REACH CARRIAGES

N30XMDR3, N45XMR3 [G138]; N30XMXDR3,

N45XMXR3 [B264]; W20/30ZR [B455]; N25XMDR3,
N30-40XMR3 [C470]; N50XMA3 [C471]

PART NO. 1503619 4500 SRM 971

 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!

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

©2007 HYSTER COMPANY i

Table of Contents Reach Carriages

TABLE OF CONTENTS (Continued)

Remove ........................................................................................................................................................... 34
Disassemble ................................................................................................................................................... 34
Clean and Inspect .......................................................................................................................................... 35
Assemble ........................................................................................................................................................ 35
Install ............................................................................................................................................................. 35
Carriage or Reach Assembly Adjustments ....................................................................................................... 35
Adjust Wear Plug........................................................................................................................................... 35
Adjust Side Rollers ........................................................................................................................................ 36
Adjust Thrust Rollers .................................................................................................................................... 37
Adjust Reach Cylinders ................................................................................................................................. 38
Specifications...................................................................................................................................................... 39
Troubleshooting.................................................................................................................................................. 42
(N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMDR2, N30XMDR2, N45XMR2 and
N50XMA3)...................................................................................................................................................... 42
(W20/30ZR) .................................................................................................................................................... 43

This section is for the following models:

N30XMDR3, N45XMR3 [G138];

N30XMXDR3, N45XMXR3 [B264];
W20/30ZR [B455];
N25XMDR3, N30-40XMR3 [C470];
N50XMA3 [C471]

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.

Safety Procedures When Working Near Mast

WARNING
All chains, ropes, and lifting equipment MUST
be fully examined by qualified personnel at
least once a year or more at frequent intervals
according to the local conditions of use.
WARNING
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury can re-
sult if part of the body is hit by parts of the mast
or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure the power is off and the key
is removed. Attach a DO NOT OPERATE tag
to the control handle.
• DO NOT make repairs or adjustments unless
specifically authorized to do so. Repairs and
adjustments must be performed by trained
service technicians.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• Move the truck to a safe location with room to
raise the mast if necessary. Block the wheels
of the truck to prevent movement.
The forks may be difficult to see when the mast is
raised. Be careful not to hit your head when working
around raised forks. Also, be careful not to trip over
forks on or near the floor. If possible, remove forks
from carriage before safety chaining mast.
WHEN WORKING NEAR THE MAST, ALWAYS:
• Lower the mast and carriage completely. Make
sure there is no movement in the mast. Make sure
all parts of the mast, that can move, are fully low-
ered.
OR
• If the mast must be in a raised position for re-
pairs, install a safety chain around the top or mid-
dle crossmember of the outer weldment and the
crossmember of the inner weldment to secure the
mast.
WARNING
Perform the following step from the side of the
mast using a ladder. Never stand under the car-
riage until safety chains are installed.
1. Remove forks from carriage if possible.
2. Raise mast to align bottom crossmember(s) of
weldment(s) that move within the outer weld-
ment with a crossmember on outer weldment.
On the two-stage mast, the moving part is the
inner weldment. On the three-stage mast, it is
the intermediate weldment.
3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum
size, around crossmembers of inner and outer
weldment. Secure it in place. See Figure 1.
4. Lower mast until safety chain stops mast. Make
sure there is no movement of mast.
5. Turn key switch to OFF, disconnect battery, and
place a DO NOT OPERATE tag on control han-
dle head.
6. Wrap a second safety chain, 9.5 mm (3/8 in.) min-
imum size, around crossmembers of inner and
outer weldment. Secure it in place as an addi-
tional precaution.
NOTE: The mast operator guard MUST be removed
to install safety chain. Remove safety chain and in-
stall guard AFTER repairs are complete.

1
Safety Procedures When Working Near Mast 4500 SRM 971

Legend for Figure 1

A. TWO-STAGE MAST
B. THREE-STAGE MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. SAFETY CHAIN
5. FREE-LIFT CYLINDER
6. CARRIAGE

Figure 1. Safety Chain the Mast

2
4500 SRM 971
Description
The reach carriages are used to extend the reach of
the carriage. There are two types of reach carriages.
There is a single-reach carriage with one set of scis-
sor arms. The other carriage has two sets of scis-
sor arms for double reach. Both carriages have a tilt
cylinder to tilt the forks. Each carriage is also avail-
able with the optional sideshift function. The parts
of the reach carriages are shown in Figure 8 and Fig-
ure 9. The inner and outer frame assemblies are con-
nected by a scissor linkage. The top of the scissor
arm weldment at the inner frame is fastened to the
top of the inner frame by pins. The top of each scis-
sor arm at the outer frame is fastened to the top of
the frame by pins. On double reach units, the ends of
each set of scissor arms and scissor arm weldments
are fastened together by studs with bearings. The
bearings on each pin or stud permit the arms to pivot.
Large bearings at the center pivot of each scissor arm
and scissor arm weldment also permit the linkage to
pivot.
NOTE: The reach assembly can be removed from the
mast assembly with the load backrest and forks at-
tached. Both the two-stage and three-stage mast as-
semblies can also be removed with the reach assem-
bly installed. Do only those procedures necessary for
repair.
REACH ASSEMBLIES
The reach assembly is used to extend the reach of
the forks. There are two types of reach assemblies.
There is a single-reach assembly with one set of
scissor arms. The other reach assembly has two sets
of scissor arms for double reach. Both reach assem-
blies have a tilt cylinder to tilt the forks. Each reach
assembly may also be equipped with an optional
sideshift function. The parts of the reach assemblies
are shown in Figure 2, Figure 10, and Figure 11.
The rear- and front-frame assemblies are connected
Description
by a scissor linkage. The top of the scissor arm
weldment at the inner frame is fastened to the top
of the inner frame by pins. The top of each scissor
arm at the outer frame is fastened to the top of the
frame by pins. On double-reach units, the ends of
each set of scissor arms and scissor arm weldments
are fastened together by studs with bearings. The
bearings on each pin or stud permit the arms to
pivot. Large bearings at the center pivot of each
scissor arm and scissor arm weldment also permit
the linkage to pivot.
Two hydraulic cylinders control the reach movement
of the scissor arms. The tilt cylinder controls the
tilt action of the pivot assemblies at the heel of the
forks. The forks pivot on a large pin that connects the
forks to the frame. The sideshift cylinder controls the
movement of the mobile frame assembly and forks.
The bottom arms at the outer frame and the inner
frame have load bearings that fit into channels in the
frame assemblies. The load bearings permit the ends
of the arms to move vertically in the frame channels.
The sideshift carriages have another frame that can
move sideways on the apron. Two bearing blocks at
the top of the apron and two at the bottom reduce
the friction for side to side movement of the sideshift
frame.
The flow of oil to and from the cylinders is controlled
by the electro-hydraulic control valve. The electro-
hydraulic control valve controls the rate and direc-
tion of oil flow. The switches located in the control
handle, when actuated, direct the valve to open and
close to control the rate and direction of oil flow. A
selector valve (2, Figure 2) directs the oil flow from
the reach cylinders to the tilt cylinder, and from the
tilt cylinder to the sideshift cylinder for sideshift op-
eration.
3
Description 4500 SRM 971

Figure 2. Hydraulic Parts for Double-Reach Assembly (Single-Reach is Similar)

4
4500 SRM 971 Load Backrest Removal and Installation

Legend for Figure 2

1. COVER PLATE 20. EXTERNAL SNAP RING
2. VALVE ASSEMBLY 21. FRONT PIVOT PINS
3. 6×4 FITTING WITH O-RING 22. WASHER
4. 4×4 FITTING WITH O-RING 23. LOCKWASHER
5. LOCKWASHER 24. CAPSCREW
6. BOLT 25. LOCKWASHER
7. 6×4 FITTING WITH O-RING 26. FITTING WITH O-RING
8. HOSE ASSEMBLY 27. RETAINING PLATE
9. HOSE ASSEMBLY 28. LOCKWASHER
10. HOSE ASSEMBLY 29. CAPSCREW
11. HOSE ASSEMBLY 30. WELDMENT.
12. HOSE ASSEMBLY 31. STOP ASSEMBLY
13. HOSE ASSEMBLY 32. STOP PAD
14. HOSE ASSEMBLY 33. WASHER
15. HOSE ASSEMBLY 34. LOCKWASHER
16. WIRE CLAMP 35. CAPSCREW
17. CAPSCREW 36. CAPSCREW
18. WIRE ASSEMBLY 37. WIRE TIE
19. SHEAVE

Repair - General
NOTE: Most repairs of the reach carriage can be
done without removing the carriage from the mast.
These repair procedures require that the carriage is
installed in the mast and the scissor arms are fully
extended.
WARNING
The reach carriage can fall or tip easily and
cause an injury when not installed in the mast.
If the reach carriage cannot be installed in a
mast during repair, make sure the rear frame
is fastened to a support that cannot move. The
rear frame must be in the same position as it is
in the mast. The rear frame must also be fas-
tened so that it cannot move on the support.
The support must be strong enough to allow
full extension of the reach carriage without tip-
ping.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic lines of the system until the oil for the
system is cool.
CAUTION
Make sure the lift truck is in a location that is
level and has access to a crane or other lifting
device before doing any repairs on the reach
carriage.
NOTE: It is usually not necessary to completely dis-
assemble the reach carriage. Do only the steps of the
procedures necessary to make the required repairs.
Read and follow the Safety Procedures When Work-
ing Near Mast in the section Mast, Repair 4000
SRM 482, as well as all WARNINGS and CAU-
TIONS.

Load Backrest Removal and Installation

WARNING
The load backrest is heavy and can cause an
injury. Do not try to remove it without using a
lifting device.
1. Use a hoist to secure the load backrest in posi-
tion.
2. Loosen the four capscrews that fasten the load
backrest to the carriage assembly.
3. Lift the load backrest off the mobile frame.
4. Reverse the procedure to install the load
backrest. Tighten the capscrews to 102 N•m
(75 lbf ft).

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.

These forks are connected to the carriage by hooks.

Latch pins fit through the top fork hooks and into
slots on the top crossmember of the carriage to keep
the forks in position.

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.

To install the forks, move the fork or carriage so the

top hook on the fork engages the top crossmember
of the carriage. Raise the carriage or lower the fork
to move the lower hook through the removal notch.
Slide the fork on the carriage so both upper and lower
hooks are engaged and the latch pin engages a notch.

1. FORK 3. LATCH PIN

2. LATCH ASSEMBLY 4. SPRING

Figure 4. Forks (Current Latch Kit)

6
4500 SRM 971
Reach Assembly Removal and Installation
1. Operate the LIFT/LOWER controls to raise the
reach assembly until the rollers of the rear frame
(reach) are above the top of the outer weldment.
2. Operate the REACH/RETRACT controls to fully
retract the forks. Install safety chains so the
forks cannot extend. Install the safety chains
around the center plates of the scissor arm weld-
ment and the reach frame. Make sure a safety
chain does not touch the mount for the hose
sheave, lift chains, chain or hose sheaves, hoses,
tubes, or fittings.
3. Move the key to the OFF position and disconnect
the battery. Remove the mast guard from the
mast assembly.
4. Use safety chains to fasten the movable member
of the mast to the outer weldment so it cannot
move.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
face protection during removal or installation.
5. Remove the snap rings, washers, thrust rollers,
and spacers.
6. Disconnect the hydraulic lines (sideshift or reach
only) at the inner frame. Put tags on the fit-
tings for correct connection during installation.
Make sure to put caps on the open fittings to keep
dirt out of the system. Disconnect the electrical
connections (reach only) at the base of the inner
frame.
NOTE: Removing the pins at the chain anchors
will disconnect the lift chains without changing the
chain adjustment. Always adjust the chains if new
lift chains or other components are installed.
Reach Assembly Removal and Installation
7. Hold the lift chains to keep them from falling.
Remove the pins in the chain anchors at the back
of the outer weldment of two-stage masts. Re-
move the pins in the chain anchors at the back
of the free-lift cylinder of three-stage masts.
Disconnect the lift chains. Carefully move the
lift chains through the sheaves and lay the lift
chains over the reach assembly.
WARNING
The inner frame assembly is heavy and can
cause an injury if it tips or falls. Make sure
the carriage assembly has stability during and
after removal. If the forks are removed, put
the carriage assembly on the floor so the load
rollers are up.
CAUTION
DO NOT damage lift chains, hoses, or electrical
cables as the carriage assembly is lifted out of
the mast weldment.
8. Carefully lift the reach assembly out of the chan-
nels of the rear weldment. Carefully lower the
reach assembly to the floor.
NOTE: The reach assembly side rollers must be ad-
justed while the reach assembly is out of the mast.
Adjust the side rollers as described in Carriage or
Reach Assembly Adjustments, Adjust Side Rollers
before installing the reach assembly.
9. To install the reach assembly, reverse the re-
moval procedures. Always use new chain an-
chors when installing the lift chains. Apply
Loctite™ to the studs of the thrust rollers during
installation.
10. Adjust the reach assembly. See Adjust Reach
Cylinders, Carriage or Reach Assembly Adjust-
ments. Test the reach assembly for correct oper-
ation.
7
Carriage Load Rollers Removal and Installation 4500 SRM 971

Carriage Load Rollers Removal and Installation

For the following procedures, refer to Figure 5 and
Figure 6.
1. Remove the reach assembly from the mast as-
sembly to remove and install the carriage load
rollers. See Reach Assembly Removal and Instal-
lation.
2. Remove the jam nuts and setscrews for the load
rollers.
4. On three-stage masts, remove the safety chains
installed in Step 4. Lower the reach assembly
for access to the chain anchors at the back of the
free-lift cylinder. Use safety chains to fasten the
movable member of the mast to the outer weld-
ment so it cannot move. Move the key to the OFF
position and disconnect the battery.

3. If necessary, replace the wear plugs by pushing

at the back of the wear plug.

1. LOAD ROLLER WITH SNAP RING REMOVED

2. PRY BAR
3. MAST, REACH, OR CARRIAGE
4. SIDE ROLLER

Figure 6. Removing Load Roller

5. Install lifting eyes in the reach assembly for

1. LOAD ROLLER 6. STUB SHAFT
2. WEAR PLUG 7. MAST, REACH, chains or slings. Fasten chains or slings to the
3. SNAP RING OR CARRIAGE reach assembly so the reach assembly cannot
4. SETSCREW CHANNEL tip as it is removed from the mast weldment.
5. JAM NUT Fasten the chains to the lifting eyes. Use the
crane to raise the reach assembly so the lift
Figure 5. Load Roller and Wear Plug Assembly
chains become loose.

WARNING
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
the lift chains, hoses, and cables as they are re-
moved. Use wire to temporarily connect the
ends of the lift chains, hoses, or cable to the
masts.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
face protection during removal or installation.

8
4500 SRM 971
6. Remove the snap rings from the stub shaft for the
load roller.
7. Use a pry bar to remove the load roller from the
stub shaft for the load roller. See Figure 6.
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.
Side Rollers Disassembly and Assembly
1. Remove the reach assembly from the mast to re-
place the side rollers.
2. Remove the capscrews that fasten the side roller
bracket.
NOTE: Observe the position of the shims.
NOTE: Correct placement of shims is critical for the
operation of the reach mechanism. Unless the shims
are installed correctly, the reach mechanism will not
operate.
Reach Assembly Repair
NOTE: Most repairs of the reach assembly can be
done without removing the reach assembly from
the mast. These repair procedures require that the
reach assembly is installed in the mast and the
scissor arms are fully extended.
WARNING
The reach assembly can fall or tip easily and
cause an injury when not installed in the mast.
If the reach assembly cannot be installed in a
mast during repair, make sure the rear frame
is fastened to a support that cannot move. The
rear frame must be in the same position as it is
in the mast. The rear frame must also be fas-
tened so it cannot move on the support. The
support must be strong enough to allow full ex-
tension of the reach assembly without tipping.
Reach Assembly Repair
9. Install the reach assembly. See Reach Assembly
Removal and Installation.
10. Adjust the reach assembly. See Adjust Reach
Cylinders in Carriage or Reach Assembly Adjust-
ments.
3. Inspect and replace all damaged or worn parts.
4. Reverse the procedure to install the side rollers.
See Figure 6. Adjust the carriage side rollers dur-
ing assembly. See Carriage or Reach Assembly
Adjustments.
NOTE: To remove and replace load rollers, wear
plugs, weldments, or lift cylinders, it is necessary to
remove the two-stage mast assembly from the truck.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic lines of the system until the oil for the
system is cool.
CAUTION
Make sure the lift truck is in a location that is
level and has access to a crane or other lifting
device before doing any repairs on the reach
carriage.
It is usually not necessary to completely disassemble
the reach assembly. Do only the steps of the proce-
dures necessary to make the required repairs.
9
Reach Assembly Outer Frame 4500 SRM 971

Reach Assembly Outer Frame

For the following procedures refer to Figure 7, Fig- Move the outer frame away from the lift truck
ure 8, and Figure 9. and place it face down on the floor.

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.

NOTE: Use safety chains on the rear frame and mast

weldments to keep the reach assembly and mast
weldments from moving. Install the safety chains as
described in Safety Procedures When Working Near
Mast in this section.

NOTE: Make sure that the reach assembly is in the

fully extended position. The outer frame should be
removed with the forks removed.

1. Remove the forks as described in Fork Replace-

ment.

2. Remove the sideshift cylinder as described in

Sideshift Cylinder, Remove. 1. REAR FRAME OF REACH ASSEMBLY
2. LOAD BEARING
3. Extend the reach fully and install blocks and 3. WOOD BLOCK
clamps inside the channels of the rear frame to 4. CLAMP
make sure the load bearings cannot move in the
channel. See Figure 7. Figure 7. Typical Blocks and Clamps
Installation
4. Tag and disconnect the hydraulic lines at the bot-
tom of the rear frame. Cap or plug the hydraulic DISASSEMBLE
lines and valve ports to prevent dirt from enter-
ing the system. Make note of the location of all The numbers in the parenthesis in the following pro-
cable ties for replacement during installation. cedures refer to item numbers in Figure 9.

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

1. RETAINER 8. PIVOT PIN

2. LOCKWASHER 9. BUSHING
3. CAPSCREW 10. BUSHING
4. PIN 11. TILT CYLINDER
5. CAPSCREW 12. TILTING FRAME
6. TRUNNION CAP 13. CAPSCREW
7. FIXED FRAME 14. CAPSCREW

Figure 8. Outer Frame Without Sideshifter

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).

10. Remove tilting frame (18).

11. Remove (13 through 17) only if needed for ser-

vice.

11
Reach Assembly Outer Frame 4500 SRM 971

1. WEAR STRIP 10. FIXED FRAME 19. WEAR STRIP

2. WEAR STRIP 11. TRUNNION CAP 20. NUT
3. WEAR STRIP 12. CAPSCREW 21. MOBILE FRAME
4. WASHER 13. ROD 22. CAPSCREW
5. LOCKWASHER 14. WIPER 23. BRACKET
6. CAPSCREW 15. SEAL 24. CAPSCREW
7. TILT CYLINDER 16. SLEEVE 25. PIN
8. PIVOT PIN 17. SEAL 26. BUSHING
9. BUSHING 18. TILTING FRAME 27. LUBE FITTING

Figure 9. Outer Frame With Sideshifter

CLEAN AND INSPECT CAUTION

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
Do NOT use steam to clean the load bearings.
Do not use compressed air on the bearings.
The bearings are sealed and permanently lu-
bricated. The air can force the lubricant out of
the bearings.
Clean all of the parts of the outer frame with solvent.
Dry the parts with compressed air. Inspect the parts
of the outer frame for damage and wear. Replace all
bushings.

12
4500 SRM 971
ASSEMBLE
1. To assemble, reverse the removal procedure.
2. If removed, install the hydraulic hoses for the tilt
and sideshift cylinder. Always use new O-rings
on the O-ring fittings.
INSTALL
WARNING
The points between the scissor arms and the
outer frame is a pinch point and can cause an
injury. Do NOT put any part of your body be-
tween these assemblies. Use a screwdriver or
other tool to move the bearing blocks or assem-
blies into the correct positions.
1. Use multipurpose grease to lubricate the bush-
ings on the inner and outer scissor arms. Use
multipurpose grease to lube the bottom bearings
in the channel at the bottom of the outer frame.
2. Use a crane to lift the outer frame. Align the
outer frame with the outer scissor arms. Install
the pivot pins that retain the inner scissor arms
to the outer frame.
3. Install the brackets and hardware to retain the
pivot pins.
NOTE: The reach assembly must be installed on the
mast before starting Step 4.
4. After all hydraulic lines are connected, operate
the functions to check for leaks and correct oper-
ation. Remove the air from the system and ad-
just the stroke of the tilt cylinder as described in
Carriage or Reach Assembly Adjustments.
5. If necessary, install the forks and load backrest
as described in Fork Replacement and Load
Backrest Removal and Installation.
REMOVE WITHOUT SIDESHIFTER
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 that
the load bearings cannot move in the channel.
See Figure 7.
Reach Assembly Outer Frame
CAUTION
Do NOT use steam to clean the load bearings.
Do not use compressed air on the bearings.
The bearings are sealed and permanently lu-
bricated. The air can force the lubricant out of
the bearings.
NOTE: Use safety chains on the rear frame and mast
weldments to keep the reach assembly and mast
weldments from moving. Install the safety chains as
described in Safety Procedures When Working Near
Mast in this section.
1. If necessary, remove the load backrest as de-
scribed in Load Backrest Removal and Installa-
tion.
2. If necessary, remove the forks as described in
Fork Replacement.
3. Install labels for correct connection during in-
stallation and remove the hoses at the top of the
outer frame. For units without sideshift, see Fig-
ure 8. For units with sideshift, see Figure 9.
Make a note of the location of all cable ties for
correct installation of new cable ties during in-
stallation. Install caps on the hydraulic lines of
the selector valve to prevent dirt from entering
the system.
WARNING
The points between the scissor arms and the
outer frame are pinch points and can cause
an injury. Do NOT put your finger in the hole
when you remove the pins. Use the brass drift
to remove the pins.
WARNING
The outer frame is heavy and can tip forward
and cause an injury when removed from the
scissor arms. Tipping is even more possible if
the forks or outer frame are installed. Make
sure to install the chains or slings between the
crane and outer frame to prevent tipping.
4. Use a crane as a support for the outer frame. Use
a brass drift to remove the pivot pin that fas-
tens the outer frame to the top ends of the scissor
arms.
13
Reach Assembly Outer Frame
CAUTION
Do not let the load bearings or shims fall off the
scissor arms.
5. Carefully move the top of the outer frame away
from the scissor arms. Slowly lower the outer
frame until the load bearings at the bottom of the
scissor arms are out of the frame channels. Move
the outer frame away from the scissor arms. Put
the outer frame on the ground so that the scissor
side is down.
NOTE: Install labels for each set of shims and the
load bearing for correct installation during installa-
tion of the outer frame. When new load bearings are
installed, the shim arrangement will normally be the
same or similar.
NOTE: Correct placement of shims is critical for the
operation of the reach mechanism. Unless the shims
are installed correctly the reach mechanism will not
operate.
DISASSEMBLE WITHOUT SIDESHIFTER
NOTE: The bearings for the outer frame are normally
removed and installed with the outer frame. The
selector valve for the tilt/sideshift functions is also
installed on the outer frame. Plugs are installed at
the ports for the sideshift cylinder and the solenoids.
The tilt pivot assembly is also installed on the outer
frame.
1. Remove the tilt cylinder and tilt pivot assemblies
as described in Tilt Cylinder.
2. Remove the solenoid valve body and hose guide.
Disassemble the selector valve as described in
Tilt/Sideshift Selector Valve Repair, Disassem-
ble.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
CAUTION
Do NOT use steam to clean the load bearings.
Do not use compressed air on the bearings.
14
4500 SRM 971
The bearings are sealed and permanently lu-
bricated. The air can force the lubricant out of
the bearings.
NOTE: Inspect the load bearings of the scissor arms
for wear or damage. If necessary, replace the load
bearings before installing the outer frame.
Clean all parts of the outer frame with solvent. Dry
the parts with compressed air. Inspect the parts of
the outer frame for damage and wear.
ASSEMBLE WITHOUT SIDESHIFTER
For the following procedures, see Figure 9.
NOTE: The bearings for the outer frame are normally
removed and installed with the outer frame. The se-
lector valve is installed on the outer frame.
1. If removed, install the solenoid valve on the outer
frame.
2. To assemble, reverse the removal procedure.
INSTALL WITHOUT SIDESHIFTER
For the following procedures, see Figure 9.
NOTE: Make all repairs for the scissor arm assembly
before installing the outer frame. See Single-Reach
Scissor Arms and Double-Reach Scissor Arms to re-
pair the scissor arm assembly. If necessary, install
new load bearings using the same shims as marked
during removal of the outer frame. When new load
bearings are installed, the shim arrangement will
normally be the same or similar.
NOTE: The outer frame can be installed with the
forks installed.
WARNING
The outer frame is heavy and can cause an
injury during installation. NEVER put any
part of your body between the outer frame and
the scissor arm assembly. Tipping is even more
possible if the forks are installed. Make sure to
install the chains or slings between the crane
and outer frame to prevent tipping.
1. Use a crane as a support for the outer frame.
Move the outer frame into the approximate posi-
tion for installation on the scissor arm assembly.
4500 SRM 971
CAUTION
Do not let the load bearings or shims fall off the
scissor arms.
2. Make sure the shims and load bearings are
installed in the correct positions on the scissor
arms. If necessary, use tape to keep the load
bearings on the scissor arms. Do not let the load
bearings fall during installation of the outer
frame.
NOTE: Correct placement of shims is critical for the
operation of the reach mechanism. Unless the shims
are installed correctly, the reach mechanism will not
operate.
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 that
the load bearings cannot move in the channel.
See Figure 7.
CAUTION
Do NOT operate any functions if the outer
frame has been removed. Hydraulic oil can
come out of the hoses.
NOTE: Another installation method for the outer
frame is to raise the scissor arms and rear frame as a
unit. Operate the lift system of the lift truck to raise
the scissor arms and rear frame above the outer
frame. Use the crane and a bar to align the channels
of the outer frame under the load bearings of the
scissor arms. Tilt the outer frame forward for clear-
ance. Have another person slowly lower the scissor
assembly so the load bearings are in the channels.
Tilt the outer frame to align the scissor arms for
installation of the pins and retaining brackets.
NOTE: Use safety chains on the rear frame and mast
weldments to keep the rear frame and mast weld-
ments from moving. Install the safety chains as de-
scribed in Safety Procedures When Working Near
Mast in this section.
Reach Assembly Outer Frame
3. Use the crane to move the outer frame for align-
ment with the scissor arms. Tip the outer frame
forward and align the channels with the load
bearings of the scissor arms. Slowly lift the outer
frame to install the load bearings in the channels.
NOTE: Another removal method for the outer frame
is to raise the scissor arms and rear frame as a unit.
All auxiliary hoses must be plugged to do this. Re-
move the safety chains and operate the lift system of
the lift truck to raise the scissor arms and rear frame
off the outer frame.
4. The load bearings must move in the channels and
have minimum clearance with free movement.
Keep the outer frame in vertical alignment and
move it up and down on the load bearings. If nec-
essary, add or remove shims for free movement
and minimum clearance.
5. Install new bushings in the top end of each scis-
sor arm. Lubricate the bushings with multipur-
pose grease. Tip the outer frame back and align
the holes for the pivot pins with the bushings in
the top scissor arms.
6. Keep the pivot pins (8) (Figure 8 and Figure 9) in
alignment to install the retaining brackets and
hardware. Install the pins and brackets.
7. Install the hoses and wire at the base of the
rear frame as marked during removal. For units
without sideshift, see Figure 8. For units with
sideshift, see Figure 9.
8. After all hydraulic lines and wire are connected,
operate the functions to check for leaks and cor-
rect operation. Remove the air from the system
as described in Carriage or Reach Assembly Ad-
justments. Install new cable ties at the original
locations for clearance of hoses and electrical ca-
bles during operation.
15
Single-Reach Scissor Arms
Single-Reach Scissor Arms
REMOVE AND DISASSEMBLE
NOTE: The reach assembly must be in the fully-ex-
tended position.
For the following procedures, see Figure 10.
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 that
the load bearings cannot move in the channel.
See Figure 7.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
face protection during removal or installation.
NOTE: Use safety chains on the rear frame and mast
weldments to keep the rear frame and mast weld-
ments from moving. Install the safety chains as de-
scribed in Safety Procedures When Working Near
Mast in this section.
1. Remove the front frame as described in Reach
Assembly Outer Frame. Remove the snap rings
and hose sheaves at the scissor arm weldment.
Fasten the cable and hoses at the rear frame so
that they are not damaged.
2. Use a crane and chains or slings as a support for
the scissor arm weldment. Do not damage the
hose sheave mount.
WARNING
The points between the scissor arms and the
front frame are pinch points and can cause an
injury. DO NOT put your finger in the hole
when you remove the pins. Use the brass drift
to remove the pins.
16
4500 SRM 971
3. Remove the shoulder bolt and nut. Use a drift to
remove the pins that fasten the rod ends of the
reach cylinders to the scissor arm weldment. Use
wire to hold each reach cylinder and their hoses
in a position for clearance as the load bearings
move. Remove the bushings from the mounts.
WARNING
The load bearings and scissor arms can move
and cause an injury when the clamps and
blocks at the load bearings are removed. Make
sure the crane is in a position to prevent move-
ment of the scissor arms as the clamps and
blocks are removed.
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
bearings with the removal notch in the rear
frame. Raise the scissor arm weldment and the
scissor arms to move the load bearings out of the
rear frame.
NOTE: Install labels for each set of shims and the
load bearing on the scissor arms for correct assembly
during installation of the scissor arms. When new
load bearings are installed, the shim arrangement
will normally be the same or similar. Remove the
load bearings and shims.
WARNING
The scissor arms are heavy and can cause an
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation.
5. Install labels for correct installation of the right-
hand or left-hand scissor arms. Carefully remove
the three capscrews, the lockwashers, the end
cap, and the two thrust washers at the center
pivot for the scissor arm and scissor arm weld-
ment. Hold the scissor arm and carefully slide it
off the bushing and stub shaft of the scissor arm
weldment. Remove the bushing and the other
two thrust washers. Remove the other scissor
arm following this same procedure.
4500 SRM 971 Single-Reach Scissor Arms

1. CAPSCREW, LOCKWASHER, 10. MAIN BUSHING 19. SCREW

AND LOCTITE® 11. THRUST WASHER 20. PIN
2. END CAP 12. SHEAVE 21. PIN ROD END
3. THRUST WASHER 13. RETAINING RING 22. LOCK NUT
4. THRUST WASHER 14. FRONT ARM LOAD BEARING 23. FITTING WITH O-RING
5. RH OUTER ARM ASSEMBLY AND SHIM 24. FITTING WITH O-RING
6. LH OUTER ARM ASSEMBLY 15. INNER ARM WELDMENT 25. RH CYLINDER ASSEMBLY
7. BEARING AND SHIM 16. BUSHING 26. LH CYLINDER ASSEMBLY
8. BEARING 17. BUSHING
9. LUBE FITTING 18. PIN

Figure 10. Single-Reach Scissor Arms

17
Single-Reach Scissor Arms
WARNING
The points between the scissor arms and the
rear frame are pinch points and can cause an
injury. DO NOT put your finger in the hole
when you remove the pins. Use a hammer and
brass punch to remove the pins.
6. Remove the pivot pins that fasten the scissor arm
weldment to the rear frame. Move the scissor
arm weldment and put it on the floor without
damaging the hose sheave mount. Remove the
bushings.
7. If necessary, install the forks and load backrest
as described in Fork Replacement and Load
Backrest Removal and Installation.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Always wear
the proper protective equipment including
eye protection and petroleum resistant gloves
when handling. Always follow the recommen-
dations of the manufacturer.
CAUTION
DO NOT use steam to clean sealed bearings.
DO NOT use compressed air or immerse in sol-
vent to clean sealed bearings. Sealed bearings
are self-contained and permanently lubri-
cated. Wipe bearings off with a clean cloth and
turn to check for proper operation. Replace if
movement is restricted or if bearing does not
turn smoothly.
Clean all of the parts of the scissor arm assembly
with solvent. Inspect the parts of the scissor arm
assembly for damage and wear. Replace all bushings
and load rollers.
ASSEMBLE AND INSTALL
NOTE: Safety chain the rear frame and mast weld-
ments to keep the rear frame and mast weldments
from moving. Install the safety chains as described
in Safety Procedures When Working Near Mast in
this section.
NOTE: Always use new bushings and load rollers.
Install a thin coat of multipurpose grease on all
18
4500 SRM 971
new bushings, all thrust washers, all shims, all stub
shafts, and all pins of the scissor arm assembly.
WARNING
The points between the scissor arms and the
rear frame are pinch points and can cause an
injury. DO NOT put your hands near pinch
points when removing the pivot pins. Use a
hammer and brass drift to remove the pivot
pins.
1. Use a crane and chains or slings as a support for
the scissor arm weldment. Do not damage the
hose sheave mount. Move the weldment into a
position of alignment to install the pins that fas-
ten the weldment to the rear frame. Install the
bushings, pins, and shoulder bolt. See Figure 15.
WARNING
The scissor arms are heavy and can cause an
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation.
2. Install two thrust washers and the bushing on
each stub shaft of the scissor arm weldment. In-
stall the right-hand and left-hand scissor arms
as shown in Figure 10. Use the other two thrust
washers, the end cap, lockwashers, and cap-
screws on each stub shaft and bushing. Tighten
the three capscrews at each end cap to 41 N•m
(30 lbf ft).
WARNING
The scissor assembly is heavy and can cause
an injury during installation. NEVER put any
part of your body between the rear frame and
the scissor arm assembly. NEVER put any part
of your body between the parts of the scissor
arm assembly.
CAUTION
DO NOT let the load rollers or shims fall off the
scissor arms.
NOTE: Correct placement of shims is critical for the
operation of the reach carriage assembly. Unless the
shims are installed correctly, the reach carriage as-
sembly will not operate.
3. Slowly raise the weldment so you can install the
shim sets and load rollers on each scissor arm
as marked during removal and disassembly. If
4500 SRM 971
necessary, use tape to keep the load rollers on the
scissor arms.
4. Use the crane to slowly raise the scissor arm
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
assembly so the load rollers move into the chan-
nels.
5. Slowly raise the scissor arm assembly to align
the mounts with the rod ends of the reach cylin-
ders. Install the bushings, pins, and shoulder
bolt to fasten the reach cylinders to the scissor
arm weldment. See Figure 15.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
Double-Reach Scissor Arms
REMOVE AND DISASSEMBLE
For the following procedures, refer to Figure 11.
NOTE: The reach assembly must be in the fully
extended position.
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 inner frame to make sure that
the load bearings cannot move in the channel.
See Figure 7.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers and wear eye and
face protection during removal or installation.
Double-Reach Scissor Arms
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers and wear eye and
face protection during removal or installation.
CAUTION
DO NOT let the load rollers or shims fall off the
scissor arms.
6. Install the shims and load rollers on the scissor
arm weldment as marked during removal and
disassembly. If necessary, use tape to keep the
load rollers on the scissor arms. Install the hoses
on the hose sheaves, and install the hose sheaves
and snap rings at the mount of the scissor arm
weldment.
NOTE: Use safety chains on the inner frame and
mast weldments to keep the inner frame and mast
weldments from moving. Install the safety chains as
described in Safety Procedures When Working Near
Mast in this section.
1. Remove the outer frame as described in Reach
Assembly Outer Frame. Remove the snap rings
and hose sheaves at the scissor arm weldments.
Fasten the cable and hoses at the inner frame so
they are not damaged.
2. Use a crane and chains or slings as a support for
the scissor arm weldment A. Make sure to install
the chains or slings so the weldment cannot slip
inside the chains or slings. Do not damage the
hose sheave mount.
3. Remove the two capscrews, lockwasher, end cap,
and two thrust washers (12 through 15, Fig-
ure 11) from the bottom pivot points of scissor
arms 1A and 2A.
19
Double-Reach Scissor Arms 4500 SRM 971

Figure 11. Double-Reach Scissor Arms

20
4500 SRM 971 Double-Reach Scissor Arms

Legend for Figure 11

1. INNER ARM WELDMENT 14. INNER ARM WELDMENT 27. FITTING WITH O-RING
2. BEARING 15. SHIM 28. EXTEND CYLINDER (RH)
3. BUSHING 16. OUTER ARM ASSEMBLY (LH) 29. FITTING WITH O-RING
4. BUSHING FRONT 30. SHEAVE
5. WASHER 17. OUTER ARM ASSEMBLY (LH) 31. RETAINING RING
6. OUTER ARM ASSEMBLY (LH) FRONT 32. SHIM
REAR 18. END CAP 33. WASHER
7. MECHANISM ARM 19. END CAP - CENTER 34. PIN
8. MAIN BUSHING 20. LOCKWASHER 35. WASHER
9. OUTER ARM ASSEMBLY (RH) 21. CAPSCREW 36. WASHER
REAR 22. BEARING 37. SCREW
10. ROD END 23. ROLLER - FRONT ARM 38. NUT
11. CYLINDER ASSEMBLY 24. WASHER 39. CABLE CLAMP
12. PIN - ROD END 25. SCREW 40. WASHER
13. LUBE FITTING 26. EXTEND CYLINDER (LH) 41. CAPSCREW
cylinders to scissor arm weldment B. Use wire to
WARNING hold each reach cylinder and hoses in a position
The scissor arms are heavy and can cause an for clearance as the load bearings move.
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation. WARNING
The load bearings and scissor arms 1B and 2B
NOTE: Install labels for correct installation of the can move and cause an injury when the clamps
right-hand or left-hand scissor arms. and blocks at the load bearings are removed.
Make sure the crane (Step 5) is in a position
4. Carefully remove the three capscrews, the lock- to prevent movement of the scissor arms as the
washers, the end cap, and the two thrust washers clamps and blocks are removed.
at the center pivot for scissor arm 1A and scis-
sor arm weldment A. Hold scissor arm 1A and 7. Carefully remove the clamps and blocks at the
slide it off the bushing and stub shaft of the scis- load bearings on the channels of the inner frame.
sor arm weldment. Remove the bushing and the Slowly move scissor arm weldment A to align the
other two thrust washers at the center pivot. Re- load bearings of scissor arms 1B and 2B with the
move the bushing and the other two thrust wash- removal notch in the inner frame. See Figure 11.
ers from the stub shaft at the end of the scissor Use the crane to move the scissor arm assembly
arm. Remove scissor arm 2A following this same so the load bearings are out of the inner frame.
procedure.
NOTE: Install labels for each set of shims and the
5. Slowly lower scissor arm weldment A so it hangs load bearing on scissor arms 1B and 2B. Install the
from the ends of scissor arms 1B and 2B. Move labels for correct assembly during installation of the
the crane and chains or slings so they are a sup- scissor arms. When new load bearings are installed,
port for the scissor arm weldment B. the shim arrangement will normally be the same or
similar. Remove the load bearings and shims.
WARNING NOTE: Correct placement of shims is critical for the
The points between the scissor arms and the in- operation of the reach mechanism. Unless the shims
ner frame are pinch points and can cause an in- are installed correctly the reach mechanism will not
jury. Do NOT put your finger in the hole when operate.
you remove the pins. Use the brass drift to re-
move the pins. 8. Carefully lower the crane so the scissor arm as-
sembly "retracts" as the ends of the scissor arms
6. Remove the shoulder bolts in the rod ends of the move down the outside of the channel. Do not
reach cylinders (Figure 15). Use a drift to remove damage the stub shafts for the load bearings.
the pins that fasten the rod ends of the reach

21
Double-Reach Scissor Arms
9. Install a safety chain between the inner frame
and scissor arm weldment B so the weldment
cannot move. Move the crane and chains or
slings so they are a support for scissor arm weld-
ment A.
10. Remove the two capscrews, lockwasher, end cap,
and two thrust washers from the top pivot point
of scissor arms 1B and 2B.
WARNING
The scissor arms are heavy and can cause an
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation.
11. Install labels for correct installation of the right-
hand or left-hand scissor arms. Carefully remove
the three capscrews, the lockwashers, the end
cap, and the two thrust washers at the center
pivot for scissor arm 1B and scissor arm weld-
ment B. Make sure the crane is the support for
scissor arm weldment A so it cannot fall. Hold
scissor arm 1B and slide it off the bushing and
stub shaft of scissor arm weldment B. Remove
the bushing and the other two thrust washers at
the center pivot. Remove the bushing and the
other two thrust washers from the stub shaft at
the end of the scissor arm. Remove scissor arm
2B following this same procedure. Move scissor
arm weldment A and put it on the floor without
damaging the hose sheave mount.
12. Use the crane and chains or slings as a support
for scissor arm weldment B so it cannot fall. Do
not damage the hose sheave mount. Carefully
remove the safety chain.
WARNING
The points between the scissor arms and the in-
ner frame are pinch points and can cause an in-
jury. Do NOT put your finger in the hole when
you remove the pins. Use the brass drift to re-
move the pins.
13. Remove the shoulder bolts and pivot pins that
fasten scissor arm weldment B to the inner
frame. Move scissor arm weldment B and put it
on the floor without damaging the hose sheave
mount. Remove the bushings.
22
4500 SRM 971
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Always wear
the proper protective equipment including
eye protection and petroleum resistant gloves
when handling. Always follow the recommen-
dations of the manufacturer.
CAUTION
DO NOT use steam to clean sealed bearings.
DO NOT use compressed air or immerse in sol-
vent to clean sealed bearings. Sealed bearings
self contained and permanently lubricated.
Wipe bearings off with a clean cloth and turn
to check for proper operation. Replace if
movement is restricted or if bearing does not
turn smoothly.
Clean all of the parts of the scissor arm assembly
with solvent. Dry the parts with compressed air. In-
spect the parts of the scissor arm assembly for dam-
age and wear. Replace all bushings and load bear-
ings.
ASSEMBLE AND INSTALL
For the following procedures, refer to Figure 11.
NOTE: Use safety chains on the inner frame and
mast weldments to keep the inner frame and mast
weldments from moving. Install the safety chains as
described in Safety Procedures When Working Near
Mast in this section.
NOTE: Always use new bushings and load bearings.
Install a thin coat of multipurpose grease on all
new bushings, all thrust washers, all shims, all stub
shafts, and all pins of the scissor arm assembly.
WARNING
The points between the scissor arms and the in-
ner frame are pinch points and can cause an in-
jury. Do NOT put your finger in the hole when
you remove the pins. Use the brass drift to re-
move the pins.
1. Use a crane and chains or slings as a support
for scissor arm weldment B. Do not damage the
hose sheave mount. Move the weldment into a
4500 SRM 971
position of alignment to install the pins that fas-
ten the weldment to the inner frame. Install the
bushings, pins, and shoulder bolts. Slowly lower
the weldment so it hangs from the pins. Remove
the crane and chains or slings.
WARNING
The scissor arms are heavy and can cause an
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation.
2. Install two thrust washers and the bushing on
each stub shaft of scissor arm weldment B. In-
stall scissor arm 2B on scissor arm weldment B.
Make sure there are two thrust washers on each
side of the scissor arm. Tighten the three cap-
screws at the end cap to 41 N•m (30 lbf ft).
3. Install two of the thrust washers and the bushing
on the stub shaft at the end pivot of scissor arm
2B.
4. Install the crane and chains or slings as a support
for scissor arm weldment A. Move the weldment
into a position of alignment to install the weld-
ment on scissor arm 2B. Install the weldment,
the other two thrust washers, the end cap, a new
lockwasher, and the two capscrews. Tighten the
two capscrews to 41 N•m (30 lbf ft).
WARNING
The scissor arms are heavy and can cause an
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation.
5. Install scissor arm 1B on scissor arm weldments
B and A. Make sure there are two thrust washers
on each side of the scissor arm at the center pivot.
Also make sure there are two thrust washers on
each side of the arm of scissor arm weldment A.
Use lockwashers at the end pivots. Tighten the
three capscrews at the center pivot to 41 N•m
(30 lbf ft). Tighten the two capscrews at the end
pivots to 41 N•m (30 lbf ft).
WARNING
The scissor arm assembly is heavy and can
cause an injury during installation. NEVER
Double-Reach Scissor Arms
put any part of your body between the inner
frame and the scissor arm assembly. NEVER
put any part of your body between the parts of
the scissor arm assembly.
CAUTION
Do not let the load bearings or shims fall off the
scissor arms.
NOTE: Correct placement of shims is critical for the
operation of the reach mechanism. Unless the shims
are installed correctly, the reach mechanism will not
operate.
6. Slowly raise the weldment so you can install the
shim sets and load bearings on scissor arms 1B
and 2B as marked during removal. If necessary,
use tape to keep the load bearings on the scissor
arms.
7. Use the crane to slowly raise scissor arm weld-
ment B by lifting weldment A to align the load
bearings with the removal notches in the inner
frame. Use the crane to move the scissor arm as-
sembly so the load bearings move into the chan-
nels.
8. Slowly raise scissor arm assembly to align the
mounts with the rod ends of the reach cylinders.
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
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation.
9. Move scissor arm weldment A for alignment and
install scissor arm 2A on scissor arm weldments
A and B. Make sure there are two thrust wash-
ers on each side of the scissor arm at the center
pivot. Tighten the three capscrews at the center
pivot to 41 N•m (30 lbf ft). Also make sure there
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).
Install scissor arm 1A using the same procedure.
23
Inner Frame Assembly
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
face protection during removal or installation.
CAUTION
Do not let the load bearings or shims fall off the
scissor arms.
Inner Frame Assembly
For the following procedures, refer to Figure 12.
NOTE: If the scissor arm assembly will be removed,
it is easier to remove while the inner frame is still in-
stalled in the mast. See Single-Reach Scissor Arms,
Remove and Disassemble or Double-Reach Scissor
Arms, Remove and Disassemble to remove the scis-
sor arm assembly.
REMOVE
NOTE: Remove the inner frame to replace the reach
assembly load rollers or side rollers. Other repairs
to the inner frame can be done without removing the
inner frame. The inner frame can be removed by re-
moving the complete reach assembly from the mast
as one assembly. The inner frame assembly can also
be removed after the scissor assembly has been re-
moved.
CAUTION
DO NOT operate any functions if the outer
frame has been removed. Hydraulic oil can
come out of the hoses.
1. If the outer frame assembly is installed, operate
the REACH/RETRACT control handle to fully re-
tract the forks. Use safety chains to fasten the
parts of the reach assembly so the forks cannot
extend.
2. Operate the LIFT/LOWER control handle to
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
NOTE: Correct placement of shims is critical for the
operation of the reach mechanism. Unless the shims
are installed correctly, the reach mechanism will not
operate.
10. Install the shims and load bearings on scissor
arm weldment A as marked during removal and
disassembly. If necessary, use tape to keep the
load bearings on the scissor arms. Install the
hoses on the hose sheaves, and install the hose
sheaves and snap rings at the mounts of the scis-
sor arm weldments.
3. Move the key to the OFF position and disconnect
the battery.
NOTE: Use safety chains on the inner frame and
mast weldments to keep the inner frame and mast
weldments from moving. Install the safety chains as
described in Safety Procedures When Working Near
Mast.
4. Use safety chains to fasten the reach assembly or
inner frame assembly and outer weldment of the
mast so that they cannot move.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
face protection during removal or installation.
Remove the snap rings, washers, thrust rollers, and
spacers. Install labels on the thrust rollers for correct
installation during installation.
5. Remove the safety chains installed in Step 4.
Lower the reach assembly or inner frame assem-
bly for access to the chain anchors of the inner
frame. Install safety chains so they support the
reach assembly or inner frame and the lift chains
become loose. Move the key to the OFF position
and disconnect the battery.
4500 SRM 971 Inner Frame Assembly

Figure 12. Inner Frame

25
Inner Frame Assembly 4500 SRM 971

Legend for Figure 12

1. INNER FRAME WELDMENT 25. O-RING FITTING
2. BUSHING 26. O-RING FITTING
3. VALVE BODY 27. CAPSCREW
4. BRACKET 28. BRACKET
5. SHIM 29. LOCKWASHER
6. SIDE ROLLER 30. CAPSCREW
7. SHIM 31. CAPSCREW
8. LOAD ROLLER 32. SHEAVE
9. RETAINING RING 33. SHIM
10. RETAINING RING 34. SHIM
11. LUBE FITTING 35. RETAINING RING
12. SIDE ROLLER ASSEMBLY 36. WASHER
13. LOCKWASHER 37. CAPSCREW
14. MANIFOLD BLOCK 38. LOCKWASHER
15. WEAR PLUG 39. CABLE CLAMP
16. SCREW 40. WASHER
17. NUT 41. CAPSCREW
18. FITTING 42. CAPSCREW
19. NUT 43. WASHER
20. HOSE ASSEMBLY 44. PLATE
21. HOSE ASSEMBLY 45. CAPSCREW
22. HOSE ASSEMBLY 46. NUT
23. HOSE ASSEMBLY 47. NUT
24. CABLE CLAMP

NOTE: Removing the pins at the chain anchors
will disconnect the lift chains without changing the
chain adjustment. Always adjust the chains if new
lift chains or other components are installed.
WARNING
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
the lift chains, hoses, and cables as they are re-
moved. Use wire to temporarily connect the
ends of the lift chains, hoses, or cable to the
masts.
6. Hold the lift chains to keep them from falling and
remove the pins in the chain anchors of the inner
frame. Carefully fasten the ends of the lift chains
so they do not move over the chain sheaves.
WARNING
The reach assembly or inner frame assembly is
heavy and can cause an injury if it tips or falls.
Make sure the reach assembly is stable during
and after removal.
at the manifold block. Put tags on the fittings
for correct connection during installation. Make
sure to put caps on the open fittings and ports
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
frame.
CAUTION
DO NOT damage lift chains, hoses, or electrical
cables as the carriage assembly is lifted out of
the mast weldment.
Carefully lift the reach assembly or inner frame as-
sembly out of the rear weldment. Carefully lower the
reach assembly or inner frame assembly to the floor.
WARNING
Make sure that the reach assembly is stable
and cannot fall to cause an injury. Make sure
the safety chains are still installed (Step 1). If
the forks are removed, put the reach assembly
(or inner frame assembly) on the floor so that
the mast side is on top.

7. Install lifting eyes in the reach assembly in-
ner frame assembly for chains or slings. Fasten
chains or slings to the lifting eyes. Use a crane to
raise the reach assembly or inner frame assem-
bly high enough to disconnect the hydraulic lines
8. The side rollers must be adjusted while the reach
assembly is out of the mast channels. Adjust the
side rollers as described in Adjust Side Rollers,
Carriage or Reach Assembly Adjustments.

26
4500 SRM 971 Inner Frame Assembly

DISASSEMBLE enough force to cause an injury. Always use

NOTE: It is usually not necessary to remove all the
parts of the inner frame assembly. Remove only the
necessary parts to do the repair. The thrust rollers
are removed during removal of the inner frame as-
sembly.
1. If necessary, remove the reach cylinders. See
Reach Cylinders.
the correct snap ring pliers, and wear eye and
face protection during removal or installation.
4. Remove the snap rings from the stub shaft for the
load roller.
5. Use a pry bar to remove the load roller from the
stub shaft for the load roller. See Figure 14.

2. Remove the jam nuts and setscrews for the wear

plugs.

3. If necessary, replace the wear plugs by pushing

at the back of the wear plug. See Figure 13.

1. LOAD ROLLER WITH SNAP RING REMOVED

2. PRY BAR
3. MAST OR CARRIAGE (CARRIAGE SHOWN)

Figure 14. Removing Load Roller

6. Remove the capscrews that fasten the side roller

brackets. Remove the side rollers and shim sets.
Install labels for correct installation of the shim
1. LOAD ROLLER 5. JAM NUT sets in the same positions. When the new side
2. WEAR PLUG 6. STUB SHAFT rollers are installed, the shim arrangement will
3. SNAP RING 7. INNER FRAME normally be the same or similar.
4. SETSCREW
NOTE: Correct placement of shims is critical for the
Figure 13. Load Roller and Wear Plug Assembly operation of the reach mechanism. Unless the shims
are installed correctly, the reach mechanism will not
WARNING operate.
Be careful when removing or installing snap 7. If necessary, remove the hydraulic lines and
rings. These snap rings are large and can hoses at the base of the inner frame.
come loose during removal or installation with

27
Inner Frame Assembly
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Always wear
the proper protective equipment including
eye protection and petroleum resistant gloves
when handling. Always follow the recommen-
dations of the manufacturer.
CAUTION
DO NOT use steam to clean sealed bearings.
DO NOT use compressed air or immerse in sol-
vent to clean sealed bearings. Sealed bearings
self-contained and permanently lubricated.
Wipe bearings off with a clean cloth and turn
to check for proper operation. Replace if
movement is restricted or if bearing does not
turn smoothly.
Clean all of the parts of the inner frame with solvent.
Dry the parts with compressed air. Inspect the parts
of the inner frame for damage and wear. Inspect all
rollers for cracks, flat spots, or bearings that do not
turn freely. Replace any roller that shows wear or is
damaged.
ASSEMBLE
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
face protection during removal or installation.
WARNING
The inner frame assembly is heavy and can
cause an injury if it tips or falls. Make sure
the inner frame assembly is stable before in-
stalling any parts.
NOTE: If the scissor arms are not installed, install
the inner frame in the mast before installing the scis-
sor arm assembly. See Install.
1. Install all parts that were removed. Install all
shim sets in the original positions as marked dur-
ing removal. Use new snap rings. Install the load
28
4500 SRM 971
rollers on the inner frame. Install the shims at
each location as marked during disassembly.
2. Adjust the carriage side rollers during assembly.
See Adjust Side Rollers, Carriage or Reach As-
sembly Adjustments.
- Install the side rollers as removed. Measure
and adjust the side rollers as necessary. See Car-
riage or Reach Assembly Adjustments.
3. If the rod ends of the reach cylinders were re-
moved, the reach cylinders must be adjusted
after the reach assembly is completely assem-
bled and installed in the mast. See Adjust Reach
Cylinders, Carriage or Reach Assembly Adjust-
ments.
INSTALL
NOTE: If the scissor arm assembly will be installed
in the inner frame, it is easier to install after the in-
ner frame is installed in the mast. See Single-Reach
Scissor Arms or Double-Reach Scissor Arms to install
the scissor arm assembly.
1. The side rollers must be adjusted while the reach
assembly is out of the mast channels. Adjust the
side rollers as described in Adjust Side Rollers,
Carriage or Reach Assembly Adjustments.
Install lifting eyes in the reach assembly or in-
ner frame assembly for chains or slings. Fasten
chains or slings to the lifting eyes. Use a crane to
raise the reach assembly or inner frame assem-
bly to align the load rollers with the channels of
the inner weldment of the mast. Carefully lower
the inner frame assembly into the mast channels.
Continue to lower the assembly to a position to
connect the hydraulic lines at the manifold block.
NOTE: Use safety chains on the inner frame and
mast weldments to keep the inner frame and mast
weldments from moving. Install the safety chains as
described in in this section.
2. Use safety chains to fasten the carriage or inner
frame assembly and inner weldment of the mast
so that they cannot move.
4500 SRM 971 Reach Cylinders

Install the thrust rollers as marked during removal.

WARNING
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
the lift chains, hoses, and cables as they are re-
moved. Use wire to temporarily connect the
ends of the lift chains, hoses, or cable to the
masts.
If the thrust rollers are replaced, install the correct
size [74, 76, or 78 mm (2.88, 2.96, or 3.04 in.) OD]
thrust rollers. See Adjust Thrust Rollers, Carriage
or Reach Assembly Adjustments at the end of this
section.
5. Remove the safety chains and the lifting eyes
from the carriage or inner frame.

3. Connect the hydraulic hoses from the mast to the

manifold block as marked during removal. Con-
nect the electrical cable at the base of the inner
frame.
NOTE: The lift chains must be adjusted if the nuts of
the chain anchors at the mast were removed. Adjust
the lift chains as described in Carriage or Reach As-
sembly Adjustments.
4. Use new cotter pins and install the lift chains on
the chain anchors of the inner frame.
CAUTION
DO NOT operate any functions if the outer
frame has been removed. Hydraulic oil can
come out of the hoses.
6. After all hydraulic lines are connected, operate
the functions to check for leaks and correct op-
eration. Remove the air from the system as de-
scribed in Carriage or Reach Assembly Adjust-
ments.

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.

NOTE: Fully extend the reach mechanism. If the

scissor arms and front frame are installed, use
clamps and blocks to prevent the scissor arms from
retracting. Install the clamps and blocks on the
channels of the inner frame and the front frame.
Install the blocks under the load bearings. See
Figure 15.

Tighten the clamps so the blocks cannot move.

1. Operate the LIFT/LOWER control handle to

raise the reach assembly for access to the reach
cylinders from the operator compartment of the
lift truck.
1. INNER FRAME 5. REACH CYLINDER
2. BUSHING 6. ROD END
3. PIN 7. SCISSOR ARM
4. SHOULDER BOLT
AND NUT

Figure 15. Reach Cylinder Mounts

29
Reach Cylinders 4500 SRM 971

2. Install labels on the hydraulic lines for correct
connection during installation. Disconnect the
hydraulic lines at the reach cylinders. Install
caps on the hydraulic lines and cylinder ports to
prevent dirt from entering the system. Check the
hydraulic fittings for damage. Replace as neces-
sary.
3. Remove shoulder bolts and pins from each end of
the cylinder.
fasten each end of cylinder to the frame. Remove
the other reach cylinder using the same proce-
dure.
7. Remove the bushings from each mount of the in-
ner frame and each scissor arm.
DISASSEMBLE
For the following procedures, refer to Figure 16.

4. Remove cylinders. NOTE: In most instances, it is more cost effective to

simply replace the reach cylinders with a whole new
NOTE: If disassembly of a reach cylinder is neces- unit than to repair them.
sary, loosen the retainer in the cylinder shell while
the cylinder is installed in the reach assembly. It NOTE: Take care not to scratch the cylinder rod dur-
is possible that reach adjustments will not be nec- ing the repair process.
essary. If disassembly is NOT necessary and the rod
1. Loosen the capscrew at the rod end. Hold the rod
ends will NOT be replaced, mark the reach cylinders
to keep it from turning and remove the rod end
for installation in the same position.
from the cylinder rod.
5. Mark each rod end of the reach cylinders for cor-
2. Carefully remove the retainer and rod assembly
rect installation. The RH and LH reach cylinders
from the cylinder shell.
are not interchangeable.
3. Carefully remove the parts of the rod assembly.
6. Have a helper hold the reach cylinder to keep it
from falling. Use a drift to remove the pins that

1. LOCK NUT 7. O-RING

2. PISTON RINGS 8. BACKUP RING
3. PISTON PACKING 9. ROD SEAL
4. PISTON 10. WIPER RING
5. CYLINDER TUBE 11. PACKING GLAND
6. PISTON ROD

Figure 16. Reach Cylinder Parts

30
4500 SRM 971
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
CAUTION
DO NOT operate any functions if the front
frame has been removed. Hydraulic oil can
come out of the hoses.
Clean all of the parts of the reach cylinder with sol-
vent. Dry the parts with compressed air. Inspect the
parts of the reach cylinder for damage and wear. Re-
place all parts that are worn or damaged. Replace all
parts included in the cylinder repair kit.
ASSEMBLE
1. Install the parts of the rod assembly as shown
in Figure 16. Make sure to replace all seals and
other parts included in the cylinder repair kit.
Use Loctite® No. 242 on the rod and nut for the
piston. Install the piston seal and piston rings.
If removed, tighten the piston nut to 95 N•m
(70 lbf ft).
CAUTION
DO NOT cut or damage seals during installa-
tion. Be especially careful when moving seals
across threads or edges of parts. Install tape
over the rod threads to protect the seals.
2. Install the rod seal, backup ring, O-ring, and
wiper on the retainer. Put a thin coat of hydraulic
fluid on the inside of the shell and all parts of the
piston and rod. Use O-ring lubricant and install
the rod assembly in the shell. Carefully install
the retainer on the rod and in the shell. Use a
spanner wrench to tighten the retainer to 129 to
142 N•m (95 to 105 lbf ft).
INSTALL
NOTE: It may be necessary to loosen the hydraulic
fittings to allow movement of the rods. The rods need
to move for correct alignment at the mounts for the
scissor arms.
Reach Cylinders
1. If removed, install the correct rod end on the rod
as marked during removal. Install new bushings
in all four mounts for the reach cylinders. Lubri-
cate the bushings with multipurpose grease.
2. Align the anchor end of the cylinders on the cylin-
der mount of the inner frame of the reach assem-
bly. See Figure 15. Install the mount pins and
shoulder bolt and nut to fasten the cylinders to
the inner frame. Use a hammer with a soft metal
(brass or copper) or a plastic face to install the
pins.
3. Connect the hydraulic lines to the reach cylin-
ders as marked during removal. Always use new
O-rings on the O-ring fittings.
4. Hold each reach cylinder to align the rod end to
the scissor arm mounts. Use a hammer with a
soft metal (brass or copper) or a plastic face to in-
stall the mount pins to fasten the rod end of each
reach cylinder. Align the holes for the shoulder
bolt and nut. Install the shoulder bolt and nut.
NOTE: If the rod ends were not removed and the
cylinders are installed in the same positions, reach
adjustment is normally not necessary.
5. If the rod ends were NOT removed, install the
shoulder bolt and nut at each mount pin. If the
rod ends were removed, reach adjustment IS nec-
essary. Make sure the adjustment is complete be-
fore installing the shoulder bolt and nut.
6. Make sure the hydraulic fittings are tightened,
and remove the clamps and blocks under the load
bearings.
CAUTION
DO NOT operate any functions if the front
frame has been removed. Hydraulic oil can
come out of the hoses.
7. Operate the REACH control lever to operate the
function to check for leaks and correct operation.
8. Remove the air from the system and adjust the
stroke of each reach cylinder as described in Car-
riage or Reach Assembly Adjustments.
31
Tilt Cylinder
Tilt Cylinder
REMOVE
Refer to Reach Assembly Outer Frame, Assemble in
this section.
NOTE: If the outer frame is installed on the scissor
arms, fully extend the reach mechanism. Use clamps
and blocks to prevent the scissor arms from retract-
ing. Install the clamps and blocks on the channels
of the inner frame and the outer frame. Install the
clamps and blocks under the load bearings. See Fig-
ure 7. Tighten the clamps so the blocks cannot move.
CLEAN, INSPECT, AND REPAIR
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
32
4500 SRM 971
Cylinder components can be disassembled to repair
the seals if damaged. Consult the Parts Manual to
select the proper cylinder repair kit for your truck.
Replace all parts included in the cylinder repair kit.
Seals and O-rings may become brittle and lose elas-
ticity over time even when the old parts show no ap-
parent damage. See Figure 17. Clean all of the parts
of the tilt cylinder with solvent. Dry the parts with
compressed air. Inspect the parts of the tilt cylinder
for damage and wear. Replace all parts that are worn
or damaged. Replace all parts included in the cylin-
der repair kit. Use hydraulic oil to lubricate the new
seals and O-rings when installing. Be careful not to
damage new seals and O-rings when installing.
INSTALL
Install tilt cylinder into front frame as removed. Re-
fer to Reach Assembly Outer Frame, Assemble in this
section.
4500 SRM 971 Tilt Cylinder

1. NUT 8. WIPER RING

2. TILTING FRAME 9. SEAL
3. WASHER 10. ROD
4. WASHER 11. BLOCK
5. SEAL 12. BUSHING
6. PISTON 13. FRONT FRAME
7. SEAL

Figure 17. Tilt Cylinder

33
Reach/Tilt Selector Valve
Sideshift Cylinder
REMOVE
The sideshift cylinder is not removable, see Reach
Assembly Outer Frame, Remove, part is integral to
tilting frame.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
Reach/Tilt Selector Valve
REMOVE
WARNING
There are pinch points on the mast and reach
assembly that can cause an injury. Use safety
chains on the inner frame and mast weldments
to keep the inner frame and mast weldments
from moving. Install the safety chains as de-
scribed in Safety Procedures When Working
Near Mast.
WARNING
The outer frame is heavy and can cause an
injury if it tips or falls. If the frame is not
installed, make sure the frame is stable. If the
frame is NOT on the floor with the fork side
down for stability, use a crane and chains to
raise the frame. Install a solid 100 mm (4 in.)
block under each fork heel and near each fork
tip. Lower the frame so the forks are on the
blocks and install a capacity load on the forks.
You can also use safety chains to fasten the
frame to an object that cannot tip or fall.
WARNING
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
the lift chains, hoses, and cables as they are re-
moved. Use wire to temporarily connect the
ends of the lift chains, hoses, or cable to the
masts.
34
4500 SRM 971
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
Clean all of the parts of the sideshift cylinder with
solvent. Dry the parts with compressed air. Inspect
the parts of the sideshift cylinder for damage and
wear. Replace all parts that are worn or damaged.
Replace all parts included in the cylinder repair kit.
WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers and wear eye and
face protection during removal or installation.
1. Remove forks as shown in Fork Replacement.
2. Remove load backrest as shown in Load Backrest
Removal and Installation.
3. Remove all hoses from block, being careful to col-
lect any spilled oil.
4. Remove wire assembly.
5. Remove cover plate.
6. Remove selector valve from cover.
DISASSEMBLE
1. Remove all fittings from the selector valve.
2. If necessary, carefully remove the solenoids,
check valves, relief valve, and spools.
3. Remove and discard all O-rings from the valve
and fitting parts.
4500 SRM 971
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
Clean all of the parts of the selector valve with sol-
vent. Dry the parts with compressed air. Inspect the
parts of the selector valve for damage and wear. Re-
place all parts that are worn or damaged. Replace all
O-rings.
ASSEMBLE
1. Use O-ring lubricant and install new O-rings on
the parts of the selector valve.
2. Install the parts in the valve block as shown in
Figure 2.
Carriage or Reach Assembly Adjustments
ADJUST WEAR PLUG
Adjust the wear plugs as follows:
1. Fully lower the reach assembly and make sure
the lift chains are the support for the reach as-
sembly. If the lift chains are loose, operate the
system to raise the reach assembly until the lift
chains are the support. See Figure 18.
WARNING
NEVER loosen the wear plugs if the carriage
or reach assembly does not move freely during
checks after an adjustment. The reach assem-
bly can suddenly move and cause an injury.
Raise the reach assembly, move the key to
the OFF position, and install safety chains as
described in Safety Procedures When Working
Near Mast in this section.
2. Loosen the jam nut on the wear plug using the
special tool available from your lift truck dealer.
See Figure 13.
3. Adjust the wear plugs to attain zero clearance be-
tween the wear plug and the weldment channel.
Carriage or Reach Assembly Adjustments
INSTALL
1. Installation is done by reversing the removal
process.
2. Hold the selector valve in the correct position on
the frame and install the two capscrews and lock-
washers.
3. Connect the hydraulic lines as marked during
disassembly. Always use new O-rings on the
O-ring fittings. Install new cable ties at the
original locations for clearance of hoses and
electrical cables during operation.
CAUTION
Do NOT operate any functions if the outer
frame has been removed. Hydraulic oil can
come out of the hoses.
4. Remove the air from the system as described in
Carriage or Reach Assembly Adjustments.
4. Adjust the clearance to approximately 0.5 mm
(0.02 in.) by turning the adjustment handle 1/3
to 1/2 turn counterclockwise. Keep the clear-
ance between the reach assembly and mast weld-
ments equal on both sides. Keep the reach as-
sembly parallel to the mast weldment.
5. Tighten each jam nut without moving the
setscrew.
6. If necessary, carefully remove the safety chains.
Raise and lower the reach assembly without
a load. Check that there is minimum clear-
ance with free movement. If the carriage does
not move smoothly during lowering, follow the
WARNING and adjust the wear plugs equally
for more clearance.
7. Raise and lower the reach assembly with a load.
Check that there is minimum clearance with free
movement. If the reach assembly does not move
smoothly during lowering, follow the WARNING
and adjust the wear plugs equally for more clear-
ance.
35
Carriage or Reach Assembly Adjustments 4500 SRM 971

A. TWO-STAGE B. THREE-STAGE MAIN LIFT

1. INNER WELDMENT 7. SNAP RING
2. CHAIN SHEAVE 8. OUTER WELDMENT
3. LIFT CHAIN 9. ADJUSTMENT NUT
4. COTTER PIN 10. REACH ASSEMBLY
5. ANCHOR PIN 11. TYPICAL FIXED ANCHOR
6. CHAIN ANCHOR 12. INTERMEDIATE WELDMENT

Figure 18. Typical Lift Chain Adjustment

ADJUST SIDE ROLLERS
1. Use a feeler gauge to measure clearance between
the side roller and mast channel (see Figure 19).
If clearance is not between 0.5 to 1.0 mm (0.02 to
0.04 in.), remove the reach assembly.
2. If necessary, remove the reach assembly from the
mast. See Reach Assembly Removal and Instal-
lation.
3. Add or remove shims under the side rollers to
reduce the clearance between the rollers to 0.5
to 1.0 mm (0.02 to 0.04 in.) per side.
NOTE: Make sure the total shim thickness for each
side is the same for each set of side rollers. Equal
shim thickness will keep the clearance equal be-
tween the reach assembly and mast weldment on
both sides.
4. Install the reach assembly. See Reach Assembly
Removal and Installation or Inner Frame Assem-
bly, Install.
5. Verify free travel of mechanism in mast. If reach
assembly binds, remove an equal amount of
shims from each side for free travel.

36
4500 SRM 971 Carriage or Reach Assembly Adjustments

2. Measure and record the distance between the in-

side faces of the thrust rollers of the reach assem-
bly. See B of Figure 20.

Figure 20. Reach Assembly Side and Thrust

Roller Widths

3. If the distance B is more than 4 mm (0.16 in.)

less than the maximum measurement of Step 1,
install smaller size thrust rollers. If the distance
B is more than 4 mm (0.16 in.) greater than
the maximum measurement of Step 1, install
larger size thrust rollers. Install the same size
rollers on each side for a minimum clearance
at the maximum measurement point (Step 1).
Thrust rollers have outside diameters of 74, 76,
or 78 mm (2.88, 2.96, or 3.04 in.).
Figure 19. Measuring Channel Width

ADJUST THRUST ROLLERS

1. Measure the width between the outside edges of
the inner weldment in several places. See Fig-
ure 19. Make a note of the location and the value
of the maximum measurement.

37
Carriage or Reach Assembly Adjustments
ADJUST REACH CYLINDERS
NOTE: The reach cylinders must be adjusted if either
reach cylinder has been replaced or the rod ends have
been removed. Adjustment is also necessary if major
parts of the reach mechanism have been replaced.
The reach mechanism must be adjusted so the outer
frame or sideshifter assembly just touches the stops
on the inner frame with the cylinders fully retracted.
The mechanism must also extend the correct dis-
tance.
WARNING
The points between the scissor arms and the
inner frame/outer frame are pinch points and
can cause an injury. DO NOT put any part of
your body between these assemblies if they can
move. Always move the key to the OFF position
and disconnect the battery.
1. Cycle the reach system several times to remove
air from the system. Operate the reach mecha-
nism to fully extend and retract the forks for sev-
eral cycles to check for proper operation.
2. Fully extend the forks, move the key to the OFF
position, and disconnect the battery. Measure
the distance between the contact surface of the
inner frame and the stops on the outer frame.
Measure the distance on both sides. The correct
distance for a single-reach unit is 610 +3 6 mm
(24 +0.12 0.24 in.). The correct distance for a
double-reach unit is 1067 +3 6 mm (42 +0.12
0.24 in.).
3. If the distance is not within specifications on both
sides, loosen the capscrews at the rod ends of the
38
4500 SRM 971
reach cylinders. Use a wrench on the wrench
flats to rotate the cylinder rods for adjustment.
Temporarily tighten the capscrews.
4. Operate the reach mechanism through several
cycles and fully extend the forks. Move the key
to the OFF position and disconnect the battery.
Measure the distance on each side again. Both
measurements must be within specifications
AND the measurements must be within 3 mm
(0.12 in.) of each other. If the measurements
are not within specifications, repeat Step 3 and
Step 4 until all measurements are correct. Tem-
porarily tighten the capscrews without moving
the rods after all measurements are correct.
5. Fully retract the forks and check each stop on the
outer frame. The inner frame must be touching
the stop pads.
6. Extend the reach mechanism, move the key to
the OFF position, and disconnect the battery.
Add or remove shims under each stop pad as nec-
essary. DO NOT use more than 3/8-in. shims.
Repeat Step 5 and Step 6 until the outer frame
touches on both sides.
7. Fully extend the forks, move the key to the OFF
position, and disconnect the battery. Loosen the
capscrews at the rod ends of the reach cylinders.
Use a wrench to rotate the cylinder rods 1/4 turn
clockwise into the cylinder. This adjustment al-
lows the stop pads to absorb the shock instead of
the reach cylinders as the mechanism retracts.
Tighten the rod end capscrews to 35 to 40 N•m
(26 to 30 lbf ft).
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

Table 2. Operating Times N30XMXDR3, N45XMXR3, N30/40XMR2,

N25XMDR2, N30XMDR2, and N45XMR2

Voltage Action Time

24V Fast Reach Time, Minimum Load [ 0 kg (0 lb)] 2.7 to 3.5 sec. 3.7 to 4.5 sec.
Fast Reach Time, Maximum Load [ 2041 kg (4500 lb)] 3.2 to 4.0 sec. 4 to 5 sec.
Slow Reach Time, Minimum Load [ 0 kg (0 lb)] 6 to 8 sec. 6 to 8 sec.
Tilt Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Tilt Time, Maximum Load [ 2041 kg (4500 lb)] 2 to 3 sec. 2 to 3 sec.
Sideshift per 3" Travel Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Sideshift per 3" Travel Time, Maximum Load [ 2041 kg 2 to 3 sec. 2 to 3 sec.
(4500 lb)]
Sideshift per 7" Travel Time, Minimum Load [ 0 kg (0 lb)] 3.5 to 4.5 sec. 3.5 to 4.5 sec.
Sideshift per 7" Travel Time, Maximum Load [ 2041 kg 4 to 5 sec. 4 to 5 sec.
(4500 lb)]
36V Fast Reach Time, Minimum Load [ 0 kg (0 lb)] 2.7 to 3.5 sec. 3.7 to 4.5 sec.
Fast Reach Time, Maximum Load [ 1361 kg (3000 lb)] 3.2 to 4.0 sec. 4 to 5 sec.
Slow Reach Time, Minimum Load [ 0 kg (0 lb)] 6 to 8 sec. 6 to 8 sec.
Tilt Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Tilt Time, Maximum Load [ 2041 kg (4500 lb)] 2 to 3 sec. 2 to 3 sec.
Sideshift per 3" Travel Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Sideshift per 3" Travel Time, Maximum Load [ 2041 kg 2 to 3 sec. 2 to 3 sec.
(4500 lb)]
Sideshift per 7" Travel Time, Minimum Load [ 0 kg (0 lb)] 3.5 to 4.5 sec. 3.5 to 4.5 sec.
Sideshift per 7" Travel Time, Maximum Load [ 2041 kg 4 to 5 sec. 4 to 5 sec.
(4500 lb)]
Fork Tilt Angle (Truck Level ±1 )
Down 3 ±1
Up 4 ±1
Fork Height, Fully Lowered (no tilt) 64 mm (2.50 in.)
Operating Pressures and Amperes (Measured at pump, ±10% acceptable)

40
4500 SRM 971 Specifications

Table 2. Operating Times N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMDR2,

N30XMDR2, and N45XMR2 (Continued)

Voltage Action Time

Relief 24 V 16,547.4 kPa 175 Amps
(2400 psi)
36 V 16,547.4 kPa 112 Amps
(2400 psi)
Reach No Load 24 V 7584 kPa 90 Amps
(1100 psi)
Capacity Load 24 V 7584 kPa 90 Amps
(1100 psi)
No Load 36 V 7584 kPa 60 Amps
(1100 psi)
Capacity Load 36 V 7584 kPa 60 Amps
(1100 psi)
Retract No Load 24 V 11,721 kPa 127.5 Amps
(1700 psi)
Capacity Load 24 V 11,721 kPa 142.5 Amps
(1700 psi)
No Load 36 V 11,721 kPa 85 Amps
(1700 psi)
Capacity Load 36 V 11,032 kPa 95 Amps
(1600 psi)
Tilt Forward No Load 24 V 9191 kPa 97.5 Amps
(1333 psi)
Capacity Load 24 V 5688 kPa 81 Amps
(825 psi)
No Load 36 V 9191 kPa 65 Amps
(1333 psi)
Capacity Load 36 V 5688 kPa 54 Amps
(825 psi)
Tilt Backward No Load 24 V 3916 kPa 73.5 Amps
(568 psi)
Capacity Load 24 V 14,527 kPa 175.5 Amps
(2107 psi)
No Load 36 V 3916 kPa 49 Amps
(568 psi)
Capacity Load 36 V 14,527 kPa 117 Amps
(2107 psi)

41
Troubleshooting 4500 SRM 971

Table 3. Operating Times W20/30ZR

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)

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The forks will not extend,
tilt, or sideshift, and there is
power steering.
Steering and auxiliary pump is not
operating.
Check and replace or repair the
power fuse for the pump motor.
Check and repair the auxiliary con-
tactor, driver, and timer. Check and
repair the pump motor.

Control handle is not operating cor- Repair or replace control handle.

rectly.

MIB not operating. Check fuse and wire connections. Re-

pair and replace as required.

42
4500 SRM 971 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The forks will not extend, Control valve not operating. Clean, repair, or replace control
tilt, or sideshift, and there is valve.
power steering. (Cont.)

Selector valve is damaged or not op- Clean, repair, or replace selector

erating. valve.

Auxiliary relief valve not operating. Clean, repair, or replace auxiliary re-
lief valve.

Wiring disconnected or damaged. Connect or repair wiring.

(W20/30ZR)

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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.

Control valve not operating. Clean, repair, or replace control

valve.

Selector valve is damaged or not op- Clean, repair, or replace selector

erating. valve.

Auxiliary relief valve not operating. Clean, repair, or replace auxiliary re-
lief valve.

Wiring disconnected or damaged. Connect or repair wiring.

43
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 TECHNICAL PUBLICATIONS

4500 SRM 971 10/07 (4/03)(11/02)(7/02)(5/01) Printed in U.S.A.