Installation Instructions
Contents
1. or aqueous base hydraulic oil is not recommended If fire resistant hydraulic oil must be used contact Lift Tek Part No 208813 R2 Stamped Serial Number LEFT HAND SIDE OF OUTER UPRIGHT CHANNEL ai Example 45D MQ 001 00025 M MAO0019 ill 45D MQ 001 00025 M Figure 1 Mast Serial Number MA0022 ill Valve Inlet Port 3 4 in SAE O ring Figure 2 Valve Inlet Port For Technical Support To Order Parts Call 1 888 946 3330 OR Write Lift Technologies 7040 South Highway 11 Westminster S C 29693 Ab aA LIFT TEK D Mast Installation 1 A ON Raise and block the front end of the truck up 1 ft 30 cm per ANSI B56 1 or drive the truck over a service pit Install the bearings to the mast lower axle mounts Lubricate the bearing surfaces of the lower axle and tilt cylinder mounting brackets with chassis grease Lift the mast using an overhead hoist and lifting strap wrapped around the upright crossmembers Position the mast lower axle mounts on the truck axle Install the mount caps and capscrews Tighten the capscrews to the truck manufacturer s torque specifications IMPORTANT Prior to connecting the tilt cylinders to the mast make sure the cylinders bottom evenly Adjust the tilt cylinders to prevent the mast from racking during tilting Refer to your truck service manual for procedures Connect the tru2. Installation Instructions 35D amp 45D Quad Roller Masts Introduction This manual provides the installation instructions and adjust ment procedures for Lift Tek 35D amp 45D Quad roller masts These masts provide exceptional visibility for the lift truck driver The mast carriage and upright channels are all roller mounted which provides smooth operation and long service life In any communication about the mast refer to the mast serial number stamped on the nameplate If the nameplate is missing these numbers are also stamped on the left hand side upper cheekplate See Figure 1 Truck System Requirements To achieve the maximum lifting capacity of the mast the truck relief valve should be set to relieve at the pressure indicated in the chart below This chart also indicates the hose and fitting size to use between the truck control valve and mast valve Cascade Relief Hose Fitting Quad Mast Pressure Size Size 35D amp 45D 2600 psi No 8 min No 8 min 13 32 in Orifice Valve inlet port is 3 4 in SAE O ring See Figure 2 WARNING For proper truck stability or to prevent interference tilt restriction may be required NOTE To achieve the proper tilt restriction contact the truck manufacturer or your truck service manual A IMPORTANT Lift Tek masts are compatible with SAE 10W petroleum base oil per Mil Spec MIL O 5606 or MIL 0 2104B only Use of synthetic
3. age is positioned as shown in Figure 4 d Free lift chain adjusting nuts 1 Locate the threaded chain anchors on the front side of the inner upright crossmember on each side of the cylinder 2 Adjust one chain to achieve the correct upright and carriage position when lowered See Figure 4 and 5 3 Adjust the other chain to achieve equal chain tension Tighten the nuts together to a torque of 50 70 ft lbs HE iSem 4 stain 3 a 68 95 Nm C 4 Raise and lower the mast several times to confirm the adjustments MA0015 ill Figure 5 Chain adjustment Operational Inspection and H Upright Adjustments Continued Rails Upright Channel Lubrication Lubricate the full length of each upright channel with chassis Lubricate only lube or Kendall SR 8X as shown See Figure 6 where indicated by the heavy line the full length of the upright Mast Skewing 1 Extend the mast to full lift height See Figure 7 e If the mast bends to the right at full extension a shim s need to be removed from the left main lift cylinder rod e If the mast bends to the left at full extension a shim s need to be installed to the left main lift cylinder rod WARNING The upright must be supported
4. by a block to avoid possible injury 2 Place a 20 in 50 cm long 4 X 4 in 10 X 10 cm wood block between the outer intermediate and outer upright crossmembers See Figure 8 Lower the mast onto the block 3 Remove the snap ring from the left hand cylinder rod Open the truck valve to allow the cylinder rod to retract Tap the cylinder rod down past the crossmember Install or remove shim s on the cylinder rod below the inner upright cross member See Figure 8 Shims are listed below Shim Thickness Part No 010 in 25 mm 205198 031 in 79 mm 205199 062 in 1 57 mm 205196 093 in 2 36 mm 205197 4 Repeat steps 1 through 3 until skewing is removed Outer Intermediate Upright 4 x4 in 10 x 10 cm Wood Block Outer Upright Figure 8 Extending Upright Lift Technologies 2001 12 01 Figure 6 Channel Lubrication Left hand i H main lift cylinder NS MA0017 il MA0028 ill Free lift cylinder Right hand main lift cylinder Figure 7 Extending upright viewed from driver seat Part No 208813 R2
5. ck supply hose to the mast valve NOTE Use as few fittings as possible Always use 45 fittings instead of 90 fittings Keep the hose length to a minimum Avoid sharp bends or pinch points when routing the hose Connect the tilt cylinders to the mast anchor brackets Tighten the pin capscrews to the truck manufacturer s torque specifications Check the oil level in the truck hydraulic tank when the mast is fully lowered Fill if required Joo O1 P Yg LL _ Oa a is 4 23 Figure 3 Mast Installation Operational Inspection and Adjustments CAUTION The factory set adjustments may not be correct for your truck Check each of the following before using the CUSHION TIRE PNEUMATIC TIRE mast for the first time 3 in Underclearance 5 in Underclearance e Inspect the chains and check chain tension e Check the main lift chains for proper adjustment e Check the free lift chains for proper adjustment Chain Inspection and Tension L5 gt The main and free lift chains have been factory lubricated using heat and pressure to force the lubricant thoroughly into C rriag the chain links Avoid removal or contamination of this factory 2j g applied lubricant Do not wash sand blast etch steam Uprights a clean or paint the chains for initial mast installation and Somm carriag
6. e below flush uprights The chains must be adjusted with equal tension to ensure proper load distribution and mast operation To determine equal tension extend the unloaded mast to put the chains under tension Press the center of a strand of chain with your thumb Then press at the same place on the other chain of the pair Each chain in a pair should have equal give If they do not have equal tension perform the Main Lift and Free Lift chain adjustments described below MA0018 ill Figure 4 Upright and Carriage Position Inner and Outer Main Lift Chain Adjustment The main lift chains should be adjusted so that when the unloaded mast is fully lowered the uprights are flush as ji shown in Figure 4 1 Adjust one chain to achieve the correct carriage position when fully lowered as shown in Figure 4 and 5 iE E ie EEI E 2 Adjust the other chain to achieve equal chain tension Tighten the nuts together to a torque of 50 70 ft Ibs inner main 68 95 Nm lift chain 3 Raise and lower the mast several times to confirm the adjusting adjustments nuts Inner main lift chain adjusting nuts Free Lift Chain Adjustment The free lift chains should be adjusted so that when the unloaded mast is fully lowered the carri
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