OPERATOR/SERVICE MANUAL
Contents
1. i OUTER RAIL MAST VIEWED FROM FRONT SIDE MAST MODEL 1400 s HYDRAULIC CYLINDER i OUTER INTERMEDIATE RAIL INNER omi li 1 pi i BOTTOM OF OUTER RAIL INTERMEDIATE RAIL i H ji INNER RAIL RAIL ROLLERS i ki CARRIAGE CARRIAGE ROLLER NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 11 CONTENTS MAST REMOVAL REPAIR AND ADJUSTMENT cont CARRIAGE CHAINS ADJUSTMENTS The carriage chains should be adjusted with the mast in a vertical position the carriage completely lowered and unloaded When properly adjusted the lower carriage rollers will protrude below the inner rail slightly with equal tension on both chains The distance or dimension that the carriage rollers protrude is critical and must be maintained for optimum mast operation Consult the chart below for the dimension A required for your mast model Before adjusting the carriage chains see the previous pages RAIL CHAINS ADJUSTMENTS CARRIAGE CHAIN ADJUSTMENT CHART DIMENSION APPLICABLE MAST MODELS o TFL 8 DCV 1 3500 3600 IMPORTANT 4300 5300 See RAIL HYDRAULIC HANS CYLINDER 1 1 8 1300 7700 ADJUSTMENTS 11 4 2100 2300 2400 for mast rails2. 18 Before returning the mast to service see MAST INSTALLATION OPERATION amp MAINTENANCE NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 8 CONTENTS MAST REMOVAL REPAIR AND ADJUSTMENT cont RAIL AND CARRIAGE ROLLER ADJUSTMENTS If excessive side play of the mast rails or carriage is observed during operation the rail rollers re quire adjustment For roller adjustment the mast must be removed from the lift truck and placed ina horizontal position see MAST REMOVAL on the previous page Before removing the carriage or rails record the roller clearances The clearance is measured at the point where the roller is nearest the rail s web see the applicable figure below Begin with the carriage rollers move the carriage to its highest position on the inner rail Check both top rollers first recording the clearances Record the center rollers where applicable and bottom rollers inthe same manner Also record the roller clearances of each mast rail assembly before itis removed Clearance is adjusted using shims 015 to 060 thickness see RAIL ROLLER SHIMS on page 7 placed on stub shafts at assembly The roller must be removed to reveal the stub shaft and shims NOTICE If the stub shaft is worn or damaged it must be replaced contact your K D MANITOU Dealer The rollers must be shimmed evenly using the same number and thickness of shims on either side of the rail keepin
3. 11 Use a signal person when placing high loads 12 Operate the mast smoothly raising lowering and tilting of mast and forks do not allow the lift cylinders to hit the end of their stroke abruptly 13 Lower the forks to the ground when the Forklift is not in use NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 23 2 CONTENTS MAST COMPONENTS K D MANITOU Masts are designed primarily for use on Industrial Fork Lift Trucks Each Mast Series is rated based on lifting capacity and lifting height The Mast s lifting capacity also varies depending on the Lift Truck and its application Load capacities are determined at 24 load centers centered on the mast and must include any attachments on the carriage The Lift Truck Identifica tion Plate shows the mast s model attachments and maximum lifting capacities based on that par ticular truck and mast combination The mast s structural rails are manufactured from SAE1027 steel beams rolling one within the other on steel rollers The rails are engineered to distribute thrust loads evenly between the rollers and rail All mast components are designed to work as a unit providing maximum strength and endur ance for the rated load The most common method of handling loads is with the use of forks Masts with ITA Industrial Truck Association carriages will also handle additional attachments contact your dealer The mast lift is powered b
4. Extend and retract the mast four more times This action will force air in the system to the top of the lift cylinders where the bleed screws are located 5 Raise the forks to about ten inches off the ground A WARNING STAY CLEAR OF THE CARRIAGE AND FORKS A AS THEY ARE LOWERED DURING CYLINDER BLEEDING CAUTION WEAR PROPER EYE PROTECTION WHEN BLEEDING THE HYDRAULIC CYLINDERS 6 Each cylinder must be bled one at a time any sequence Open the bleed screw no more than one turn The weight of the carriage will force any air and hydraulic oil out of the cylinder through the bleed hole If the carriage reaches the bottom of its travel before all the air is bled close the bleed screw and repeat steps 5 and 6 7 When the oil stream no longer contains air bubbles close the bleed screw 8 Check the lift truck s hydraulic tank and add fluid if necessary 9 Extend and retract the mast again if the mast doesn t operate smoothly or if it appears to be spongy repeat steps 2 through 9 10 Test the mast with a light load if any problems occur at this point see chapter TROUBLE SHOOTING GUIDE If operating smoothly test the mast with 1 2 its rated load capacity and then its full rated load capacity If the mast continues to operate smoothly it is ready to place into service NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 5 CONTENTS MAST INSTALLATION OPERATION amp MAINTENAN
5. its status for replacement First determine the pitch of your chain by measuring the distance X between two chain pins as shown below NOTE The chain pitch will be either 5 8 3 4 or 1 A 5 8 pitch chain must be replaced if it measures 10 1 4 or more across 16 pitches or spaces A 3 4 pitch chain must be replaced if it measures 12 3 8 or more across 16 pitches or spaces A 1 pitch chain must be replaced if it measures 24 3 4 or more across 24 pitches or spaces CHAIN PITCH CHAIN PINS ONE PITCH gt X THE CHAIN TYPE SHOWN IS FOR REFERENCE ONLY CHAIN TYPES VARY DEPENDING ON THE MAST MODEL NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 6 CONTENTS MAST INSTALLATION OPERATION amp MAINTENANCE cont CHAIN ADJUSTMENTS The chains should be adjusted with the mast in a vertical position the carriage completely lowered and unloaded Facing the front of the mast adjust the chains in pairs beginning with the rear pair Provide equal tension on the chains A critical measurement during chain adjustment is the mast rails alignm
6. sary If damaged by contaminated oil flush the system replace the oil filters and add fresh oil 5 Rollers defective or shimmed 5 Re shim or repair as needed too tight Mast drifts down slowly on 1 Damaged or defective seals 1 Replace the seals Failure caused its own by oil contamination requires the system be flushed filters be replaced and fresh oil installed 2 Pressure line leaking 2 Inspect all hydraulic lines hoses and connections Tighten or replace as necessary 3 Control valve leaking 3 Repair or replace the control valve NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 16 CONTENTS PROBLEM Mast lowers too slowly partially or not at all A NOTICE See WARNING at the beginning of the Trouble Shooting Guide Carriage drifts up when load is removed then stops Cylinders leak oil Mast does not fully extend Excessive side movement in carriage or rails Carriage or rails hang up or bind during operation A NOTICE See WARNING at the beginning of the Trouble Shooting Guide PROBLEM CAUSE 1 Damaged lift cylinders s 2 Flow regulator faulty 3 Rollers defective or shimmed too tight 4 Mast rails need lubrication 1 Air in cylinder s 1 Faulty seals or O rings 1 Hydraulic oil tank low 1 Rollers need adjustment or repair 1 Rollers need adjustment or repair CORR
7. 7000 alignment 1 3 8 1100 1400 1400ER 1400M CARRIAGE 4000 7500 7600 DIMENSION 9300 9400 1 1 2 4700 4900 6900 1 5 8 8000 9000 4400 4500 5700 1 3 4 1700 4100 4200 5800 7900 BOTTOM OF INNER RAIL 4800 5500 5500ER CARRIAGE ila ROLLER 1000 1200 7300 NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 12 CONTENTS MAST REMOVAL REPAIR AND ADJUSTMENT cont PRIMARY SECONDARY CYLINDER S DISASSEMBLY Make notes during disassembly also refer to your Mast Parts Book for component descriptions and diagrams 1 Secure the Primary Secondary Cylinder in a suitable vise remove any hose fittings and fuses 2 Using achain wrench rotate the base plug until the pointed end of the lock wire appears in the base plug slot Place a screwdriver under the end of the lock wire Rotate the base plug toward the screwdriver to extract the lockwire 3 Carefully drive or push on the piston rod to remove the base plug from the bottom of the cylinder Take care not to drop any fuse held in the adapter fitting found on some Secondary Cylinders A NOTE O ring s and back up ring s must be replaced if the base plug is removed 4 Carefully drive the piston through the bottom of the barrel 5 Allseals wear rings and o
8. CE cont MAINTENANCE Some flaking of material can be expected where the carriage rollers contact the inner rail After a few hundred hours of operation this flaking should subside Keepthese flakes of material removed by cleaning the rails with a wire brush WEAR PROPER EYE PROTECTION AND GLOVES Also note the following cleaning lubrication schedule CLEANING LUBRICATION SCHEDULE 1 Every 200 Hours or monthly Lightly oil each chain with a brush using SAE 30 Non Detergent oil 2 Every 500 Hours Using a steel wire brush clean and remove any scaling or debris along all roller contact points on the rails Keep the rollers and rails clean from debris 3 Every 1 000 Hours Clean the chains with solvent blow dry with air and re oil CHAIN INSPECTION Inspect lift chains daily before operating the truck Look for cracked broken or missing link plates bent protruding or seized pins and evidence of rust or corrosion When locating this type of dam age the chains must be replaced Ensure tension on the chain pairs are equal Verify that all cotter pins and lock nuts are in place Verify that all chains are clear from side contact with headers and carriage Make sure snap rings are in the proper place on chain sheave shafts Do not operate the mast if any of these problems exist The mast chains begin to wear and stretch in length as they are used Asimple measurement of the chain s pitch over a given length will determine
9. CONTENTS MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DRIVE Waco TX 76712 6803 NOTE This Operator Service Manual contains general instructions for mast maintenance and repair It must be used in conjunction with the parts illustrations found in your Mast Parts Manual Updates of the Mast Parts Manual are made periodically revising components and Models as released for production If your Mast Model or parts are not found in the Parts Manual please contact the Manitou North America Parts Department for the latest information available MAST OPERATOR SERVICE MANUAL For Parts Orders contact your Manitou North America Dealer or call Manitou North America Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou na com CATALOG B418 R10 05 CONTENTS CONTENTS SAFETY PRECAUTIONS 3 MAST COMPONENTS 4 MAST INSTALLATION OPERATION amp MAINTENANCE 5 INSTALLATION 5 OPERATION 5 MAINTENANCE 6 LUBRICATION SCHEDULE 6 6 7 7 7 CHAIN INSPECTION CHAIN ADJUSTMENTS MAST ROLLERS CARRIAGE SIDE PLAY OR THRUST ROLLERS MAST REMOVAL REPAIR AND ADJUSTMENT 8 PREPARATION 8 MAST REMOVAL AND DISASSEMBLY 8 ROLLER ADJUSTMENTS 9 9 0 CARRIAGE THRUST ROLLERS RAIL CHAINS ADJUSTMENTS 1 CARRIAGE CHAINS ADJUSTMENTS 12 PRIMARY SECONDARY CYLINDER S DISASSEMBLY 13 PRIMARY SECONDARY CYLINDER S RE ASSEMBLY 13 TROUBLE SHOOTING GUIDE 14 NOTICE STUDY THE E
10. ECTIVE ACTIONS 1 Inspect repair or replace 2 Replace regulator 3 Re shim or repair as needed 4 Lubricate rails as required 1 Bleed the cylinder s 1 Replace seals or O rings 1 Fill tank to proper level 1 Shim or replace rollers as required 1 Shim or replace rollers as required NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST sis CONTENTS PROBLEM PROBLEM CAUSE CORRECTIVE ACTIONS Carriage is hitting or scrapping 1 Carriage rollers improperly 1 Adjust or replace the carriage the rails shimmed or worn excessively rollers Mast out of seguence on ascent 1 Carriage travel is obstructed 1 Remove obstruction rails move before the carriage 2 Carriage thrust rollers damaged 2 Adjust or replace the thrust or need adjustment rollers 3 Carriage rail rollers damaged 3 Adjust or replace the rail or need adjustment rollers 4 Load excessively off center 4 Center the load on the carriage Mast out of sequence on decent 1 Rails are shimmed too tight 1 Re shim the rails as required the carriage lowers before the rails retract 2 Center rail shimmed too tight 2 Re shim the rail as required in the outer rail 3 Obstruction or debris 3 Remove any obstructions or debris 4 Broken roller 4 Replace the roller 5 Defective flow regulator in the 5 Replace the regulator lift cylinder s Excessive
11. NTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST aie CONTENTS NOTES NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST gt CONTENTS SAFETY PRECAUTIONS IMPORTANT BEFORE YOU OPERATE THE MAST MAKE SURE YOU HAVE READ AND FULLY UNDERSTAND THE MANUFACTURER S MANUALS FOR YOUR FORK LIFT IF THE MANUALS ARE MISSING GETA REPLACEMENT MANUAL FROM YOUR EMPLOYER DEALER OR FORKLIFT MANUFACTURER KEEP SAFETY MANUALS ON THE FORKLIFT AT ALL TIMES SAFETY IS YOUR RESPONSIBILITY ONLY YOU CAN PREVENT SERIOUS INJURY OR DEATH FROM UNSAFE PRACTICES PRACTICE ALL USUAL AND CUSTOMARY SAFE WORKING PRECAUTIONS IN CLUDING THE FOLLOWING 1 NEVER CARRY PASSENGERS ON THE MAST OR FORKS 2 Never use the mast or forks as battering rams 3 Make daily inspections of the mast s performance components hydraulics and hose connections 4 Avoid entanglement hazard keep yourself and others away from the mast s moving parts 5 DO NOT climb on the mast 6 If the mast does not operate properly have it inspected and repaired immediately 7 Do not operate the Mast without a legible load chart do not over load the mast 8 Replace forks in pairs that are cracked or damaged NEVER use forks repaired by welding 9 Check that the forks are secure unable to change position while carrying loads 10 Plan ahead know how and where you will travel turn and pickup lift and place loads
12. art no Use the information to verify the shims required for proper clearance between rollers and rails as described on page 9 SHIM PART NO RAIL ROLLER SHIMS SHIM PART NO R22 0 015 THK R206 0 015 THK R426 0 060 THK R427 0 060 THK 1 13 32 1 25 32 NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST Te CONTENTS MAST REMOVAL REPAIR AND ADJUSTMENT PREPARATION 1 The work site must be clean have a concrete floor and an overhead hoist and frame rated to at least tons Follow all safety instructions regarding the use of hand and power tools 2 Steam clean the mast thoroughly removing all dirt debris and grease A CAUTION OBSERVE ALL SAFETY PRECAUTIONS WHILE OPERATING THE A HOIST AND DISMANTLING THE MAST MAST REMOVAL AND DISASSEMBLY Make notes during disassembly referring to your Mast Parts Book for component descriptions and diagrams Important record the roller clearances and chain adjustments before removing the carriage or rails see the following pages 1 Remove the load backrest if installed and forks 2 Disconnect the hydraulic hose s allowing the mast to drain Clean any spilt oil immediately 3 Attach a properly rated hoist belt to the mast lift the mast slightly 4 Disconnect the mast side shift cylinder if installed and tilt cylinders from the mast 5 Disconnect the mast from the lift truck WARNING The mast may swi
13. efore installing the new mast have an experienced mast mechanic inspect it carefully Check for any damages missing or loose components that may have occurred during shipping Contact your dealer immediately if there are any questions concerning the mast s condition 2 Before performing any welding on the mast contact K D Manitou for approval K D Manitou is not responsible for unapproved field welding attachments or mountings designed by other manufacturers 3 Mount the mast to the lift truck using a overhead hoist and frame rated to at least 3 tons Make sure the flow control valve fuse is correctly installed Connect the tilt cylinders and hydraulic hose s Insure the hydraulic tank is filled with hydraulic oil A CAUTION OBSERVE ALL SAFETY PRECAUTIONS WHEN WORKING WITH OR ON THE MAST A NEVER place any part of one s body into the working zone of the mast while it is moving or extended Never work on the mast while it is loaded remove the load first If work must be performed on an ex tended mast block and chain the rail assemblies and carriage to prevent mast collapse OPERATION INITIAL Before the mast is placed into service perform the following procedures 1 Attach the forks or approved attachment to the mast carriage 2 Without a load on the forks extend and retract the mast through one complete cycle 3 With the mast fully lowered check the lift truck s hydraulic tank and add fluid if necessary 4
14. ent to the outer rail see RAIL CHAINS ADJUSTMENT Also critical is the carriage chains adjustments When the carriage chain s are properly adjusted the lower carriage rollers will protrude below the inner rail The distance that the carriage rollers protrude varies between Mast Models See CARRIAGE CHAINS ADJUSTMENTS MAST ROLLERS All mast rail rollers carriage rollers chain sheaves and cylinder head guide rollers where applica ble are sealed for life and require no additional lubrication Bearing life of the rollers varies depend ing on application and conditions of operation Should the mast show signs of lateral wear or exces sive side play within the rail sections the mast will require shimming see RAIL ROLLER SHIMS below and or replacement of the rollers If not properly shimmed the rail rollers can distroy the stub shafts on which they ride replacing stub shafts requires welding by an authorized welder at an ap proved dealership contact K D Manitou See RAIL and CARRIAGE ROLLER ADJUSTMENTS on page 9 CARRIAGE SIDE PLAY OR THRUST ROLLERS The carriage thrust rollers keep the carriage centered and in contact with the inner rails providing smooth load handling The thrust rollers are adjustable by use of eccentric shafts and shims see your Mast Parts Book for assembly They should be checked frequently and adjusted when neces sary RAIL ROLLER SHIMS The following diagram identifies Rail Roller Shims by dimensions and p
15. g the rail properly centered When adjusted correctly the rails should be snug but free to roll manually while in a horizontal position J RAIL RAIL I RAIL I RAIL ROLLER WEB ls JU 0155 0155 015 e 015 e FIGURE A FIGURE B FIGURE FIGURE D CARRIAGE THRUST ROLLERS The thrust rollers are adjustable by use of an eccentric shaft or shims see your Mast Parts Book for assembly These rollers should be adjusted so as to center the carriage within the rail making slight contact with the inner rail during operation Inspect these rollers frequently making adjustments as required to maintain smooth carriage operation NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 9 CONTENTS MAST REMOVAL REPAIR AND ADJUSTMENT cont RAIL CHAINS ADJUSTMENTS Important adjust the rail chains before the carriage chains The chains should be adjusted with the mast in a vertical position the carriage completely lowered and unloaded Facing the front of the mast adjust the chains in pairs beginning with the rear pair Provide equal tension on the chains The rail chains of most Mast Models are adjusted aligning the mast rails evenly see figure 1 Exceptions are the Mast Models 1400 s 4700 s 4800 s and 5300 s It is critical that the masts be adjusted according to the appropriate fi
16. gure below or on the following page ALL FIGURES VIEWED FROM LEFT SIDE OF MAST FIG 1 MOST MAST MODELS HYDRAULIC Pa CYLINDER TYPICAL MAST RAIL ALIGNMENT CRITICAL Note the exceptions listed above See CARRIAGE CARRIAGE CHAINS ADJUSTMENTS CARRIAGE ROLLER MAST MODEL 4800 s HYDRAULIC CYLINDER BOTTOM OF OUTER RAIL TOP OF INNER RAIL ape TOP OF ae Mi CARRIAGE NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 10 ES CONTENTS MAST REMOVAL REPAIR AND ADJUSTMENT cont RAIL CHAINS ADJUSTMENTS cont NOTE See previous page for important information MAST VIEWED FROM LEFT SIDE FIG 4 MAST MODEL 5300 s HYDRAULIC l CYLINDER CARRIAGE 8 8 M 8 213 16 BOTTOM OF OUTER RAIL BOTTOM OF CENTER RAIL BOTTOM OF INNER RAIL
17. ng from the lift truck be cautious 6 Lay mast horizontally carriage side facing up Use blocks to level the mast on the floor 7 Remove clean and inspect the carriage chain s see CHAIN INSPECTION 8 Dismantle clean and inspect the crosshead assembly Replace any worn or damagedparts 9 Using the hoist for support roll the carriage out of the lower end of the mast 10 Dismantle clean and inspect all of the carriage rollers Note placement of all roller shims Re place any worn or damaged parts See ROLLER ADJUSTMENTS before beginning mast assembly 11 Remove the tubes hoses hose sheaves and chain sheaves as they become accessible Clean and inspect the components replacing any that are worn or damaged 12 Remove the primary cylinder assembly See PRIMARY CYLINDER DISASSEMBLY 13 Remove clean and inspect remaining chains see CHAIN INSPECTION 14 Fully extend the inner rail and using the hoist lift the inner rail through the cut out of the intermediate rail Remove clean and inspect the rollers and shims replace any worn or damaged parts Note placement of the roller shims 15 Remove secondary cylinder assemblies as they become accessible See SECONDARY CYLINDER DISASSEMBLY 16 Remove the remaining rails as they become accessible refer to instruction 1414 17 Re assemble the mast in reverse order as disassembled using your notes as necessary See ROLLER ADJUSTMENTS before beginning mast assembly
18. nstall hose fittings and fuses where applicable 9 Collapse the cylinder to prevent damage to the chrome piston surface until installation into Mast NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 2413 CONTENTS TROUBLE SHOOTING GUIDE The Trouble Shooting Guide found on the following pages addresses problems sometimes encountered during mast operations It also lists the probable causes and recommended corrective actions to restore the mast to its proper operating condition Before repairing a faulty mast read all safety precautions A WARNING IF A MAST RAIL OR CARRIAGE BECOMES JAMMED OR HUNG UP REMOVE THE MAST FROM SERVICE MAKING NECESSARY REPAIRS IMMEDIATELY USE ONLY THE APPROPRIATE TOOLS AND APPROVED HOIST HARNESS DURING MAST REPAIR OR ADJUSTMENTS NEVER PLACE ANY PART OF YOUR BODY INSIDE THE WORKING AREA OF A JAMMED MAST DO NOT OPERATE THE MAST WITH A DAMAGED HYDRAULIC SYSTEM NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 14 CONTENTS PROBLEM Mast will not lift load or lift cylinder does not move Lifts load slowly or to partial height PROBLEM CAUSE 1 Mast overloaded 2 Insufficient or no oil flow supplied to the cylinder 3 Relief valve setting too low 1 Low on oil 2 Mast cylinder seal failure 3 Relief setting too low 4 Mast rollers shimmed too tight rails a
19. re off center or not lubricated defective rollers CORRECTIVE ACTIONS 1 Reduce the load 2 Check the truck s hydraulic system low oil level defective pump damaged control valve or leaks in the supply line Make repairs as required A NOTE Anytime oil is added to the hydraulic tank check the lift cylinders for air they may need to be bled 3 Adjust relief valve do not exceed recommended setting 1 Check the truck s hydraulic system low oil level defective pump damaged control valve or leaks in the supply line Make repairs as required 2 Replace the seals Failure caused by oil contamination re quires the system be flushed filters be replaced and fresh oil installed 3 Adjust relief valve do not exceed recommended setting 4 Check rollers and rail align ment Repair adjust or lubricate as necessary NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 25 CONTENTS PROBLEM PROBLEM CAUSE CORRECTIVE ACTIONS Mast jerks or has spongy 1 Air inthe hydraulic system 1 Check hydraulic oil level in the movement tank check for vacuum leaks in the hydraulic system Bleed the lift cylinders 2 Bent or damaged cylinder 2 Repair or replace as necessary rod piston 3 Mast rails need lubrication 3 Lubricate rails as reguired 4 Defective relief valve 4 Remove and inspect the relief valve repair or replace as neces
20. ther cylinder internal parts are now accessible These parts should be removed and worn or damaged parts discarded 6 Thoroughly clean and dry all remaining parts 7 Thoroughly inspect all parts for nicks scratches or other damage A NOTE Replace the wear rings only if they are damaged or excessively worn PRIMARY SECONDARY CYLINDER S RE ASSEMBLY Lubricate all internal components wear rings seals etc with clean hydraulic fluid during assembly 1 Install both wear rings into the top of the barrel and one onto the bottom of the piston where applicable 2 Install the cylinder seal into the barrel grooved side facing bottom of barrel where applicable 3 Install the wiper seal into the barrel 4 Carefully install the piston into the barrel allow the piston to protrude from the top end of the barrel approximately four inches A NOTE Reinstall fittings using a thread sealant such as Pipe Dope Locktite etc Do not use teflon tape it may be released into the hydraulic system Ensure the fuse is properly installed in the base plug where applicable Install the back up ring then the O ring onto the top groove of the base plug Carefully install the greased base plug into the barrel Rotate the base plug until the hole in the plug aligns with the slot in the barrel Insert the hook end of the lock wire into the base plug hole Continue to rotate the base plug pulling the lockwire completely into the barrel Re i
21. wear on one inner rail 1 Carriage roller on opposite side 1 Replace the roller clean and only is broken lubricate the rail NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 18 CONTENTS NOTES NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 19 CONTENTS NOTES NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 20
22. y hydraulics supplied by the forklift at the control valve The mast is low ered using the control valve and gravity internal valves keep the mast from lowering too quickly The Figures below show the general principles of mast lifting sequences Fig 1 The mast is lowered or collapsed Fig 2 The lift lever on the forklift is activated causing hydraulic fluid to enter the primary cylinder The cylinder rises pushing the primary chain upward raising the carriage This first stage of car riage lift is called free lift it is the distance of lift available without increasing the mast s height Fig 3 As the secondary cylinders are activated the inner rail and secondary rail connected by chains rise progressively The upward lift continues until the secondary cylinders are fully ex tended The carriage is lowered in reverse sequence by gravity as hydraulic oil is removed from the lift cylinders These principles apply to 4 and 5 stage masts as well utilizing additional rails lift cylinders and chains n ire SECONDARY CHAIN PRIMARY CHAIN PRIMARY CYLINDER LOWERED INNER RAIL CARRIAGE FORKS INTERMEDIATE RAIL 7 Fig 3 OUTER RAIL PRIMARY CYLINDER EXTENDED SECONDARY CYLINDER s EXTENDED NOTICE STUDY THE ENTIRE REPAIR MANUAL BEFORE OPERATING REPAIRING OR ADJUSTING THE MAST 2A CONTENTS MAST INSTALLATION OPERATION amp MAINTENANCE INSTALLATION 1 B
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