................................................................................... 10
Clean and Inspect .......................................................................................................................................... 12
Assemble ........................................................................................................................................................ 13
Install ............................................................................................................................................................. 13
Remove Without Sideshifter ......................................................................................................................... 13
Disassemble Without Sideshifter.................................................................................................................. 14
Clean and Inspect .......................................................................................................................................... 14
Assemble Without Sideshifter....................................................................................................................... 14
Install Without Sideshifter ........................................................................................................................... 14
Single-Reach Scissor Arms ................................................................................................................................ 16
Remove and Disassemble .............................................................................................................................. 16
Clean and Inspect .......................................................................................................................................... 18
Assemble and Install ..................................................................................................................................... 18
Double-Reach Scissor Arms............................................................................................................................... 19
Remove and Disassemble .............................................................................................................................. 19
Clean and Inspect .......................................................................................................................................... 22
Assemble and Install ..................................................................................................................................... 22
Inner Frame Assembly ...................................................................................................................................... 24
Remove ........................................................................................................................................................... 24
Disassemble ................................................................................................................................................... 27
Clean and Inspect .......................................................................................................................................... 28
Assemble ........................................................................................................................................................ 28
Install ............................................................................................................................................................. 28
Reach Cylinders ................................................................................................................................................. 29
Remove ........................................................................................................................................................... 29
Disassemble ................................................................................................................................................... 30
Clean and Inspect .......................................................................................................................................... 31
Assemble ........................................................................................................................................................ 31
Install ............................................................................................................................................................. 31
Tilt Cylinder ....................................................................................................................................................... 32
Remove ........................................................................................................................................................... 32
Clean, Inspect, and Repair............................................................................................................................ 32
Install ............................................................................................................................................................. 32
Sideshift Cylinder .............................................................................................................................................. 34
Remove ........................................................................................................................................................... 34
Clean and Inspect .......................................................................................................................................... 34
Reach/Tilt Selector Valve................................................................................................................................... 34
ii
4500 SRM 971 Safety Procedures When Working Near Mast
General
This manual has a description and the repair procedures for the single-reach and double-reach carriages on
two-stage or three-stage masts.
1
Safety Procedures When Working Near Mast 4500 SRM 971
2
4500 SRM 971 Description
Description
The reach carriages are used to extend the reach of by a scissor linkage. The top of the scissor arm
the carriage. There are two types of reach carriages. weldment at the inner frame is fastened to the top
There is a single-reach carriage with one set of scis- of the inner frame by pins. The top of each scissor
sor arms. The other carriage has two sets of scis- arm at the outer frame is fastened to the top of the
sor arms for double reach. Both carriages have a tilt frame by pins. On double-reach units, the ends of
cylinder to tilt the forks. Each carriage is also avail- each set of scissor arms and scissor arm weldments
able with the optional sideshift function. The parts are fastened together by studs with bearings. The
of the reach carriages are shown in Figure 8 and Fig- bearings on each pin or stud permit the arms to
ure 9. The inner and outer frame assemblies are con- pivot. Large bearings at the center pivot of each
nected by a scissor linkage. The top of the scissor scissor arm and scissor arm weldment also permit
arm weldment at the inner frame is fastened to the the linkage to pivot.
top of the inner frame by pins. The top of each scis-
sor arm at the outer frame is fastened to the top of Two hydraulic cylinders control the reach movement
the frame by pins. On double reach units, the ends of of the scissor arms. The tilt cylinder controls the
each set of scissor arms and scissor arm weldments tilt action of the pivot assemblies at the heel of the
are fastened together by studs with bearings. The forks. The forks pivot on a large pin that connects the
bearings on each pin or stud permit the arms to pivot. forks to the frame. The sideshift cylinder controls the
Large bearings at the center pivot of each scissor arm movement of the mobile frame assembly and forks.
and scissor arm weldment also permit the linkage to
The bottom arms at the outer frame and the inner
pivot.
frame have load bearings that fit into channels in the
NOTE: The reach assembly can be removed from the frame assemblies. The load bearings permit the ends
mast assembly with the load backrest and forks at- of the arms to move vertically in the frame channels.
tached. Both the two-stage and three-stage mast as- The sideshift carriages have another frame that can
semblies can also be removed with the reach assem- move sideways on the apron. Two bearing blocks at
bly installed. Do only those procedures necessary for the top of the apron and two at the bottom reduce
repair. the friction for side to side movement of the sideshift
frame.
REACH ASSEMBLIES
The flow of oil to and from the cylinders is controlled
The reach assembly is used to extend the reach of by the electro-hydraulic control valve. The electro-
the forks. There are two types of reach assemblies. hydraulic control valve controls the rate and direc-
There is a single-reach assembly with one set of tion of oil flow. The switches located in the control
scissor arms. The other reach assembly has two sets handle, when actuated, direct the valve to open and
of scissor arms for double reach. Both reach assem- close to control the rate and direction of oil flow. A
blies have a tilt cylinder to tilt the forks. Each reach selector valve (2, Figure 2) directs the oil flow from
assembly may also be equipped with an optional the reach cylinders to the tilt cylinder, and from the
sideshift function. The parts of the reach assemblies tilt cylinder to the sideshift cylinder for sideshift op-
are shown in Figure 2, Figure 10, and Figure 11. eration.
The rear- and front-frame assemblies are connected
3
Description 4500 SRM 971
4
4500 SRM 971 Load Backrest Removal and Installation
Repair - General
NOTE: Most repairs of the reach carriage can be
WARNING
done without removing the carriage from the mast.
These repair procedures require that the carriage is Hydraulic oil is hot after system operation and
installed in the mast and the scissor arms are fully can cause burns. DO NOT disconnect any hy-
extended. draulic lines of the system until the oil for the
system is cool.
WARNING
The reach carriage can fall or tip easily and CAUTION
cause an injury when not installed in the mast. Make sure the lift truck is in a location that is
If the reach carriage cannot be installed in a level and has access to a crane or other lifting
mast during repair, make sure the rear frame device before doing any repairs on the reach
is fastened to a support that cannot move. The carriage.
rear frame must be in the same position as it is
in the mast. The rear frame must also be fas- NOTE: It is usually not necessary to completely dis-
tened so that it cannot move on the support. assemble the reach carriage. Do only the steps of the
The support must be strong enough to allow procedures necessary to make the required repairs.
full extension of the reach carriage without tip- Read and follow the Safety Procedures When Work-
ping. ing Near Mast in the section Mast, Repair 4000
SRM 482, as well as all WARNINGS and CAU-
TIONS.
5
Fork Replacement 4500 SRM 971
Fork Replacement
HOOK FORKS
WARNING
Forks are heavy and can cause an injury. DO
NOT try to remove forks without using a lifting
device.
To remove the forks, lift the latch lever and slide the
fork to the fork removal notch on the carriage. See
Figure 3 or Figure 4. The removal notch is in the bot-
tom crossmember of the carriage. Lower the carriage
with blocks under the fork or raise the fork tip. The 1. LATCH ASSEMBLY 5. SPRING
bottom hook of the fork will move through the fork re- 2. LEVER 6. LATCH PIN
moval notch. Lower the carriage further or raise the 3. ROLL PIN 7. FORK
fork so the top hook of the fork is disengaged from the 4. WASHER
top crossmember. Move the carriage away from the Figure 3. Forks (Early Latch Kit)
fork, or use the lifting device to move the fork away
from the carriage. Follow the same procedure to re-
move the other fork.
6
4500 SRM 971 Reach Assembly Removal and Installation
7
Carriage Load Rollers Removal and Installation 4500 SRM 971
WARNING
WARNING Be careful when removing or installing snap
Lift chains, hoses, and cables can roll over the rings. These snap rings are large and can
sheaves to fall and cause an injury if the ends come loose during removal or installation with
are not fastened. Keep control of the ends of enough force to cause an injury. Always use
the lift chains, hoses, and cables as they are re- the correct snap ring pliers, and wear eye and
moved. Use wire to temporarily connect the face protection during removal or installation.
ends of the lift chains, hoses, or cable to the
masts.
8
4500 SRM 971 Reach Assembly Repair
6. Remove the snap rings from the stub shaft for the 9. Install the reach assembly. See Reach Assembly
load roller. Removal and Installation.
7. Use a pry bar to remove the load roller from the 10. Adjust the reach assembly. See Adjust Reach
stub shaft for the load roller. See Figure 6. Cylinders in Carriage or Reach Assembly Adjust-
ments.
8. Use a cloth to clean each load roller. Inspect the
load rollers for cracks, flat spots, or bearings that
do not turn freely. Replace any roller that shows
wear or is damaged.
WARNING
The reach assembly can fall or tip easily and CAUTION
cause an injury when not installed in the mast. Make sure the lift truck is in a location that is
If the reach assembly cannot be installed in a level and has access to a crane or other lifting
mast during repair, make sure the rear frame device before doing any repairs on the reach
is fastened to a support that cannot move. The carriage.
rear frame must be in the same position as it is
It is usually not necessary to completely disassemble
in the mast. The rear frame must also be fas-
the reach assembly. Do only the steps of the proce-
tened so it cannot move on the support. The
dures necessary to make the required repairs.
support must be strong enough to allow full ex-
tension of the reach assembly without tipping.
9
Reach Assembly Outer Frame 4500 SRM 971
REMOVE
WARNING
There are pinch points on the reach car-
riage that can cause an injury. Use clamps
and blocks to prevent the scissor arms from
moving. Install the clamps and blocks at the
channels of the rear frame to make sure the
load bearings cannot move in the channel. See
Figure 7.
5. Tag and disconnect the wire at the bottom of the 1. Orient outer frame assembly with roller guides
rear frame. Remove the hose and wire guide. down and secure the unit.
6. Connect an overhead lifting device (crane) to the 2. Remove forks as outlined in Fork Replacement.
top of the outer frame.
3. Remove load backrest as shown in Load Backrest
7. Remove the brackets that retain the pivot pins Removal and Installation section.
in the outer frame to the inner scissor arms. Re-
4. Remove tilt cylinder nuts (20). (Used on sideshift
move the pivot pins.
only.)
8. Use the crane to lift the outer frame high enough
5. Remove brackets and hardware (24) from mobile
to allow the inner scissor arm rollers to come
frame. (Used on sideshift only.)
out of the bottom of the outer frame channels.
10
4500 SRM 971 Reach Assembly Outer Frame
6. Remove mobile frame (21). (Used on sideshift 12. Remove tilt cylinder trunnion cap and hardware
only.) (11, 12, 25).
7. Remove polymer wear strips (1, 2, 3, and 19). 13. Remove tilt cylinder bushing (26).
8. Remove pin-retaining hardware (4, 5, and 6). 14. Remove tilt cylinder (7).
9. Use a punch to remove pins (8). 15. Remove bushing from fixed frame (21).
11
Reach Assembly Outer Frame 4500 SRM 971
12
4500 SRM 971 Reach Assembly Outer Frame
ASSEMBLE
CAUTION
1. To assemble, reverse the removal procedure. Do NOT use steam to clean the load bearings.
Do not use compressed air on the bearings.
2. If removed, install the hydraulic hoses for the tilt
The bearings are sealed and permanently lu-
and sideshift cylinder. Always use new O-rings
bricated. The air can force the lubricant out of
on the O-ring fittings.
the bearings.
INSTALL NOTE: Use safety chains on the rear frame and mast
weldments to keep the reach assembly and mast
WARNING weldments from moving. Install the safety chains as
The points between the scissor arms and the described in Safety Procedures When Working Near
outer frame is a pinch point and can cause an Mast in this section.
injury. Do NOT put any part of your body be-
1. If necessary, remove the load backrest as de-
tween these assemblies. Use a screwdriver or
scribed in Load Backrest Removal and Installa-
other tool to move the bearing blocks or assem-
tion.
blies into the correct positions.
2. If necessary, remove the forks as described in
1. Use multipurpose grease to lubricate the bush-
Fork Replacement.
ings on the inner and outer scissor arms. Use
multipurpose grease to lube the bottom bearings 3. Install labels for correct connection during in-
in the channel at the bottom of the outer frame. stallation and remove the hoses at the top of the
outer frame. For units without sideshift, see Fig-
2. Use a crane to lift the outer frame. Align the
ure 8. For units with sideshift, see Figure 9.
outer frame with the outer scissor arms. Install
Make a note of the location of all cable ties for
the pivot pins that retain the inner scissor arms
correct installation of new cable ties during in-
to the outer frame.
stallation. Install caps on the hydraulic lines of
3. Install the brackets and hardware to retain the the selector valve to prevent dirt from entering
pivot pins. the system.
13
Reach Assembly Outer Frame 4500 SRM 971
14
4500 SRM 971 Reach Assembly Outer Frame
15
Single-Reach Scissor Arms 4500 SRM 971
WARNING
WARNING The load bearings and scissor arms can move
There are pinch points on the reach car- and cause an injury when the clamps and
riage that can cause an injury. Use clamps blocks at the load bearings are removed. Make
and blocks to prevent the scissor arms from sure the crane is in a position to prevent move-
moving. Install the clamps and blocks at the ment of the scissor arms as the clamps and
channels of the rear frame to make sure that blocks are removed.
the load bearings cannot move in the channel.
See Figure 7. 4. Carefully remove the clamps and blocks at the
load bearings on the channels of the rear frame.
Slowly move the scissor arms to align the load
WARNING bearings with the removal notch in the rear
Be careful when removing or installing snap frame. Raise the scissor arm weldment and the
rings. These snap rings are large and can scissor arms to move the load bearings out of the
come loose during removal or installation with rear frame.
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and NOTE: Install labels for each set of shims and the
face protection during removal or installation. load bearing on the scissor arms for correct assembly
during installation of the scissor arms. When new
NOTE: Use safety chains on the rear frame and mast load bearings are installed, the shim arrangement
weldments to keep the rear frame and mast weld- will normally be the same or similar. Remove the
ments from moving. Install the safety chains as de- load bearings and shims.
scribed in Safety Procedures When Working Near
Mast in this section.
WARNING
1. Remove the front frame as described in Reach The scissor arms are heavy and can cause an
Assembly Outer Frame. Remove the snap rings injury if allowed to fall. Have another person
and hose sheaves at the scissor arm weldment. help you support the scissor arm during re-
Fasten the cable and hoses at the rear frame so moval and installation.
that they are not damaged.
5. Install labels for correct installation of the right-
2. Use a crane and chains or slings as a support for hand or left-hand scissor arms. Carefully remove
the scissor arm weldment. Do not damage the the three capscrews, the lockwashers, the end
hose sheave mount. cap, and the two thrust washers at the center
pivot for the scissor arm and scissor arm weld-
WARNING ment. Hold the scissor arm and carefully slide it
off the bushing and stub shaft of the scissor arm
The points between the scissor arms and the
weldment. Remove the bushing and the other
front frame are pinch points and can cause an
two thrust washers. Remove the other scissor
injury. DO NOT put your finger in the hole
arm following this same procedure.
when you remove the pins. Use the brass drift
to remove the pins.
16
4500 SRM 971 Single-Reach Scissor Arms
17
Single-Reach Scissor Arms 4500 SRM 971
18
4500 SRM 971 Double-Reach Scissor Arms
necessary, use tape to keep the load rollers on the come loose during removal or installation with
scissor arms. enough force to cause an injury. Always use
the correct snap ring pliers and wear eye and
4. Use the crane to slowly raise the scissor arm face protection during removal or installation.
weldment and the scissor arms to align the load
rollers with the removal notches in the rear
frame. Use the crane to move the scissor arm CAUTION
assembly so the load rollers move into the chan- DO NOT let the load rollers or shims fall off the
nels. scissor arms.
5. Slowly raise the scissor arm assembly to align 6. Install the shims and load rollers on the scissor
the mounts with the rod ends of the reach cylin- arm weldment as marked during removal and
ders. Install the bushings, pins, and shoulder disassembly. If necessary, use tape to keep the
bolt to fasten the reach cylinders to the scissor load rollers on the scissor arms. Install the hoses
arm weldment. See Figure 15. on the hose sheaves, and install the hose sheaves
and snap rings at the mount of the scissor arm
weldment.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
19
Double-Reach Scissor Arms 4500 SRM 971
20
4500 SRM 971 Double-Reach Scissor Arms
21
Double-Reach Scissor Arms 4500 SRM 971
9. Install a safety chain between the inner frame CLEAN AND INSPECT
and scissor arm weldment B so the weldment
cannot move. Move the crane and chains or WARNING
slings so they are a support for scissor arm weld-
Cleaning solvents can be flammable and toxic
ment A.
and can cause skin irritation. Always wear
10. Remove the two capscrews, lockwasher, end cap, the proper protective equipment including
and two thrust washers from the top pivot point eye protection and petroleum resistant gloves
of scissor arms 1B and 2B. when handling. Always follow the recommen-
dations of the manufacturer.
WARNING
The scissor arms are heavy and can cause an CAUTION
injury if allowed to fall. Have another person DO NOT use steam to clean sealed bearings.
help you support the scissor arm during re- DO NOT use compressed air or immerse in sol-
moval and installation. vent to clean sealed bearings. Sealed bearings
self contained and permanently lubricated.
11. Install labels for correct installation of the right- Wipe bearings off with a clean cloth and turn
hand or left-hand scissor arms. Carefully remove to check for proper operation. Replace if
the three capscrews, the lockwashers, the end movement is restricted or if bearing does not
cap, and the two thrust washers at the center turn smoothly.
pivot for scissor arm 1B and scissor arm weld-
ment B. Make sure the crane is the support for Clean all of the parts of the scissor arm assembly
scissor arm weldment A so it cannot fall. Hold with solvent. Dry the parts with compressed air. In-
scissor arm 1B and slide it off the bushing and spect the parts of the scissor arm assembly for dam-
stub shaft of scissor arm weldment B. Remove age and wear. Replace all bushings and load bear-
the bushing and the other two thrust washers at ings.
the center pivot. Remove the bushing and the
other two thrust washers from the stub shaft at ASSEMBLE AND INSTALL
the end of the scissor arm. Remove scissor arm
For the following procedures, refer to Figure 11.
2B following this same procedure. Move scissor
arm weldment A and put it on the floor without NOTE: Use safety chains on the inner frame and
damaging the hose sheave mount. mast weldments to keep the inner frame and mast
weldments from moving. Install the safety chains as
12. Use the crane and chains or slings as a support
described in Safety Procedures When Working Near
for scissor arm weldment B so it cannot fall. Do
Mast in this section.
not damage the hose sheave mount. Carefully
remove the safety chain. NOTE: Always use new bushings and load bearings.
Install a thin coat of multipurpose grease on all
WARNING new bushings, all thrust washers, all shims, all stub
The points between the scissor arms and the in- shafts, and all pins of the scissor arm assembly.
ner frame are pinch points and can cause an in-
jury. Do NOT put your finger in the hole when WARNING
you remove the pins. Use the brass drift to re- The points between the scissor arms and the in-
move the pins. ner frame are pinch points and can cause an in-
jury. Do NOT put your finger in the hole when
13. Remove the shoulder bolts and pivot pins that
you remove the pins. Use the brass drift to re-
fasten scissor arm weldment B to the inner
move the pins.
frame. Move scissor arm weldment B and put it
on the floor without damaging the hose sheave 1. Use a crane and chains or slings as a support
mount. Remove the bushings. for scissor arm weldment B. Do not damage the
hose sheave mount. Move the weldment into a
22
4500 SRM 971 Double-Reach Scissor Arms
position of alignment to install the pins that fas- put any part of your body between the inner
ten the weldment to the inner frame. Install the frame and the scissor arm assembly. NEVER
bushings, pins, and shoulder bolts. Slowly lower put any part of your body between the parts of
the weldment so it hangs from the pins. Remove the scissor arm assembly.
the crane and chains or slings.
CAUTION
WARNING Do not let the load bearings or shims fall off the
The scissor arms are heavy and can cause an scissor arms.
injury if allowed to fall. Have another person
help you support the scissor arm during re- NOTE: Correct placement of shims is critical for the
moval and installation. operation of the reach mechanism. Unless the shims
are installed correctly, the reach mechanism will not
2. Install two thrust washers and the bushing on operate.
each stub shaft of scissor arm weldment B. In-
stall scissor arm 2B on scissor arm weldment B. 6. Slowly raise the weldment so you can install the
Make sure there are two thrust washers on each shim sets and load bearings on scissor arms 1B
side of the scissor arm. Tighten the three cap- and 2B as marked during removal. If necessary,
screws at the end cap to 41 N•m (30 lbf ft). use tape to keep the load bearings on the scissor
arms.
3. Install two of the thrust washers and the bushing
on the stub shaft at the end pivot of scissor arm 7. Use the crane to slowly raise scissor arm weld-
2B. ment B by lifting weldment A to align the load
bearings with the removal notches in the inner
4. Install the crane and chains or slings as a support frame. Use the crane to move the scissor arm as-
for scissor arm weldment A. Move the weldment sembly so the load bearings move into the chan-
into a position of alignment to install the weld- nels.
ment on scissor arm 2B. Install the weldment,
the other two thrust washers, the end cap, a new 8. Slowly raise scissor arm assembly to align the
lockwasher, and the two capscrews. Tighten the mounts with the rod ends of the reach cylinders.
two capscrews to 41 N•m (30 lbf ft). Install the bushings, pins, and shoulder bolts
to fasten the reach cylinders to the scissor arm
weldment.
WARNING
The scissor arms are heavy and can cause an
WARNING
injury if allowed to fall. Have another person
help you support the scissor arm during re- The scissor arms are heavy and can cause an
moval and installation. injury if allowed to fall. Have another person
help you support the scissor arm during re-
5. Install scissor arm 1B on scissor arm weldments moval and installation.
B and A. Make sure there are two thrust washers
on each side of the scissor arm at the center pivot. 9. Move scissor arm weldment A for alignment and
Also make sure there are two thrust washers on install scissor arm 2A on scissor arm weldments
each side of the arm of scissor arm weldment A. A and B. Make sure there are two thrust wash-
Use lockwashers at the end pivots. Tighten the ers on each side of the scissor arm at the center
three capscrews at the center pivot to 41 N•m pivot. Tighten the three capscrews at the center
(30 lbf ft). Tighten the two capscrews at the end pivot to 41 N•m (30 lbf ft). Also make sure there
pivots to 41 N•m (30 lbf ft). are two thrust washers on each side of the arm
of scissor arm weldment B. Tighten the two cap-
screws at the end pivots to 41 N•m (30 lbf ft).
WARNING Install scissor arm 1A using the same procedure.
The scissor arm assembly is heavy and can
cause an injury during installation. NEVER
23
Inner Frame Assembly 4500 SRM 971
1. If the outer frame assembly is installed, operate 5. Remove the safety chains installed in Step 4.
the REACH/RETRACT control handle to fully re- Lower the reach assembly or inner frame assem-
tract the forks. Use safety chains to fasten the bly for access to the chain anchors of the inner
parts of the reach assembly so the forks cannot frame. Install safety chains so they support the
extend. reach assembly or inner frame and the lift chains
become loose. Move the key to the OFF position
2. Operate the LIFT/LOWER control handle to and disconnect the battery.
raise the reach assembly or inner frame assem-
bly until the rollers of the inner frame are above
the top of the front weldment.
24
4500 SRM 971 Inner Frame Assembly
25
Inner Frame Assembly 4500 SRM 971
NOTE: Removing the pins at the chain anchors at the manifold block. Put tags on the fittings
will disconnect the lift chains without changing the for correct connection during installation. Make
chain adjustment. Always adjust the chains if new sure to put caps on the open fittings and ports
lift chains or other components are installed. to keep dirt out of the system. Install labels for
correct connection of the wire and disconnect the
electrical connections at the base of the inner
WARNING
frame.
Lift chains, hoses, and cables can roll over the
sheaves to fall and cause an injury if the ends
are not fastened. Keep control of the ends of CAUTION
the lift chains, hoses, and cables as they are re- DO NOT damage lift chains, hoses, or electrical
moved. Use wire to temporarily connect the cables as the carriage assembly is lifted out of
ends of the lift chains, hoses, or cable to the the mast weldment.
masts.
Carefully lift the reach assembly or inner frame as-
6. Hold the lift chains to keep them from falling and sembly out of the rear weldment. Carefully lower the
remove the pins in the chain anchors of the inner reach assembly or inner frame assembly to the floor.
frame. Carefully fasten the ends of the lift chains
so they do not move over the chain sheaves. WARNING
Make sure that the reach assembly is stable
WARNING and cannot fall to cause an injury. Make sure
The reach assembly or inner frame assembly is the safety chains are still installed (Step 1). If
heavy and can cause an injury if it tips or falls. the forks are removed, put the reach assembly
Make sure the reach assembly is stable during (or inner frame assembly) on the floor so that
and after removal. the mast side is on top.
7. Install lifting eyes in the reach assembly in- 8. The side rollers must be adjusted while the reach
ner frame assembly for chains or slings. Fasten assembly is out of the mast channels. Adjust the
chains or slings to the lifting eyes. Use a crane to side rollers as described in Adjust Side Rollers,
raise the reach assembly or inner frame assem- Carriage or Reach Assembly Adjustments.
bly high enough to disconnect the hydraulic lines
26
4500 SRM 971 Inner Frame Assembly
27
Inner Frame Assembly 4500 SRM 971
CLEAN AND INSPECT rollers on the inner frame. Install the shims at
each location as marked during disassembly.
WARNING 2. Adjust the carriage side rollers during assembly.
Cleaning solvents can be flammable and toxic See Adjust Side Rollers, Carriage or Reach As-
and can cause skin irritation. Always wear sembly Adjustments.
the proper protective equipment including
eye protection and petroleum resistant gloves - Install the side rollers as removed. Measure
when handling. Always follow the recommen- and adjust the side rollers as necessary. See Car-
dations of the manufacturer. riage or Reach Assembly Adjustments.
28
4500 SRM 971 Reach Cylinders
Reach Cylinders
REMOVE
For the following procedures, refer to Figure 15.
CAUTION
DO NOT operate any functions if the front
frame has been removed. Hydraulic oil can
come out of the hoses.
29
Reach Cylinders 4500 SRM 971
2. Install labels on the hydraulic lines for correct fasten each end of cylinder to the frame. Remove
connection during installation. Disconnect the the other reach cylinder using the same proce-
hydraulic lines at the reach cylinders. Install dure.
caps on the hydraulic lines and cylinder ports to
prevent dirt from entering the system. Check the 7. Remove the bushings from each mount of the in-
hydraulic fittings for damage. Replace as neces- ner frame and each scissor arm.
sary.
DISASSEMBLE
3. Remove shoulder bolts and pins from each end of
the cylinder. For the following procedures, refer to Figure 16.
30
4500 SRM 971 Reach Cylinders
CLEAN AND INSPECT 1. If removed, install the correct rod end on the rod
as marked during removal. Install new bushings
WARNING in all four mounts for the reach cylinders. Lubri-
cate the bushings with multipurpose grease.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection 2. Align the anchor end of the cylinders on the cylin-
for eyes and skin. When using cleaning sol- der mount of the inner frame of the reach assem-
vents, always follow the recommendations of bly. See Figure 15. Install the mount pins and
the manufacturer. shoulder bolt and nut to fasten the cylinders to
the inner frame. Use a hammer with a soft metal
CAUTION (brass or copper) or a plastic face to install the
DO NOT operate any functions if the front pins.
frame has been removed. Hydraulic oil can
3. Connect the hydraulic lines to the reach cylin-
come out of the hoses.
ders as marked during removal. Always use new
Clean all of the parts of the reach cylinder with sol- O-rings on the O-ring fittings.
vent. Dry the parts with compressed air. Inspect the
4. Hold each reach cylinder to align the rod end to
parts of the reach cylinder for damage and wear. Re-
the scissor arm mounts. Use a hammer with a
place all parts that are worn or damaged. Replace all
soft metal (brass or copper) or a plastic face to in-
parts included in the cylinder repair kit.
stall the mount pins to fasten the rod end of each
ASSEMBLE reach cylinder. Align the holes for the shoulder
bolt and nut. Install the shoulder bolt and nut.
1. Install the parts of the rod assembly as shown
in Figure 16. Make sure to replace all seals and NOTE: If the rod ends were not removed and the
other parts included in the cylinder repair kit. cylinders are installed in the same positions, reach
Use Loctite® No. 242 on the rod and nut for the adjustment is normally not necessary.
piston. Install the piston seal and piston rings. 5. If the rod ends were NOT removed, install the
If removed, tighten the piston nut to 95 N•m shoulder bolt and nut at each mount pin. If the
(70 lbf ft). rod ends were removed, reach adjustment IS nec-
essary. Make sure the adjustment is complete be-
CAUTION fore installing the shoulder bolt and nut.
DO NOT cut or damage seals during installa-
6. Make sure the hydraulic fittings are tightened,
tion. Be especially careful when moving seals
and remove the clamps and blocks under the load
across threads or edges of parts. Install tape
bearings.
over the rod threads to protect the seals.
31
Tilt Cylinder 4500 SRM 971
Tilt Cylinder
REMOVE Cylinder components can be disassembled to repair
the seals if damaged. Consult the Parts Manual to
Refer to Reach Assembly Outer Frame, Assemble in select the proper cylinder repair kit for your truck.
this section. Replace all parts included in the cylinder repair kit.
Seals and O-rings may become brittle and lose elas-
NOTE: If the outer frame is installed on the scissor
ticity over time even when the old parts show no ap-
arms, fully extend the reach mechanism. Use clamps
parent damage. See Figure 17. Clean all of the parts
and blocks to prevent the scissor arms from retract-
of the tilt cylinder with solvent. Dry the parts with
ing. Install the clamps and blocks on the channels
compressed air. Inspect the parts of the tilt cylinder
of the inner frame and the outer frame. Install the
for damage and wear. Replace all parts that are worn
clamps and blocks under the load bearings. See Fig-
or damaged. Replace all parts included in the cylin-
ure 7. Tighten the clamps so the blocks cannot move.
der repair kit. Use hydraulic oil to lubricate the new
seals and O-rings when installing. Be careful not to
CLEAN, INSPECT, AND REPAIR
damage new seals and O-rings when installing.
WARNING INSTALL
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection Install tilt cylinder into front frame as removed. Re-
for eyes and skin. When using cleaning sol- fer to Reach Assembly Outer Frame, Assemble in this
vents, always follow the recommendations of section.
the manufacturer.
32
4500 SRM 971 Tilt Cylinder
33
Reach/Tilt Selector Valve 4500 SRM 971
Sideshift Cylinder
REMOVE for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
The sideshift cylinder is not removable, see Reach the manufacturer.
Assembly Outer Frame, Remove, part is integral to
tilting frame. Clean all of the parts of the sideshift cylinder with
solvent. Dry the parts with compressed air. Inspect
CLEAN AND INSPECT the parts of the sideshift cylinder for damage and
wear. Replace all parts that are worn or damaged.
WARNING Replace all parts included in the cylinder repair kit.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
34
4500 SRM 971 Carriage or Reach Assembly Adjustments
ASSEMBLE CAUTION
Do NOT operate any functions if the outer
1. Use O-ring lubricant and install new O-rings on frame has been removed. Hydraulic oil can
the parts of the selector valve. come out of the hoses.
2. Install the parts in the valve block as shown in 4. Remove the air from the system as described in
Figure 2. Carriage or Reach Assembly Adjustments.
35
Carriage or Reach Assembly Adjustments 4500 SRM 971
ADJUST SIDE ROLLERS NOTE: Make sure the total shim thickness for each
side is the same for each set of side rollers. Equal
1. Use a feeler gauge to measure clearance between shim thickness will keep the clearance equal be-
the side roller and mast channel (see Figure 19). tween the reach assembly and mast weldment on
If clearance is not between 0.5 to 1.0 mm (0.02 to both sides.
0.04 in.), remove the reach assembly.
4. Install the reach assembly. See Reach Assembly
2. If necessary, remove the reach assembly from the Removal and Installation or Inner Frame Assem-
mast. See Reach Assembly Removal and Instal- bly, Install.
lation.
5. Verify free travel of mechanism in mast. If reach
3. Add or remove shims under the side rollers to assembly binds, remove an equal amount of
reduce the clearance between the rollers to 0.5 shims from each side for free travel.
to 1.0 mm (0.02 to 0.04 in.) per side.
36
4500 SRM 971 Carriage or Reach Assembly Adjustments
37
Carriage or Reach Assembly Adjustments 4500 SRM 971
38
4500 SRM 971 Specifications
Specifications
Table 1. General Specifications
Action Specification
Load Backrest Capscrews, Torque 203 N•m (150 lbf ft)
Scissor Arms, Torques
Center Pivot Capscrews 41 N•m (30 lbf ft)
End Pivot Capscrews (Double Reach Only) 39 N•m (29 lbf ft)
Reach Cylinder, Torques
M8 Bolt 34 N•m (25 lbf ft)
Reach Mechanism
Reach Cylinder Stroke +6.4/ 9.6 mm (+0.25/ 0.38 in.)
Reach Assembly Travel
Single Reach 610 mm (24 in.)
Double Reach 1067 mm (42 in.)
39
Specifications 4500 SRM 971
40
4500 SRM 971 Specifications
41
Troubleshooting 4500 SRM 971
Action Time
Reach - No Load
Extend 4.06 sec.
Retract 3.93 sec.
Reach - 1360 kg (3000 lb)
Extend 4.37 sec.
Retract 4.03 sec.
Tilt - No Load
Tilt (Up) 1.52 sec.
Tilt (Down) 1.52 sec.
Tilt - 1360 kg (3000 lb)
Tilt (Up) 2.44 sec.
Tilt (Down) 1.66 sec.
Sideshift - No Load
Left 2.44 sec.
Right 1.66 sec.
Sideshift - 1360 kg (3000 lb)
Left 2.44 sec.
Right 1.66 sec.
Troubleshooting
(N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMDR2, N30XMDR2, N45XMR2 AND
N50XMA3)
The forks will not extend, Steering and auxiliary pump is not Check and replace or repair the
tilt, or sideshift, and there is operating. power fuse for the pump motor.
power steering. Check and repair the auxiliary con-
tactor, driver, and timer. Check and
repair the pump motor.
42
4500 SRM 971 Troubleshooting
The forks will not extend, Control valve not operating. Clean, repair, or replace control
tilt, or sideshift, and there is valve.
power steering. (Cont.)
Auxiliary relief valve not operating. Clean, repair, or replace auxiliary re-
lief valve.
(W20/30ZR)
The forks will not extend, Extend, tilt, or sideshift buttons are Replace buttons/switches.
tilt, or sideshift. not operating correctly.
Control handle not operating. Check fuse and wire connections. Re-
pair and replace as required.
Auxiliary relief valve not operating. Clean, repair, or replace auxiliary re-
lief valve.
43
NOTES
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