Service Manual - Lift Technologies, Inc.
Contents
1. Figure 7 Channel lubrication 8 687250 R3 x2 Installation Instructio _ Internal Reeving Hi Vis Installation 30D 35D 40D and 50D 1 Install the shafts sheaves and hose guards to the crosshead center plate Leave the capscrew and nut finger tight to allow hose installation 2 Install the carriage bracket to the tabs between the Figure 8 Crosshead Assembly carriage sideplates Leave the capscrews finger tight 3 Install fittings to bracket Single Function Install the fittings to the left or right side location Tighten the fittings finger tight Double Function Install the fittings to the left and right side location Tighten the fittings finger tight lt _OR 3 a 8 OD OD OD OD T FHRS SINGLE DOUBLE FUNCTION FUNCTION Figure 8 Carriage Bracket Assembly gs Figure 9 Carriage bracket Installation 9 687250 R3 sein Installation Instructions Internal Reeving Hi Vis Installation 30D 35D 40D and 50D 4 Install the brackets hose clamps and sheaves to the uprights Tighten the bracket capscrews to a torque of 38 ft lbs 51 Nm 5 Completely lower the carriage Route the hoses down behind the top carriage bar to the carriage bracket fittings Connect the hoses fittings to the carriage fittings and tighten 6 Loosen the crosshead coverplate capscrew Route the hoses up over the2. 4 7 4 ene es Figure 28 Cylinder Service 2600 PSI 687250 R3 sein Service 5 29 Free Lift Cylinder Service 1 Remove the cylinder from the mast as described in Section 5 2 6 or 5 2 7 2 Use a claw type spanner wrench to remove the retainer See Figure 29 3 Remove the plunger piston assembly from the shell 4 Remove the Hydraulic Fuse Lowering Cushion compo nents 5 Inspect all components for nicks or burrs Minor nicks or burrs can be removed with 400 grit emery cloth NOTE Minor nicks are those that will not bypass oil when under pressure If they cannot be removed with emery cloth replace the part If the piston requires replacing refer to Section 5 2 10 6 Replace the retainer and piston seals back up rings O rings and bearing Lubricate the new seals with petroleum jelly prior to installation Note the correct 8 2 seal directions The cylinder will not operate correctly Retainer if the seals are installed backwards 7 When replacing the piston check valve O ring make sure the check valve is reinstalled with the arrow pointed in the correct direction 8 Install the plunger retainer on the plunger Install the plunger piston assembly into the cylinder shell Pour 1 2 cup 120 ml hydraulic oil into the cylinder cavity between the shell and rod Tighten the retainer to a torque of 275 300 ft lbs 375 405 Nm using the claw spanner wrench and a strap wrench 28 Plunge
3. Ill 14 Raise and lower the mast slowly through several cycles 2 i checking for proper hose alignment clearances and hose Jil tracking 1 G 7 Crosshead p N Coverplates MA0279 ill Figure 13 Crosshead Assembly 12 687250 R3 san Installation Instructions _ Internal Reeving Std Vis Installation 55D 60D 1 Install the reeving brackets to the crosshead Tighten the capscrews to a torques of 12 ft lbs 17Nm 2 Install the rollers and hose guards to the crosshead reeving bracket Leave the nut finger tight to allow hose installation Figure 14 Center Crosshead Sheaves 3 Double Function Internal Reeving Install the sheaves to the crosshead chain shafts Leave the capscrews finger tight to allow for hose installation me A 7 Q g a i ON MA0537 ill Figure 15 Outer Crosshead Sheaves 13 687250 R3 sein Installation Instructions Internal Reeving Std Vis Installation 55D 60D Single Function 1 Install the carriage bracket to the tabs on the carriage side plates Tighten the nuts to a torque of 38 ft lbs 51Nm 2 Install the bulkhead and 90 fitting to the middle two holes in the carriage bracket 3 Install the hoses to the carriage bracket fittings Leave the fittings loose 4 Route the hoses up and over the rollers on the center of the crosshead Tighten the hose guard capscre
4. ate upright assembly A pair of shim adjustable load rollers are attached to stub shafts located at the bottom of the upright The free lift chain anchors are attached to the center crossmember The free lift cylinder rests on a cradle which is integral with the lower crossmember Intermediate Upright Inner Upright Chain Anchors Spacer 2600 psi Cylinder Only Chain Anchor Nuts Thrust Plug Chain Sheaves Snap Ring Load Rollers AA TA Load Rollers S Le Chain Sz Anchor i N 4 Shims Chain Anchors Outer Upright Nuts MA0850 eps 687250 R3 sein Service 552 Upright Operation Fully Lowered The main Lift chains are anchored to the outer upright top crossmember then travel over the intermediate upright chain sheaves and attach to the inner upright anchors The free lift chains are anchored to the inner upright center crossmember then travel over the free lift cylinder chain sheaves and attach to the carriage chain anchors Free Lift Actuating the truck hoist valve causes the free lift cylinder to raise which draws the carriage to the top of the inner upright Full Extension When the free Lift cylinder reaches the end of its stroke the main lift cylinders begin to rise The extension of the cylinders causes the intermediate and inner uprights to raise Lowering The main li
5. Angle Iron MA0412 eps Figure 49 Shim Installation 41 Left Hand Three Stage Mast shown WARNING The intermediate upright must be supported by angle iron to avoid possible injury 1 JE Da Cylinder 1 Freelift Main Lift Cylinder NI Right Hand Main Lift Cylinder MA0411 ill Figure 50 Extended Upright 687250 R3 Chains 561 Inspection and Tension Each pair of chains has been factory lubricated using heat and pressure to force the lubricant thoroughly into the chain links Avoid removal or contamination of this factory applied lubricant Do not wash sand blast etch steam clean or paint the chains on initial mast installation 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 tension is not equal adjust the chains as de scribed in Chain Adjustment Inspect the chains If inspection reveals that one strand of a pair of chains requires replacement both strands of the pair should be replaced Check for rust and corrosion Check for cracked side plates If you find cracked side plates replace both strands of chai
6. lies 5 EE SZ U U MA0275 ill Figure 11 Hose Routing 8 Route the hoses under the lower inner crossmember to loop up to the lower hose bracket Install the hose clamps leaving the capscrews finger tight Align the hoses under the crossmember and into the clamp Tighten the clamp capscrews to a torque of 8 ft lbs 11Nm 9 Route the hoses up to and over the upper hose sheaves and then down to the upper hose bracket Assemble the clamp and hoses to the upper bracket leaving the capscrews finger tight Starting with the outer hose pull down on the hoses with 80 lbs of force to remove slack then tighten the clamp capscrews to a torque of 8 ft lbs 11Nm 10 Attach the hose ends to the center hose bracket aligning the hoses with their natural curve Tighten the clamp capscrews to a torque of 8 ft lbs 11Nm 11 Attach the left hand cylinder supply hose and clamp to the outer upright center crossmember Tighten the clamp MA0283 il capscrew to a torque of 8 ft lbs 11Nm Figure 12 Main Lift Hose 11 687250 R3 sin Installation Instructions Internal Reeving Hi Vis Installation 30D 35D 40D and 50D 12 Tighten the crosshead coverplate capscrew to a torque of 51 ft lbs 7ONm 13 Tighten the carriage bracket capscrews to a torque of 46 ft lbs 63 Nm
7. Install the hose clamp to the two center hoses half way 2 between the crosshead and lower crossmember 10 Pull down on the hoses to remove slack and stretch the hoses one inch Install the brackets on the front side of the crossmember using the next hole down Tighten the capscrew to a torque of 38 ft lbs 51Nm 11 Raise and lower the mast several times to make sure the hoses are tracking correctly Use the white line on the hose to detect twisting Adjust the hose ends if re quired Tighten the fittings making sure they do not twist MA05339 ill 15 a oO AAAA 7 CCI IIE EAA J 687250 R3 3 1 Periodic Maintenance For proper operation and an extended service life your Lift Tek Mast should be inspected and serviced regularly as part of your normal lift truck maintenance schedule accord ing to the following outlines and ANSI B56 1 procedures The recommended intervals are for masts operating under normal conditions If the mast is operating in severe conditions or corrosive atmospheres the inspections should be per formed more frequently WARNING Never work on the mast with a load on the forks or attachment in the raised position without supports or while anyone is near the lift truck control handles per ANSI B56 1 311 Daily Inspection Perform the following at the beginning of each work shift 1 Extend the carriage a few inches off the ground and make s
8. NOTE Underclearance is based on mast production series actual mast underclearance may vary by truck model Figure 53 Upright and Carriage Position Main Lift Chain Adjusting Nuts MA0415 ll Figure 55 Main Lift Chains 687250 R3 secin D Service 5 6 5 Main Lift Chain Service WARNING The intermediate upright must be supported by a block to avoid possible injury 1 Raise the inner upright 3 ft 90 cm Place a 3 ft 90 cm block under the free lift cylinder support casting then lower the cylinder support onto the block The main lift chains should be slack See Figure 51 2 Remove the cotter pins and pins from the chain anchors Remove the chains 3 Inspect the chain anchors for cracks Replace as required 4 For reassembly reverse the above procedures Adjust MAD0SE GpS the chains as described in Section 5 6 3 Figure 56 Main Chains 566 Free Lift Chain Service WARNING The carriage must be supported by a block to avoid possible injury 1 Raise the carriage 12 in 30 cm Place a 12 in 30 cm block under the carriage then lower the carriage onto the block The free lift chains should be slack See Figure 52 2 Remove the cotter pins and pins from the chain anchors Remove the chains 3 Inspect the chain anchors for cracks Replace as required 4 For reassembly reverse the above
9. Skewing 41 Chains 42 Inspection and Tension 42 Measuring Chain Stretch 43 Main Lift Chain Adjustment 43 Free Lift Chain Adjustment 43 Main Lift Chain Service 44 Free Lift Chain Service 44 Section 1 ntro duct O n 1 1 Introduction This manual provides the installation instruction periodic maintenance troubleshooting and service procedures for the Lift Tek Series masts In any communication about the mast refer to the mast serial number stamped in the nameplate If the nameplate is missing these numbers are also stamped on the left hand upper cheekplate See Figure 1 WARNING Do not install a Lift Tek Mast A on a truck with a capacity greater than the truck rated capacities shown below TRUCK CAPACITY AT 24IN 610 mm LOAD CENTER 30D 35D 40D 50D 55D 60D 3000 Ibs 3500 lbs 4000 Ibs 5000 lbs 5500 lbs 6000 Ibs 1361 kg _ 1585kg 1812kg 2268kg 2491kg 2718kg Modifications and additions which affect capacity or safe operation shall not be performed without prior written approval from Lift Technologies per ANSI B56 1 Special Definitions A statement preceded by amp WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPORTANT A statement preceded by IMPORTANT that possesses special significance NOTE A statem
10. crosshead sheaves Orient the hoses with the natural curve over the sheaves 7 Route the hoses down between the free lift cylinder and middle inner crossmember to the bracket behind the free lift cylinder The hoses route through the wire loop then underneath the lower inner crossmember Assemble the Sheno Se Outer clamp and hoses then pull down on the hoses with 80 Q pro aa lbs force to remove slack Tighten the clamp capscrews A to a torque of 8 ft lbs 11Nm ee a eo a Inner Intermediate Upright Upright NS ra 71 he MA0274 ill ff 2 Figure 10 Bracket Installation 687250 R3 sin INStallation Instructions Internal Reeving Hi Vis Installation 3 30D 35D 40D and 90D O O LEE ae n am Up Bracket H al kg A 10 Center SINGLE DOUBLE Bracket FUNCTION FUNCTION c gt l anA 7 Carriage Je Bracket Fittings uh SINGLE FUNCTION SINGLE FUNCTION i Goa Ce D DOUBLE DOUBLE gt FUNCTION FUNCTION i mm 1 L Typical all clamps pe a
11. fittings making sure they do not twist MA0538 ill 14 687250 R3 sein 2 Installation Instructions Internal Reeving Std Vis Installation 55D 60D Double Function 1 Install the carriage bracket to the tabs on the carriage side plates Tighten the nuts to a torque of 38 ft lbs 51Nm 2 Install the bulkhead and 90 fitting to the holes in the carriage bracket 3 Install the hoses to the carriage bracket fittings Leave the fittings loose 4 Route the hoses up and over the rollers on the cross head Tighten the sheave capscrews to a torque of 38 ft lbs 51Nm WARNING Chain and block the uprights and carriage to secure for step 5 5 Raise the carriage approximately 8 ft 240 cm Route the hoses downward on the front side of all crossmem bers then under the tab on the front side of the cylinder support Feed the hoses backward under the cross member around the casting guide upward under the back side tabs Pull the hose ends to remove slack Remove the existing capscrew from the main lift chain shafts Install the hoses sheaves shaft and spacers to the main lift chain shafts Tighten the capscrew to a torque of 58 ft lbs 79Nm Make sure the sheaves rotate freely Attach the hoses to the brackets and fittings Leave the fittings loose on the bracket A Cylinder Support Figure 17 Hose Routing 9
12. lift height to verify c External leaks at retainer c Replace all cylinder seals d Piston check valve leaking d Replace check valve Spongy or jerky action a Sticky or defective truck relief valve a remove and check the truck relief valve If contaminated oil caused the malfunction drain and flush the system change the filter and refill with fresh oil A WARNING Extreme care should be used when working on a unit when the carriage with or without a load is in the raised position b Bent or damaged cylinder plunger b Disassemble check and repair cylinder assembly A WARNING Extreme care should be used when working on a unit when the carriage with or without a load is in the raised position c Load rollers not properly adjusted c Adjust or repair as necessary or defective WARNING Extreme care should be used when working on a unit when the carriage with or without a load is in the raised position d Mast channels improperly lubricated d Lubricate mast A WARNING Extreme care should be used when working on a unit when the carriage with or without a load is in the raised position e Low Battery charge e Charge battery f Low pump volume f Install accumulator g Low oil level g Fill oil reservoir h Insufficient hydraulic tank capacity h Install larger tank baffles or baffles Other Contact Lift Technologies 17 687250 R3 sim OerVICe 1 Mast Removal 1 Raise and blo
13. the inner and intermediate upright outward 2 ft 60 cm 6 Lift the cylinder from the base mount and angle inward to remove through the gap at the top of the uprights 7 Note the number of shims if equipped on each cylinder rod For reassembly reverse the above procedures except as follows WARNING Main lift cylinders must be bled to remove trapped air prior to returning the mast to operation Refer to Section 5 2 11 24 687250 R3 sein Service s26 Free Lift Cylinder Removal Mast on Floor 1 Remove the mast from the truck as described in Section 5 1 Lay the mast down as shown Roll the carriage toward the center of the cylinder to slacken the chains and internal reeving hoses if equipped Disconnect the hose from the cylinder 45 fitting Cap the fitting and plug the hose Remove the chain guards from the crosshead For reassembly tighten the capscrews to a torque of 48 52 ft lbs 65 70 Nm Remove the snap ring fastening the crosshead to the cylinder rod Pull the crosshead with chains and hoses if equipped off the cylinder rod Remove the cylinder strap Remove the cylinder from the mast 10 For reassembly reverse the above procedures Figure 25 Cylinder Removal 25 MAO778 tif 687250 R3 sein Service 527 Free Lift Cylinder Removal Mast on Truck 1 Completely lower the carriage Remove forks or attachment if equipped Make s
14. the lowering control valve where it is re stricted at a controlled speed determined by the load being handled 3 As the main lift cylinder pistons lower over the spear in the bottom of the shell a high pressure area is devel oped between the piston and shell which engages the cushion valve to restrict flow This slows the piston plunger just prior to bottoming providing a smooth transition to the free lift cylinder lowering N 22 687250 R3 wn D OEFVICe Triple Mast MT Hydraulic Schematic Main Lift Cylinder Main Lift Cylinder Free Lift Cylinder Shell Plunger Plunger Check Valve Not used in Main Lift Ckeck 2600 psi cylinders Valve Piston Q 7 Piston Hydraulic Fuse Cushion Valve Lowering Control Valve i lupe L Inlet Port To Truck Valve Figure 23 Cylinder Operation 23 687250 R3 sein Service 5 2 5 Main Lift Cylinder Removal Mast on Floor 1 Remove the mast from the truck as described in Section 5 1 2 Lay the mast down on wooden blocks as shown Block under the outer upright so the inner upright will be free to move The carriage must be positioned between the blocks and free to move 3 Disconnect the cylinder supply hoses from the cylinder inlet ports Remove the special long fittings from the cylinder ports and install plug fittings NOTE Each fitting holds a compressed spring in place 4 Remove the snap rings fastening the cylinder rods to the intermediate upright 5 Pull
15. the main lift cylinder stroke Electric trucks limit the control valve movement to achieve 50 speed Retract all cylinders Repeat four times 3 Cycle the mast with a half load 50 mast rated capacity through full cylinder extension several times The cylinders should extend smoothly Repeat the steps if cylinder extension is not smooth Valve 5 3 1 Valve Cartridge Service 1 Completely lower the mast 2 Remove the truck supply hose from the valve car tridge See Figure 32 Plug the hose 3 Remove the valve cartridge from the valve Note the stamped part no on the Cartridge for ordering a replacement WARNING Replacing the valve cartridge with a different part no cartridge may cause the mast to malfunction 4 For reassembly reverse the above procedures 29 MA0677 eps Figure 31 Piston Removal MA0238 eps Figure 32 Valve Cartridge Service 687250 R3 in OErVICe s4 Carriage 541 Description The carriage shown below is the structure that hook type forks or attachments are attached The carriage travels within the rails of the mast inner upright on four or six optional shim adjustable rollers The rollers are held in the uprights All load rollers are interchangeable There are four side thrust rollers to transfer carriage side loading to the inner rails These rollers are eccentrically adjustable A pair of chain anchors are used to connect
16. 4 Free Lift Chain adjustment SEE SECTION 5 6 6 3 in 5 in Underclearance Underclearance Outer Upright and Carriage Flush Outer Upright i Carriage 2 in i Below Outer LE Upright NL MA2777 eps NOTE Underclearance is based on mast production series actual mast underclearance may vary by truck model Figure 5 Upright and Carriage Position 687250 R3 sein Installation Instructions 2 4 4 2 4 5 2 4 6 2 4 7 Free lift Cylinder Supply Hose Tracking Adjustment Make sure the cylinder supply hose is not twisted and travels evenly in the hose guide Check the hose to be sure it is not scuffing Adjust the hose by loosening the hose end connection at the valve and twist the hose Tighten the hose end while holding the hose in place See Figure 10 Tension on the hose can be adjusted by using a different set of bracket holes Use the holes that place a small amount of tension on the hose MA03838 ill Figure 6 Free Lift Cylinder Supply Hose Adjustment Upright Rail Lubrication Lubricate the full length of each upright rail with chassis lube or Kendall SR 12X as shown in Figure 6 Upright Rails Cylinder Bleeding SEE SECTION 5 2 11 Mast Skewing Check for mast skewing as described in Section 5 5 6 J maog41 eps LUBRICATE ONLY WHERE INDICATED BY THE HEAVY LINE FOR THE FULL LENGTH OF EACH UPRIGHT
17. 5 2 5 2 Use a claw type spanner wrench to remove the retainer See Figure 27 3 Remove the plunger piston assembly from the shell 4 Remove the Hydraulic Fuse Lowering Cushion compo nents 5 Inspect all components for nicks or burrs Minor nicks or burrs can be removed with 400 grit emery cloth NOTE Minor nicks are those that will not bypass oil when under pressure If they cannot be removed with emery cloth replace the part If the piston requires re placing refer to Section 5 2 10 6 Replace the retainer and piston seals back up rings O rings and bearing Lubricate the new seals with petroleum jelly prior to installation Note the correct seal directions The cylinder will not operate correctly if the seals are installed backwards 7 2000 PSI CYLINDERS When replacing the piston check valve O ring make sure the check valve is reinstalled with the arrow pointed in the correct direction 8 Install the plunger retainer on the plunger Install the plunger piston assembly into the cylinder shell Tighten the retainer to the torque value listed below using the claw spanner wrench and a strap wrench 30D 35D 40D 95 125 ft lbs 129 169 Nm 2000 PSI 27 eS Hydraulic Fuse Lowering Cushion A M M MA0071 eps Figure 27 Claw Type Spanner Wrench A Retainer E A XZ AE UL S Plunger Piston Assembly Check Valve WO SS IZZZA SW KN
18. 5 4 4 Lubricate the inner upright rails with chassis lube or Kendall SR 12X See Figure 34 Assemble shims and load rollers on the stub shafts The shims should be installed to provide a total side to side clearance no looser than 1 16 in 1 5 cm at the tightest point throughout the travel of the car raige Use an equal amount of shims side to side Adjust the carriage side thrust rollers for unrestricted clearance along the travel of the carriage The rollers have eccentric mount bases Turn the base of the roller toward the upright rail to decrease clear ance See Figure 28 Tighten the capscrews to a torque of 70 80 ft lbs 95 110 Nm Check and adjust the free lift chains as described in Section 5 6 4 and 5 6 6 Carriage Side Thrust Rollers IMPORTANT Adjust Roller base toward rail in direction shown MA0783 tif Load Upright Rollers Rails Figure 35 Carriage Removal Figure 34 Rail Lubrication and Carriage Side Thrust Rollers 31 687250 R3 sein Service Carriage Removal Mast on Floor Load Upright Channels 5 4 3 Rollers 1 Remove mast from truck as described in Section 5 1 2 Remove chain anchor nuts Note location of double nuts for reassembly Remove the chain anchors 3 Disconnect the internal reeving hoses for the carriage fittings if equipped Plug the hose ends 4 Roll the carriage tot he bottom of the mast 5 Attach an overhead hois
19. Install the inner upright through the top of the intermediate upright 6 Assemble shims and load rollers to the intermediate upright top and inner upright lower stub shafts The shims should be installed to provide a total side clearance no loosest than 1 16 in 1 5 mm at the tightest point throughout the travel in the upright Use an equal amount of shims side to side NOTE Roll the upright past the thrust plugs before checking roller clearances 7 Install the chain sheave and free lift hose sheave to the intermediate upright Tighten the capscrew to a torque of 26 30 ft lbs 35 40 Nm 8 Install the main lift chain anchors long anchors and chains to the outer upright crossmember Inner Upright MA0856 eps Figure 47 Mast Reassembly 39 687250 R3 sein Service 555 Upright Reassembly Continued 9 Install the chain anchors long anchors to the back side of the inner upright lower crossmember 10 Pull the main lift chains over the chain sheaves and attach to the lower inner upright chain anchors 11 Install the free lift chain anchors short anchors and chains to the inner upright center crossmember 12 Install the free lift cylinder supply hose through the hole in the outer upright top crossmember and over the sheave on the intermediate top upright 13 Install the carriage as described in Section 4 5 3 14 Install the free lift cylinder as described in Section 5 2 6 15 Install the inte
20. Service Manual 30D 35D 40D 50D 55D 60D Full Free Lift 3 Stage Mast MT Manual Part Number 687250 R3 LETTEKE ees Lift Technologies Inc 2005 Contents Page INTRODUCTION Section 1 4 Introduction 4 Special Definitions 4 INSTALLATION INSTRUCTIONS Section 2 5 Truck System Requirements 5 Mounting Bracket Installation 5 Mast Installation 6 Inspection and Adjustments 7 Chain Inspection and Tension 7 Main Lift Chain Adjustment 7 Free Lift Chain Adjustment 7 Free Lift Cylinder Supply Hose Tracking Adjustment 8 Upright Rail Lubrication 8 Cylinder Bleeding 8 Mast Skewing 8 Internal Reeving Installation 9 PERIODIC MAINTENANCE Section 3 16 TROUBLESHOOTING Section 4 17 SERVICE Section 5 18 Mast Removal 18 Cylinders 19 2000 PSI Main Lift Cylinder Description 19 2600 PSI Main Lift Cylinder Description 20 Free Lift Cylinder Description 21 Cylinder Operation 22 Main Lift Cylinder Removal Mast on Floor 24 Free Lift Cylinder Removal Mast on Floor 25 Free Lift Cylinder Removal Mast on Truck 26 Main Lift Cylinder Service 27 Free Lift Cylinder Service 28 Piston Removal 29 2600 PSI Cylinder Bleeding 29 Valve 29 Valve Cartridge Service 29 Carriage 30 Description 30 Carriage Removal Mast on Truck 31 Carriage Removal Mast on Floor 32 Carriage Inspection 33 Mast Uprights 34 Upright Description 34 Upright Operation 35 Upright Disassembly 36 Upright Inspection 37 Upright Reassembly 38 Mast
21. ackets and cross members to fit your lift truck consult with the nearest Lift Tek Service Department listed on the back cover You must supply dimensions A through F shown in Figure 3 Failure to install the correct brackets and cross Front View members can result in mast structural failure bodily injury and loss of warranty WARNING Failure to install the correct TN and crossmembers can result in mast structural failure bodily injury and loss of warranty Tilt Cylinders Side View MA0031 eps Figure 3 Determining Mounting Bracket Location 5 687250 R3 seein 2 IN 23 Mast Installation 1 Raise and block the front end of the truck 1ft 30 cm per ANSI B56 1 or drive the truck over a service pit 2 Install the bearings to lower the axle mounts 3 Lubricate the bearing surfaces of the lower axle and tilt cylinder mounting brackets with chassis grease 4 Lift the mast using an overhead hoist with chain hooks attached to the cheekplate lifting holes Position the mast by lowering the 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 5 Connect the lift truck hose to the ma
22. ck the front end of the truck 1ft 30cm or drive the truck over a service pit 2 Disconnect the lift truck supply hose from the mast valve Plug the hose end and cap the valve fitting WARNING Do not stand on or near the mast while suspended by the hoist 3 Attach overhead hoist with lifting strap routed under all upper crossmembers Take up slack in the strap 4 Disconnect the tilt cylinders from the mast anchor A brackets For reassembly tighten the pin capscrews to the truck manufacturer s torque specifications D 5 Disconnect the mast lower mounts For reassembly tighten the capscrews to the truck manufacturer s torque specifications 6 Lift away the mast 7 For mast installation refer to Section 2 1 WARNING Do not stand the mast upright unless it is chained to a support 50D MAST OQ MA0943 eps Figure 19 Mast Removal 18 687250 R3 cin OErVICe 5 2 5 2 1 Cylinders 2000 PSI Main Lift Cylinder Description The main lift cylinders are single stage piston type cylin ders They consist of a shell and a telescoping plunger piston assembly During extension oil pressure is acting against the full piston area The truck hoist control valve holds the cylinder in place once extension has stopped The shell is internally threaded at the top end to hold the retainer The retainer seals provide a high pressure hydraulic seal agai
23. e the free lift cylinder supply hose and sheave Remove the main lift chain sheaves 11 Roll the inner upright downward to expose the inner and intermediate upright load rollers Remove the load rollers Note the number of shims behind each load roller 12 Attach an overhead hoist to the inner upright Remove the inner upright through the top of the intermediate upright 36 687250 R3 sein Service 5 5 3 Upright Disassembly Continued CAUTION The chain anchor nuts should be used one time only and be replaced after removal 13 Remove the main lift chain anchors long anchors and chains from the outer upright crossmember Tag the anchors for reassembly 14 Roll the inner upright downward to expose the interme diate and outer upright load rollers Remove the load rollers Note the number of shims behind each load roller 15 Attach an overhead hoist to the intermediate upright Remove the intermediate upright through the top of the outer upright Figure 43 Upright Disassembly 55 4 Upright Inspection 1 Inspect the load rollers for excessive wear or damage Rollers with visible flat spots or cracks should be replaced See Figure 44 2 Inspect the load roller bearings by turning the rollers on their shafts Rollers with roughness or noticeable restrictions to turning should be replaced 3 Inspect the load roller stub shafts If they are damaged or have cracks at the base the upright mast must be
24. eal provide a high pressure hydraulic seal against the plunger The retainer also limits the upward stroke of the plunger A piston is attached to the bottom end of the plunger The piston seal provides a high pressure hydraulic seal against the shell A check valve is located in the bottom on the pis ton The check valve allows residual oil between the shell and plunger to escape when the cylinder is extending A hydraulic fuse cushion valve is located in the cylinder port In case of a hose failure between the lowering control valve and cylinder the fuse limits the lowering speed of the cylin der Retainer Piston Plunger Assembly Check Valve free flow in direction of arrow Hydraulic Fuse Assembly Hi AAAS Viii HIN AT AHA MA0747 eps Figure 22 Free Lift Cylinder 21 687250 R3 sein Service 524 Cylinder Operation re blab Raising 1 When the truck hoist control valve is actuated oil enters the lowering control valve through the inlet port and flows unrestricted through the lowering control car tridge 2 Oil flows to the cylinder inlet ports Due to the larger bore diameter of the free lift cylinder compared to both main lift cylinders the free lift cylinder will raise com pletely before the main lift cylinders raise 3 Oil flows through the free lift cylinder hydraulic fuse cushion valve to the bottom of the piston Lifti
25. ent preceded by NOTE is information that is handy to know and may make your job easier OR XXXXXX XXXX XXXXXX Stamped Serial Numbers Example 55D MT 001 00025 M MA2779 eps Figure 1 Serial Mast Number Location 687250 R3 secion 2 INStallation Instructions 21 Truck System Requirements To achieve 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 fitting size to use between the truck control valve and masts valve Lift Tek Relief Hose Fitting Mast Pressure Size Size 30D 35D 40D 2000 psi No 8 min No 8 min 30D 385D 40D 2600 psi No 6min No 6 min 50D 55D 60D 2600 psi No 8 min 13 32 in Orifice Valve inlet port is 3 4 in SAE O ring See Figure 2 MA0022 eps WARNING For proper truck stability or to prevent interference tilt restriction may be required Contact the truck manufacturer IMPORTANT Lift Tek Masts are compatible with SAE 10W petroleum base oil per Mil Spec MIL 0 5606 or MIL 0 2104 Valve Inlet Port B only Use of synthetic or aqueous base hydraulic oil is not 3 4 in SAE O ring recommended If fire resistant hydraulic oil must be used Figure 2 Valve inlet Port contact Lift Tek Mounting Bracket Installation If it is necessary to install mounting br
26. ft cylinders lower at the same time Once the main lift cylinder have nottomed out the free lift cylinder begins to lower resulting in a smooth lowering of the carriage 35 Inner Intermediate Upright Upright Outer a Upright Main Lift Chains Free Lift Chains Main Lift Cylinders Carriage Free Lift Cylinders MA0787 tif Figure 41 Upright Operation 687250 R3 sein Service 553 Upright Disassembly 1 Remove the mast assembly from the truck as de scribed in Section 5 1 2 Remove the main lift cylinders from the mast as de scribed in Section 5 2 5 3 Turn the mast over 4 Remove the free lift cylinder from the mast as de scribed in Section 5 2 6 5 Remove the carriage from the mast as described in Section 5 4 3 6 Remove the internal hose reeving sheave and hoses equipped Inner Upright Intermediate Upright 7 Remove the pins fastening the main lift chains to the inner upright chain anchors Pull the main lift chains back through the chain sheaves CAUTION The chain anchor nuts should be used one time only and be replaced after removal 8 Remove the main lift chain anchors long anchors from the inner upright lower back side Tag the anchors for reassembly MA0852 eps Figure 42 Upright Disassembly 9 Remove the pins fastening the free lift chains to the inner upright chain anchors 10 Remov
27. n Check for tight joints If tight joints are caused by rust or corrosion loosen them with SAE 40 wt oil or penetrating oil If they cannot be loosened or if the tight joints are caused by bent pins or plates or by peened plate edge replace both strands of the chain Check for protruding or turned pins Replace both strands of the chain Check for chain side wear If pins and outside plates show signs of wear check for misalignment os sheaves anchors or other components Correct the misalignment If wear is excessive replace both strands of chain Check for worn broken or misaligned chain anchors Replace or adjust as required Lubricate the full length of the chains with SAE 40 wt oil or Bowman Heavy Load Red Grease 42 CRACKED SIDE PLATES Figure 51 Chain Inspection 687250 R3 sein Service 5 6 3 5 6 4 Regular inspection and lubrication of the chains will increase their service life and reduce downtime If the chains stretch beyond the recommended amount they should be replaced in pairs Chain stretch can be measured with chain wear scale Measure the chains according to the instructions printed on the chain wear scale without a load on the carriage to check the free lift chains raise the carriage 1 ft 30 cm off the ground to put tension on the chains To check the main lift chains raise the mast until the inner upright starts to extend ensuring tension on the chains Mai
28. n Lift Chain Adjustment The main lift chains should be adjusted so that when the unloaded mast is fully lowered the uprights are positioned as shown in figure 53 1 Adjust one chain to achieve the correct upright position when fully lowered See Figure 55 2 Adjust the other chain to achieve equal chain tension Tighten the nuts together to a torque of 50 70 ft lbs 98 96 Nm 3 Raise and lower the mast several times to confirm the adjustments Free Lift Chain Adjustment The free lift chains should be adjusted so that when the unloaded mast is fully lowered the upright channels and carriage are positioned as shown in Figure 53 1 Locate the threaded chain anchors on the front side of the inner upright crossmember on each side of the cylinder Adjust one chain to achieve the correct upright position when fully lowered See Figure 54 2 Adjust the other chain to achieve equal chain tension Tighten the nuts together to a torque of 50 70 ft lbs 68095 Nm 3 Raise and lower the mast several times to confirm the adjustments Cylinder Strap Free Lift Adjusting Nuts MA0387 ill Free Lift Chains 43 op o V A on CIDE oles 8 9 0 Coyle of MA0634 eps New Chain Stretched Chain Figure 52 Measuring Chain Stretch 3 in 5 in Underclearance Underclearance Outer Upright and Carriage Flush Outer Upright Upright H Carriage 2 in MA2777 eps Below Outer
29. ng force is created against the bottom of the piston causing the plunger to raise Oil in the area between the plunger and shell is allowed to escape through the check valve in the piston as the plunger raises to the end of its stroke 4 2000 PSI Piston Type Main Lift Cylinders Oil flows through the hydraulic fuse cushion valve to the bottom of the piston Lifting force is created against the bottom of the piston causing the plunger to raise Oil in the area between the plunger and shell is allowed to escape through the check valve in the piston as the plunger raises 2600 PSI Displacement Type Main Lift Cylinders Oil flows through the hydraulic fuse cushion valve to the piston The piston is internally ported to allow oil flow to the area between the plunger and shell Lifting force is created that acts on the diameter of the plunger causing the plunger to raise 5 When oil flow from the truck hoist control valve is discontinued the cylinders are held in position by the closed center spool of the truck valve Cylinders Lowering 1 When the truck hoist control valve is actuated the main lift then free lift cylinder plungers lower forcing oil out through the hydraulic fuse cushion valves NOTE The restriction setting of each hydraulic fuse is lower allows more oil flow than the setting of the lowering control valve The hydraulic fuses restrict flow only in the instance of a lowering control valve or hose failure Oil flows to
30. nspection Figure 18 Load Roller Clearances 16 687250 R3 cin 4 Troubleshooting The following table lists problems that may be encountered on your Lift Tek Mast the probable causes and rec ommended corrective action that should be taken to restore the mast to normal operating condition PROBLEM PROBABLE CAUSE SOLUTION Cylinders don t lift load or won t move Empty a Plugged inlet hose a Unplug hose or replace b Insufficient oil b Check the truck hydraulic system for correct oil level in tank defective pump or pump drive leaks in the lines or disconnect control valve linkage Repair or replace as necessary c Bent or jammed plunger c Repair or replace as necessary A WARNING Extreme care should be used when working on a unit when the carriage with or without a load is in the raised position Loaded a Plugged piston check valve a Unplug check valve or replace b Truck relief valve setting low b Raise truck relief setting to specified level c Over capacity c Reduce load to specified capacity d Mechanical bind due to bent plunger d Remove mechanical bind by or bad rollers replacing freeing plunger and rollers WARNING Extreme care should be used when working on a unit when the carriage with or without a load is in the raised position Cylinders drift a External leak in pressure line a Tighten or replace as necessary b Truck valve defective cycle to full b Repair or replace truck valve
31. nst the plunger The retainer also limits the upward stroke of the plunger A piston is attached to the bottom end of the plunger The piston seal provides a high pressure hydraulic seal against the shell A check valve is located in the bottom of the piston The check valve allows residual oil between the shell and plunger to escape when the cylinder is extending A hydraulic fuse cushion valve is located in the cylinder port In case of a hose failure between the lowering control valve and cylinders the fuse limits the lowering speed of the cylinder The valve also cushions the piston when the cylinder nears the fully lowered position Retainer Bleed Screw Shell 19 Plunger Piston Assembly AAA SS ANN K ANS ASN Check Valve free flowing direction of arrow NY PLZZ ZA EA BBD RR L Hydraulic Fuse Cushion Valve YA NZ Ao eh ZZ NY i D 7 x LLL Nii RAN Figure 20 2000 PSI Cylinder 687250 R3 LL MA0609 eps 5 2 2 sein D OCFV CE_ 2600 PSI Main Lift Cylinder Description The main lift cylinders are a single stage displacement type cylinders They consist of a shell and a telescoping plunger piston assembly During extension the oil pressure is acting against the plunger outer diameter due to the internal porting through the piston The piston seals do no
32. procedures Adjust the chains as described in Section 5 6 4 MA0798 tif Figure 57 Free Lift Chains 44 687250 R3 Manual Change Summary R3 07 20 05 Remove description cushion and pneumatic from figures 5 and 53 Add note to page 30 Add nameplate to figure 1 45 687250 R3 Do you have any questions that need to be answered right now Lift Technologies Inc 7040 South Highway 11 Westminster SC 29693 USA Tel 1 864 647 1119 Fax 1 864 647 5406 Customer Service North America Toll Free 1 888 946 3330 Other Lift Technologies Locations Lift Technologies Inc Corporate Head Office 251 Woodlawn Road W Unit 217 Guelph ON N1H 8J1 Canada Tel 1 519 823 4545 Lift Technoloies Inc 11 2003 Lift Tek Elecar Srl 29015 Castel San Giovanni PC Via G Galilei Italy DM LETTEK 2 ELECAR2
33. r Piston Assembly ERS Figure 29 Claw Type Spanner Wrench MA0071 eps N A N Check Valve Hydraulic Fuse Lowering Cushion ih eS CI Figure 30 Cylinder Service 687250 R3 _ sind OEFVICe 5 2 10 Piston Removal 1 Remove the plunger piston assembly from the cylinder shell as described in Section 5 2 8 or 5 2 9 2 Use a strap wrench and 400 grit emery cloth to secure the plunger while turning the piston with a pin type spanner wrench 3 Turn the piston until the snap wire end is visible through the hole Use a screwdriver to start the wire end out the hole Turn the piston to feed the wire out 4 Pull the piston from the plunger 5 For reassembly reverse the above procedures except as follows Install a new snap wire when installing the piston 5211 Cylinder Bleeding WARNING The cylinders must be bled to remove air Air in the cylinders will compress on the first extension which could rupture the cylinders causing serious bodily injury and property damage After repair the cylinders may have air trapped in them that must removed To bleed air do the following 1 Without a load extend the free lift cylinder and con tinue to extend the main lift cylinders to 90 of full stroke Retract all cylinders completely Repeat three times 2 Extend the cylinders without a load at 50 full engine speed then build to full system pressure at the end of
34. re placed or repaired 0 Z 4 Inspect the outer and intermediate upright thrust plugs a If the wear surface is worn to less than 1 16 in 1 5 mm they should be replaced MA0628 eps 5 Inspect the hoist chains as described in Section Figure 44 Upright Inspection 5 6 1 37 687250 R3 sein Service 555 Upright Reassembly 1 Lubricate the outer upright rails with chassis lube or Kendall SR 12X See Figure 45 Upright Rail N Attach an overhead hoist to the intermediate upright Install the intermediate uptight through the top of the outer upright o Install the thrust plugs to the uprights A Assemble shims and load rollers to the outer upright and lower intermediate upright stub shafts The shims should be installed to provide a total side to side clearance no looser than 1 16 in 1 5 mm at the MA0629 eps tightest point throughout the travel in the upright Use an equal amount of shims side to side NOTE Roll Lubricate only where indicated the upright past the thrust plugs before checking roller by the heavy lines for the full clearances length of each upright oa Lubricate the intermediate upright rails with chassis lube or Kendall SR 12X See Figure 40 Figure 45 Rail Lubrication Intermediate Upright Figure 46 Mast Reassembly MA0854 eps 38 687250 R3 sein Service 55 5 Upright Reassembly Continued 5 Attach an overhead hoist to the inner upright
35. rnal reeving sheave and hoses if equipped as described in Section 2 4 16 Turn the mast over 17 Install the main lift cylinders as described in Section 5 2 5 18 Install the mast to the truck as described in Section 5 1 19 Adjust the main lift and free lift chains as described in Sections 5 6 3 and 5 6 4 Check for mast skewing as described in Section 5 5 6 6 Figure 48 Upright Reassembly MA0857 eps 40 687250 R3 sein Service 556 Mast Skewing Extend the mast to the full lift height 1 A If the mast kicks to the right at full extension a shim part no 200524 needs to be installed to the right hand main lift cylinder rod If the mast kicks to the left at full extension a shim part no 200524 needs to be installed to the left hand main lift cylinder rod Place a 6 in 15 cm long 2 X 2 in 5 X 5 cm angle iron between the top of the main lift cylinder and the crossmember See Figure 45 Lower the crossmember onto the angle iron Remove the snap ring from the cylinder to be adjusted Open the truck valve to allow the center free lift cylinder to fully retract Tap the main lift cylinder rod down past the crossmember to install the shim Slowly hydraulically power the main lift cylinder back into the crossmember and reinstall the snap ring 5 Repeat steps through until skewing is removed Snap Rin 3 z Intermediate l Upright X Outer Shim Upright
36. rs on their shafts Rollers with roughness or noticeable restrictions to turning should be replaced oo Inspect all welds between the carriage side plates and the carriage fork bars If any welds are cracked replace the carriage 4 Inspect the roller stub shafts If they are damaged or if there are cracks at the base of the stub shafts the carriage must be replaced or repaired Contact Lift Tek for repair procedures Carriage Weldment a Pin Kf Cotter Pin Chain Side Thrust Anchor Rollers Cotter Pin Nut Chain Anchor Nut Figure 39 Carriage MA0845 eps IMPORTANT The chain anchor nuts must be installed as shown for correct operation 33 687250 R3 sein Service 5 5 5 5 1 Mast Uprights Upright Description Outer Upright Assembly The outer upright assembly is mounted to the truck A pair of shim adjustable load rollers are attached to stub shafts located near the top of the upright A pair of adjustable hoist chain anchors are located on the top crossmember Intermediate Upright Assembly The intermediate upright assembly telescopes within the outer upright assembly A pair of shim adjustable load rollers are attached to stub shafts located at the top and bottom of the upright A pair of chain sheaves are located near the top of the upright to provide a rolling surface for the main lift chains Inner Upright Assembly The inner upright assembly telescopes within the intermedi
37. st valve 6 Connect the tilt cylinders to the mast anchor brackets Tighten the pin capscrews to the truck manufacturer s torque specifications NOTE Use as few fittings as possible and always use 45 fittings instead of 90 fittings Keep the hose lengths to a minimum Avoid sharp bends or pinch points when routing the hose 50D MAST Contact Lift Tek if additional fittings are required See back cover MA0942 eps Figure 4 Mast Installation 6 687250 R3 Section _ 2 4 2 4 1 2 4 2 2 4 3 ion T Inspection and Adjustments Chain Inspection and Tension The hoist Chains have been factory lubricated using heat and pressure to force the lubricant thoroughly into the chain links Avoid removal or contamination of this factory applied lubricant Do not wash sand blast etch steam clean or paint the chains for internal mast installation The chains must be adjusted with equal tension to ensure proper load distribution and mast operation To determine equal tension extend the unload 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 preform the hoist chain adjust ments described in Section 5 6 3 and 5 6 4 Main Lift Chain Adjustment SEE SECTION 5 6
38. t affect cylinder extension The truck hoist control valve holds the cylinders in place once extension has stopped The shell is internally threaded at the top end to hold the retainer The retainer seals provide a high pressure hy draulic seal against the plunger The retainer also limits the upward stroke of the plunger A piston is attached to the bottom end of the plunger The piston seal provides a high pressure hydraulic seal against the shell that engages the cushion valve when the cylinder is fully lowered A hydraulic fuse cushion is located in the cylinder port In case of a hose failure between the lowering control valve and cylinders the fuse limits the lowering speed of the cylinder The valve also cushions the piston when the cylinder nears the fully lowered position Hydraulic Fuse Cushion Valve 20 Retainer Bleed Screw A D Shell Plunger Piston Assembly TENEN A eee ZN at MA0610 eps Figure 21 2600 PSI Cylinder 687250 R3 w D OerVICe The 2000 and 2600 psi free lift cylinders are single stage piston type cylinders They consist of a shell and a plunger piston assembly During extension the oil pressure is acting against the full piston area The truck hoist control valve holds the cylinder in place once extension has stopped The shell is internally threaded at the top end to hold the re tainer The retainer s
39. t to the carriage for bars Remove the carriage through the bottom of the mast MAO784 tif 6 Note the number of shims located behind each load LUBRICATE ONLY WHERE INDICATED roller for reassembly TU LENGTH OF EACH UPRIGHT Figure 36 Rail Lubrication 7 For Reassembly reverse the above procedures except as follows inspect the carriage as described in Section 5 4 4 Lubricate the inner upright rails with chassis lube or Kendall SR 12X See Figure 37 Carriage Removal Figure 38 9 i 9 Assemble shims and load rollers on the carriage stub shafts The shims should be installed to provide a total side to side clearance no looser than 1 16 in 1 5 mm at the tightest point throughout the travel of the carriage Use an equal amount of shims side to side MA0849 eps Carriage Side f i F Thrust Roll Adjust the carriage side thrust rollers for unrestricted ae clearance along the travel of the carriage The rollers have eccentric mount bases Turn base of rollers toward the upright rail to decrease clearance ee Tighten to a torque of 70 80 ft lbs 96 110 Nm shown IMPORTANT Adjust Roller Check and adjust the free lift chains as described in Figure 38 Carriage Side Thrust Rollers Section 5 6 4 and 5 6 6 32 687250 R3 1 Inspect the rollers for excessive wear or damage Rollers with visible flat spots or cracks should be re placed N Inspect the roller bearings by turning the rolle
40. the carriage chains to the carriage Except on 6 roller carriages where the top roller extends past the top of the mast inner upright at full extention and are held in place by a retainer plate Carriage Weldment wa Pin a Chain Side Thrust Anchor Rollers Cotter Pin Jam Nut Chain Anchor Nut Figure 33 Carriage Service MA0845 eps IMPORTANT The chain anchor nuts must be installed as shown for correct operation 30 687250 R3 sti Service 42 Carriage Removal Mast on Truck 1 Raise the mast high enough to place a 20 in 50 cm long 4X4 in 10 X 10cm wood block between the intermediate lower crossmember and the ground Lower the carriage to be even with the bottom of the inner upright 2 Attach an overhead hoist to the carriage Raise the carriage to slacken the carriage chains p 3 Remove the chain anchor nuts Note the location of the double nuts for reassembly we OKAM R S m Inner Upright 4 Disconnect the internal reeving hoses from the carriage fittings if equipped Plug the hose ends N ENN Intermediate S lt gt Upright 5 Using the overhead hoist lower the carriage to the bottom of the mast to remove Outer Upright __ 6 Note the number of shims behind each load roller for reassembly 2 73 Con 7 For reassembly reverse the above procedures except as follows inspect the carriage as described in Section
41. ure the chains are under equal tension Refer to Section 5 6 3 and 5 6 6 for chain adjustment 2 Extend the mast to its fullest height to make sure the mast rails and carriage extend freely without binding 3 While the mast is extended inspect the upright rails for proper lubrication Refer to Section 2 4 5 Step for rail lubrication 4 Make sure the internal reeving hoses if equipped travel evenly in the hose guides Adjust the hose ends if re quired Tighten the fittings making sure they do not twist 100 Hour Inspection After each 100 hours of lift truck operation and in addition to the daily inspection Pry Here 1 Inspect and lubricate the full length of the chains with SAE 40 wt oil or Bowman Heavy Load Red Grease CAUTION The chains must be coated with a film of lubricant at all times Load Rollers 500 Hour Inspection After each 500 hours of lift truck operation and in addition to the Daily and 100 Hour Inspection 1 Each pair of load rollers on the uprights and carriage should be shimmed so that a total side to side clearance no greater than 1 16 in 1 5 mm occurs at the tightest point throughout the travel of the member Pry between the upright and load roller so that the opposite load roller is tight against the upright Measure the clearance for the pair of rollers at XXX shown See Figure 18 MAO773 tif 2 Check the chains for wear and stretch Refer to Section 5 6 1 for complete chain i
42. ure the free lift cylinder is completely retracted Attach an overhead hoist to the top carriage bar WARNING The carriage must be supported by a block while removing the cylinder to avoid possible injury 2 Raise the carriage to the center of the cylinder to slacken the chains and internal reeving hoses if equipped Block the carriage in place using a 4 X 4 X 24 in 10 X 10 X 60 cm wood block between the lower carriage bar and the floor 3 Remove the cylinder strap 4 Remove the chain guards from the crosshead For reassembly tighten the capscrews to a torque of 48 52 ft lbs 65 70 Nm 5 Remove the snap ring fastening the crosshead to the cylinder rod 6 Pull the crosshead with chains and hoses if equipped off the cylinder rod and lay over upper carriage bar 7 Pry the cylinder up out of the support casting to gain access to the cylinder hose fitting Remove the hose from the 45 fitting Cap the fitting and plug the hose 8 Remove the cylinder from the mast from the top 2 For reassembly reverse the above procedures 26 lt 7 ci A lt e Y NN T ow SR N eee MAO779 tif Figure 26 Cylinder Removal 687250 R3 sein Service 52 8 Main Lift Cylinder Service 1 Remove the cylinder from the mast as described in Section
43. w to a torque of 38 ft lbs 51Nm WARNING Chain and block the uprights and carriage to secure for step 5 5 Install spacers to the inner crossmember backside tabs 6 Raise the carriage approximately 8 ft 240cm route the hoses downward on the front side of all the cross members then under the tab on the front side of the cylinder support Feed the hoses backward under the cross member around the casting guide upward under the back side 7 Pull the hose ends to remove hose slack 8 Remove the existing capscrews from the main lift chain shafts Install the hose sheaves shafts and spacers to the main lift chain shafts Tighten the capscrews to a torque of 58 ft lbs 79Nm Make sure the sheaves rotate freely 9 Attach the hoses to the brackets and fittings Leave the fittings loose on the bracket Cylinder Support Figure 16 Hose Routing 10 Install the hose clamps to the hoses half way between the crosshead and lower crossmember 11 Pull down on the hoses to remove slack and stretch hoses one inch Install the brackets on the front side of the crossmember using the next hole down Tighten the Casting capscrew to a torque of 38 ft lbs 51 Nm Guide 12 Raise and lower the mast several times to make sure the hoses are tracking correctly Use the white line on the hose to detect twisting Adjust the hose ends if re quired Tighten
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