30_35!40!45HR MT Reach Truck Mast R8

S ERVICE MANUAL

Manual Number 246552 R8 ORION

30/35/40/45HR MTOrion Triple Stage

Full FreeliftPantograph Mast

12/15/07

246552R R8 Orion 12/15/07

ContentsIntroduction Section 1 ..................................................................................................................................................4

Introduction ................................................................................................................................................. 4Special Definitions ....................................................................................................................................... 4

Installation Section 2 ....................................................................................................................................................5Truck System Requirements .......................................................................................................................5Mast Installation .......................................................................................................................................... 5Mast Inspection ........................................................................................................................................... 6Chain Lubrication ........................................................................................................................................ 6Upright and Carriage ...................................................................................................................................6Position, Chain Tension .............................................................................................................................. 6Channel Lubrication .................................................................................................................................... 7Mast Skewing .............................................................................................................................................. 7

Periodic Maintenance Section 3 ..................................................................................................................................8Daily Inspection ........................................................................................................................................... 8100 - Hour Inspection .................................................................................................................................. 8200 - Hour Inspection .................................................................................................................................. 8500 - Hour Inspection .................................................................................................................................. 9

Trouble Shooting Section 4 .......................................................................................................................................10Troubleshooting Chart ............................................................................................................................... 10

Mast Uprights Section 5 .............................................................................................................................................11Upright Description .................................................................................................................................... 11

Upright Removal Section 6 ........................................................................................................................................ 12Upright Removal ....................................................................................................................................... 12Upright Disassembly ................................................................................................................................. 14

Upright Chain Inpection Section 7 ............................................................................................................................ 20Upright Chain Inspection ........................................................................................................................... 20Chain Length Adjustment .......................................................................................................................... 22Chain Lubrication ...................................................................................................................................... 25Chain Removal and Replacement ............................................................................................................. 26Other Chain Service Notes ........................................................................................................................ 26

Upright Cylinders Section 8 .......................................................................................................................................27Main Lift Cylinder Description .................................................................................................................... 27Free Lift Cylinder Description .................................................................................................................... 28Cylinder Operation .................................................................................................................................... 29Main Lift Cylinder Service .......................................................................................................................... 30Free Lift Cylinder Service .......................................................................................................................... 32

Upright Shimming Section 9......................................................................................................................................34Upright Rail to Roller Clearance ................................................................................................................ 34Determining the Number of Shims needed to make roller adjustments ..................................................... 43Shim Adjustment ....................................................................................................................................... 44

Pantograph Removal Section 10 ............................................................................................................................... 45Preparation ................................................................................................................................................ 45Pantograph Removal ................................................................................................................................. 45

Pantograph Service Section 11 .................................................................................................................................50Pantograph & Fork Carriage Assembly Service ........................................................................................ 50Fork Carriage Removal ............................................................................................................................. 52Servicing Pantograph Arm Rollers ............................................................................................................ 54Tilt Cylinder Service .................................................................................................................................. 56Reach Cylinder Service ............................................................................................................................. 62Side Shift Cylinder Service ........................................................................................................................ 67Reach and Tilt Selector Valve ................................................................................................................... 71Side Shifter Solenoid Control Valve ........................................................................................................... 79Servicing a Double Reach Pantograph ...................................................................................................... 84

Pantograph Shimming Section 12 ............................................................................................................................ 87Checks and Adjustments ........................................................................................................................... 90

Pantograph Valve Service Section 13 ......................................................................................................................... 96Reach / Tilt Valve Service ........................................................................................................................... 96Side Shifter Valve Service ........................................................................................................................... 99

This manual provides the installation Instructions, periodicmaintenance requirements, troubleshooting and serviceprocedures for the Lift Tek Series masts.

These masts provide excellent visibility for the lift truckdriver. The mast carriage and upright channels are allroller-mounted which provides smooth operation and longservice life.In any communication about the mast, refer to the mastserial number stamped on the nameplate. If the nameplateis missing, these numbers are also stamped on theleft-hand lower outer rail. See Figure 1-1.

Special DefinitionsWARNING

1.2

A statement preceded by is informationthat should be acted upon to prevent bodily injury. AWARNING is always inside a ruled box.

CAUTIONA statement preceded by CAUTION is information thatshould be acted upon to prevent machine damage.

IMPORTANTA statement preceded by IMPORTANT thatpossesses special significance.

NOTEA statement preceded by NOTE is information that is handy

Figure 1-1. Serial Mast Number Location

I

MA0974.eps

StampedSerial Number

Example:40HR-MT-001-00025-M

1.1

WARNING

ntroduction Section 1

Introduction

Mast Installation

I

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. Disconnect the truck power supply.

3. Lift the mast using an overhead hoist with a sling looped under the upper upright crossmembers. Position the mast on the truck. Install the mounting blocks and capscrews. Tighten the capscrews to the truck manufacturer’s torque specifications.

4. Connect the lift truck hydraulic supply hose to the mast valve.

NOTE: Use as few fittings as possible and always use 45o

fittings instead of 90o fittings. Keep the hose lengths to aminimum. Avoid sharp bends or pinch points when routingthe hose.

5. Connect all electrical connections to the mast.

6. Connect the truck power supply.

7. Check the hydraulic fluid level in the truck hydraulic tank when the Mast is fully lowered. Fill if required.

MA0975.eps

2

4

2

Figure Figure 2-1. Mast Installation.

Contact Lift Tek ifadditional fittings arerequired. See backcover.

nstallation Section 2

2.1 Truck System Requirements

WARNING: For proper truck stability or toprevent interference, tilt restriction may berequired. Contact the truck manufacturer.

IMPORTANT: Lift Tek Masts are compatible with SAE 10Wpetroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104B only. Use of synthetic or aqueous base hydraulic oil is notrecommended. If fire resistant hydraulic oil must be used,contact Lift Tek.

2.2

I nstallation

Mast InspectionCheck each of the following before using the Mast for thefirst time.

CAUTION: The factory-set adjustments may not becorrect for your truck.

1. Inspect all chains for lubrication.

2. Inspect all chains for any visible damage.

3. Inspect the main lift chain adjustment for proper tension and upright position.

4. Inspect the free lift chain adjustment for proper tension and carriage position.

5. Inspect for lubrication in the Mast upright channels.

6. Check for Mast skewing.

Chain LubricationThe main and free lift chains have been factory lubricatedusing heat and pressure to force the lubrication thoroughlyinto the chain links. Avoid removal or contamination ofthis factory-applied lubrication. Do not wash, sand blast,etch, steam clean, or paint the chains for initial Mastinstallation. If chains need lubrication, refer toSection 7.2. Chain Lubrication

Upright and CarriagePosition, Chain TensionThe main lift chains should be adjusted so that when theunloaded Mast is fully lowered, the uprights are flush atthe bottom. The free lift chains should beadjusted so that when the unloaded Mast is fully lowered,the carriage is properly positioned depending on the trucktype.

CONTINUED ON NEXT PAGE

MA0977.eps

Free Lift ChainsAdjusting Nuts

Outer MainLift ChainAdjusting Nuts

Figure 2-2. Adjusting Chain AnchorLocation (driver’s view).

Section 2

2.3

2.3-2

2.3-1

Upright and CarriagePosition, Chain Tension

( Continued )

I nstallation

All chains should also be adjusted for equal tension of thepairs to ensure proper load distribution and mast opera-tion. Chains are adjusted at the chain anchors (seeFigure 2-2). To determine equal tension, extend theunloaded mast to put the chains under tension. Then pressthe center of the strand with your thumb. Then pressat the same place on the other chain of the pair. Eachchain in a pair should have equal “give”.

If the uprights or carriage are not in correct adjust-ment, of if the chain pairs do not have equal tension,perform the Main Lift and Free Lift Chain Adjustmentsas described in section 7.1.

Channel Lubrication

MA0978.eps

OuterUpright

Lubrication

Figure 2-4. Lubricating upright channels.

Inspect the upright channels for lubrication. If necessary,lubricate the full length of each upright channel withchassis lube or Kendall SR-12X (see Figure 2-4).

Mast SkewingTo adjust the Mast to eliminate skewing, perform the MastSkewing Adjustment as described below.

Extend the mast to full lift height and inspect for mastskewing (see Figure 2-5).

* If the mast bends to the right at full extension, a shim(s) needs to be removed from the left main lift cylinder rod.

* If the mast bends to the left at full extension, a shim(s) needs to be installed on the left main lift cylinder rod.

MA0979.eps

Left HandMain LiftCylinder

Three StageMast shown

FreeliftCylinder

Right HandMain LiftCylinder

1

11

Figure 2-5. Extending Mast to checkfor skewing (driver’s view).

AlignmentPin

AlignmentPin Tab

Cylinder

Shim

WasherSnap Ring

IntermediateUpright

MA0980.eps

Figure 2-3. Shimming ML cylinders.

Section 2

2.3-2

2.3-3

2.3-4

P3.1 Periodic Maintenance

For proper operation and an extended service lift, theMast should be inspected and serviced regularly as part ofyour normal lift truck maintenance schedule according tothe following outlines and ANSI B56.1 procedures.

The recommended intervals are for Masts operating undernormal conditions. If operation is in severe conditions orcorrosive atmospheres, inspect the Mast more frequently,

WARNING: Never work on a raised mast witha load without supports, or while anyone is nearthe lift truck control handles per ANSI B56.1.

3.1-1 Daily InspectionPerform the following at the beginning of each work shift:

3.1-2 100 - Hour InspectionAfter each 100 hours of lift truck operation, and in addition tothe Daily inspection:

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 oflubricant at all times.

Pry from topof Mast - Here

Check ClearanceHere

Roller

MA0981.eps

Figure 3-1. Measuring Load Roller andThrust Plug Clearances.

1. Check cylinder rods and retainer for obvious damage ,nicks, marring,scratches that might damage the cylinder packings. Check the conditionof hydraulic plumbing and connections. Tighten connections if loose.

2. Check lift chains for damage.3. Check the chain anchor pins. Be sure the cotter pins (6) are in place

and not damaged.4. Examine the hydraulic plumbing and connections. Tighten loose

connections.5. Check harness hold-down clamps, brackets, and connectors for security

of mounting and damage.

3.1-3 200 - Hour Inspection1. Clean and lubricate pantograph assembly.

2. 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 oflubricant at all times.

3. Lubricate the full length of each mast upright rail.

eriodic Maintenance Section 3

500 - Hour InspectionP eriodic Maintenance

3.1-4

After each 500 hours of lift truck operation, and in addition to the Daily and 100 - Hour Inspections:

1. Measure load roller clearances in the carriage/pantograph and Mast uprights. Pry between the upright and load roller so that the opposite load roller is tight against the upright (see Figure 9 ). Total side-to-side clearance should be 0.020 in. (.5 mm) max. across the tightest point throughout the travel of the upright. If shimming is required.

2. Check chains for wear and stretch.

3. Check the backrest capscrews for tightness. Tighten capscrews to 145 ft.-lbs. ( 195 Nm ).

Section 3

T

PROBLEM PROBABLE CAUSE SOLUTION

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.

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 levelc) 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.

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. 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.

b) Bent or damaged cylinder plunger. b) Disassemble, check and repair cylinder assembly.

c) Load rollers not properly adjusted c) Adjust or repair as necessary. or defective.

d) Mast channels improperly lubricated. d) Lubricate mast.

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

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 don’t lift load or won't move




The Following Table lists problems that may be encountered on your Mast, the probable causes, and the recommendedcorrective action that should be taken to restore the Mast to normal operating condition.

Troubleshooting Chart

rouble Shooting Section 4

4.0

OuterUprightRollers

IntermediateUprightRollers

InnerUprightRollers Intermediate

UprightRollers

PantographRollers

PantographRollers

MA2191.eps

Upright Description

Outer Upright AssemblyThe outer upright assembly is mounted to the truck. A pairof shim adjustable load rollers are attached to stub shaftslocated near the top of the upright. A pair of adjustablehoist chain anchors are located in the top crossmember. Thesecondary cylinders rest on an integral lower crossmember.

Intermediate Upright AssemblyThe intermediate upright assembly telescopes within theouter upright assembly. A pair of shim adjustable loadrollers are attached to stub shafts located at the top andbottom of the upright. A pair of chain sheaves are locatednear the top of the upright to provide a rolling surface forthe main lift chains.

Inner Upright AssemblyThe inner upright assembly telescopes within the intermedi-ate upright assembly. A pair of shim adjustable load rollersare attached to stub shafts located at the bottom of theupright. The free lift chain anchors are attached to thecenter crossmember. The free lift cylinder rests on a cradlewhich is integral with the lower crossmember.

5.1

M ast Uprights Section 5

Mast Uprights

Figure 5-1

5.0

UUpright Removal

NOTE: It is recommended that thepantograph carriage assembly beremoved before attempting to removethe upright.

Preparation1. Turn key switch off.

*Remove key from switch.

2. Disconnect truck battery at the battery disconnect.

3. Remove battery from truck.

NOTEThe pantograph must be removedbefore attempting to remove theupright.

DisconnectBattery

MA1035.eps

4. Remove any overhead guards and/or screen guards.

5. Elevate and support each side of truck with suitable 3”hardwood (Oak) blocking. See figure 6-2.

6. Disconnect all hydraulic supply lines to the upright.Cap all open lines and fittings.

7. Disconnect all electrical connections to the mast andtie wires out of the way.

MA1036.eps

3" Blocking (Oak) Hardwood Figure 6-2

pright Removal Section 6

6.0

Figure 6-1

6.0-1

Upright Removal (Continued)

MA1037.eps

Truck Side

Hardwood (Oak) Blocking

MA1038.eps

Inner Rail Assembly

IntermediateRail Assembly Outer

Rail Assembly

Outrigger(s)

TopBottom

8. Place lifting strap beneath the upper tie bars of theouter, intermediate and inner rail assemblies.Connect strap ends to the chain hoist. Be certain thehoist is equipped with safety hooks. See Figure 6-3.

9. Raise lift to remove slack in the strap. Strap should betaut enough to support the upright after it is discon-nected from the truck.

10. Remove all fasteners securing the upright to thetruck.

11. Use hardwood (Oak) blocks to support the bottomend of the upright and to keep it level when laidhorizontally on the floor. Avoid resting the mast onhydraulic fittings.

12. Lower the upright onto the blocks with the truck sidedown. This will allow the rail assemblies to be pulledout of the outer rail assembly to access rail rollersand secondary cylinders. See figure 6-4.

Figure 6-3

Figure 6-4

6.0

WARNING: Do not stand on or near the Mastwhile it is suspended by an overhead hoist.

WARNING: Do not stand the Mast up verticallyunless it is chained to a support.

U pright Removal Section 6

Upright Disassembly

1. Pull the inner and intermediate rail assemblies partway out of the outer rail assembly to provide accessfor secondary cylinder removal. The rail cylindersmust be removed to adjust or replace the lower railrollers. Refer to figure 6-6.

2. Loosen and remove the hydraulic fittings at the baseof the left and right secondary cylinders. Discard oldO-Rings. Install new O-Ring(s) at time of installation.See figure 6-5.

3. Remove the snap ring at the base of each cylinder.

MA1039.eps

Left HandCylinder

Right HandCylinder

Tube

Elbow

FlowRegulator

Fitting

O-Ring

Truck Side


MA1038.eps

Inner Rail Assembly


Rail Assembly

Outrigger(s)

TopBottom

MA1040.epsSnap Ring

CylinderBase

Figure 6-5

Figure 6-6

Rail Cylinders

Rollers and ShimsPulling the rail assemblies part way out of the bottomof the outer rail assembly will allow access to removeand/or replace rollers and shims. The rail cylindersmust be removed to accomplish this.

6.1


AlignmentPin

AlignmentPin Tab

Cylinder

Shim

WasherSnap Ring

IntermediateUpright

MA0980.eps

NOTERecord the number of shims re-moved for each side. The samenumber of shim should be rein-stalled on each side to prevent“racking” of the upright assem-blies.

4. Remove the external snap ring from the top ofeach cylinder piston rod. See figure 6-7.

5. Remove the washer from each cylinder rod.

6. Support the cylinders, and move the rails outwardfar enough to allow removal of the cylinders.

NOTEEach cylinder is equipped witha weldment near the top end ofeach barrel assembly. Thisweldment fits over an alignmentpin that is part of the chainanchor mount of the outer up-right.

WARNINGRail cylinders are heavy andcare must be taken to avoidpersonal injury.

Upright Disassembly (Continued)

Figure 6-7

6.1


Cable, Hose and Chain Sheaves (Refer to figure 6-8 6-10, 6-11 and 6-12)

Free Lift Cylinder(Refer to figure 6-8)

* Remove cotter pins (7), jam nuts (11), full nuts (10)and ecentrical washer.

* Remove chain anchors (8) and lift chains (13).

* Remove snap ring (14). Lift cylinder off alignment pin(12) and out of upright.

Installation is reverse of removal.

NOTEThe free lift cylinder may be re-moved with upright attached totruck..

WARNINGThe free lift cylinder is heavyand care must be taken toavoid personal injury.

Free Lift Cylinder

12

3

4

56

15

7

8

9

11

10

12

13

13

14

16

MA1041.eps

Truck Side


MA1038.eps

Inner Rail Assembly


Rail Assembly

Outrigger(s)

TopBottom

Figure 6-8

Figure 6-9

* Remove snap rings (6) and sheaves (5).

* Remove screws (4) securing mounting plates tocrosshead (16) and remove assembly from block.

* Remove pins (15) and crosshead (16) from primarycylinder piston rod.

* Loosen and remove nuts (1), capscrews (3), andspacers (2).

* Disassemble assembly. Replace and worn and/ordamaged components.

Installation is the reverse of removal.

6.2-1

6.2-2


MA1042.eps

MountingPlate

Capscrew

Allen HeadScrew

Nut

Roller

Block

Roll PinSecures Block to Cylinder Rod

Sheave

Snap Ring

1

2Spacer

11

5

6

10

43

Figure 6-10


Figure 6-11

Figure 6-12


Tri-Line Hose/Cable Routing

MA2583.eps

PantographCable end

MastCable end

PantographTri-Line Hose/Cable

MastTri-Line Hose/Cable

SOCKET (Not Shown)

PIN PLUG

SEAL-INTERMEDIATE

SEAL-PROTECTOR SEAL

CAP

SEAL

SPADE FEMALE

WIRE COLOR:WIRE #1-BLACK W/BROWN STRIPEWIRE #2-GREY W/YELLOW STRIPEWIRE #3-GREY W/GREEN STRIPEWIRE #4-GREYWIRE #5-GREEN

POSITION 1

WIRE #2 (REACH)WIRE #2

WIRE #5

WIRE #1 (POWER)WIRE #1

POSITION 1

WIRE #3WIRE #4

WIRE #5 (TILT IND.)WIRE #4 (TILT)

WIRE #3 (SS)

POSITION 1

(LENGTH TO BE SAME AS WIRE 1-4)

WIRE 4WIRE 5

POSITION 1WIRE 1WIRE 2

WIRE 3

MA2584.eps

Mast to Pantograph Cable Assembly

Mast End Pantograph End

Cable and Chain Sheaves (Refer to figure 6-13 and 6-14)

* Loosen and remove retainer bolt from stubshaft.

* Remove washer, sheaves and spacer.

* Replace worn and/or damaged components.

Installation is the reverse of removal.

Removal

Bolt

Washer

Bushing

Sheave

ChainSheave

IntermediateRail Assembly MA1043.eps

Chain SheaveHose Sheave

MA1044.eps

6.2-3


Figure 6-13

Figure 6-14

Upright Chain Inspection7.0

Each 50-250 hours of operation (more frequently insevere or extreme environments), chains should beinspected and lubricated. Inspection should involvethe following:

ElongationWhen a length of 12.00 inches (305 mm) of a newchain has elongated to a length of 12.360 inches (315mm), it should be discarded and replaced. It isimportant to measure the chain in the section thatmoves over the sheaves because it receives the mostfrequent articulation. Measuring the chain near itsclevis terminals could give an erroneous reading as itwould not have flexed as frequently, if indeed at all,as nearer the middle of the assembly. See figure 7-1.

Chains should be replaced when wear exceeds 3% ofthe pitch or when 12 inches (305 mm) of chain isstretched 3.8 inch (10 mm).

Edge WearCheck the chain for wear on the link plate edgescaused by running back and forth over the sheave.The maximum reduction of the material should notexceed 5%. This can be compared to a normal linkplate height by measuring a portion of chain that doesnot run over the sheave. Distorted or battered plateson the leaf chain can cause tight joints and preventflexing. See figure 7-1.

Worn contours and worn surfaces on the outside linksor pin heads should not exceed 5% of new height.

Turning or Protruding PinsHighly loaded chain operated with inadequatelubrication can generate abnormal friction forcesbetween pin and link plates. In extreme instances, thetorque could surpass the press fit force between thepins and the outside plates, resulting in pin rotation.When chain is allowed to operate in this condition, apin, or series of pins, can begin to twist out of thechain resulting in failure. The pin head rivets shouldbe examined to determine if the “VEE” flats are still incorrect alignment. Chains with rotated/displacedheads or abnormal protrusion should be replacedimmediately. Do not attempt to repair the chain bywelding or driving the pin(s) back into the chain. Oncethe press fit integrity between outside plates and pinshas been altered, it cannot be restored. Any wearpattern on the pin heads or the sides of the link platesindicates misalignment in the system. This conditiondamages the chain and increases frictional loading,and should be corrected. See Figure 7-1.

Figure 7-1

U pright Chain Inspection Section 7

Upright Chain Inspection (Continued)

U

Cracked PlatesThe chains should be periodically inspected verycarefully, front and back as well as side to side,for any evidence of cracked plates. If any onecrack is discovered, the chain(s) should bereplaced. It is important, however, to determinethe causes of the crack before installing newchain so the condition does not repeat itself.

Fatigue Cracking - Fatigue cracks are aresult of repeated cyclic loading beyond thechains endurance limit. The magnitude of theload and frequency of its occurrence arefactors which determine when fatigue failurewill occur. The loading can be continuous orintermittent (impulse load).

Fatigue cracks almost always startat the link plate pin hole (point of higheststress) and are perpendicular to the chainpitch line. They are often microscopic in theirearly stage. Unlike a pure tensile failure,there is no noticeable yielding (stretch ) of thematerial.

Stress-Corrosion Cracking - The outsidelink plates which are heavily press fitted tothe pins, are particularly susceptible to stresscorrosion cracking. Like cracks, these initiateat the point of highest stress (pin hole) buttend to extend in an arch-like pattern be-tween the holes on the plate.

More than on e crack can oftenappear on a link plate. In addition to rusting,this condition can be caused by exposure toan acidic or caustic medium or atmosphere.

Stress corrosion is an environmen-tally assisted failure. Two conditions must bepresent: a corrosive agent and static stress.In the chain, static stress is present at the pinhole due to the press fit pin. No cycle motionis required, and the plates can crack duringidle periods. The reaction of many chemicalagents (such as battery acid fumes) withhardened steel can liberate hydrogen whichattacks and weakens the steel grain struc-ture.

For this same reason, never attemptto electroplate a leaf chain or its components.The plating process liberates hydrogen andhydrogen embrittlement cracks will appear.These are similar in appearance to stresscorrosion cracks.

If a plated chain is required, consultLift-Tek. Plated chains are assembled frommodified, individually plated componentswhich may reduce the chain rating.

7.0

MA1002.eps

Figure 7-2. Arc-Like Cracks in plate are asign of stress corrosion.

Corrosion Fatigue - Corrosion fatigue cracks arevery similar (in many cases identical) to normalfatigue cracks in appearance. They generally begin atthe pin hole and move perpendicular (900) to thechain pitch line.Corrosion fatigue is not the same as stress corrosion.Corrosion fatigue is the combined action of anaggressive environment and a cyclic stress (not astatic stress alone, as in stress corrosion).

Ultimate Strength FailureThis type of failure is caused by overloads far inexcess of the design load. See Figure 7-3.

Tight JointsAll joints in leaf chain should flex freely. Tight jointsresist flexure and increase internal friction, thusincreasing chain tension required to fit a given load.Increased tension accelerated wear and fatigueproblems.

MA1003.eps

Figure 7-3

pright Chain Inspection Section 7

An upright or carriage can moveunexpectedly:

Do not walk or stand under raised forks.

Keep clear of load and carriagewhen making any check or adjustment.

Keep your arms and fingers away frommoving parts of the upright.

Block the carriage or upright when workingwith the components in a raised position.

Do not reach through open areas of theupright.

Never attempt to move or align the rails byhand. Use a prybar.

Failure to follow these warning canresult in serious injury.

WARNING:

*

*****

Chain Length Adjustment

Threaded chain anchors must be left freeto pivot in mounting hole.

Anchor pis heads must be to the inside ofthe upright.

Torque jam nuts to adjustment nuts to 100- 200 Nm (74 - 148 Ft-Lbs).

Make sure chain anchors are secured sothat no twist is evident in the chains.

IMPORTANT

IMPORTANTThe carriage stop must not be al-lowed to contact the upright stopunder any circumstances during

normal operations.

****

7.1


Triple-Stage Upright (TSU) Chain Length AdjustmentsTriple-Stage uprights use two chain set; one set forcarriage lift and one set for rail lift. Adjustmentanchors for the lift cylinder stage are located at theback of the outer rail. Adjustment anchors for theprimary lift stage are behind the primary cylinder.Carriage chain anchors are not intended for adjust-ment.For TSU inner rail lift chains, chain length must beadjusted if the difference between the bottom of theinner rail and the outer rail is greater 10 mm (0.40 in.)

For the TSU primary cylinder lift chain, the chainlength must be adjusted if:

With standard fork setting, the fork clearanceshould be adjusted to provide from 1 3/4” to 2”clearance when the upright is vertical.

With the optional forks to floor setting, the fork tofloor clearance should be adjusted to providefrom 1/4” to 1/2” clearance when the upright isvertical.

The center of the bottom carriage roller comeswithin 20 mm (0.80 in.) of the bottom edge of theinner rail.

The carriage safety stop hit the inner rail stop atfull extension height.

To adjust the secondary cylinder lift chains on a TSUuse the following illustration and procedures:

1. Set the upright in the vertical position.

2. Break the jam nuts loose on the chain anchors.

3. Adjust the chain anchor adjustment nuts until thebottom of the inner rail is within 2.5 mm (0.10 in.)of the bottom of the outer rail.

To adjust the primary cylinder lift chains on a TSU usethe following illustration and procedures:

1. Fork-to-ground clearance:

a. Set the upright to vertical position.

b. Break the jam nuts loose on the chain

anchors.

c. Turn the chain adjustment nuts until clearancebetween forks and ground is 10-20 mm (0.40-0.80 in.).

(Continued on next page)

*

*

*

To Carriage

Adjust Chain Length Here

Adjust chain length here

To inner rail

MA1004.eps

Threaded chain anchors must be left freeto pivot in mounting hole.

Anchor pis heads must be to the inside ofthe upright.

Torque jam nuts to adjustment nuts to 100- 200 Nm (74 - 148 Ft-Lbs).

Make sure chain anchors are secured sothat no twist is evident in the chains.

IMPORTANT****

Figure 7-4

Figure 7-5

7.1-1


*

Triple-Stage Upright (TSU) Chain Length Adjustments(Continued)

IMPORTANTThe carriage stop must not be al-lowed to contact the upright stopunder any circumstances during

normal operations.

2. Carriage roller position:

a. Raise carriage about 1M (3.2 ft.) and smear abead of grease on the bottom 75 mm (3 in.) ofthe inner rail in the area of the roller pattern.

b. Tilt upright fully back and completely lower.

c. Measure the distance from where the center ofthe bottom carriage roller stopped to the bottomedge of the inner rail. Distance should not beless than 20 mm (0.80 in.) or chain lengthadjustment is required.

3. Carriage Stop-to-Upright:

a. Lift upright to its full height and check forclearance on the carriage safety stop.

b. If carriage stop hits the upright stop, adjust thechain anchor adjustment nuts out until there is atleast 3 mm (0.12 in.) clearance between thestops.

If all three chain length requirements listed previously cannotbe met, the tire diameter may be out of the design range allow-ance. Also, excessive tire wear will decrease carriage stopclearance.

7.1-1


Like all bearing surfaces, the precision manufactured,harden-steel, joint-wearing surfaces of a leaf chainrequire a film of oil between all mating parts toprevent accelerated wear.

Maintaining a lubrication film on all chains surfaceswill:

* Minimize joint wear.* Improve corrosion resistance.* Reduce the possibility of pin turning.* Minimize tight joints.* Lower chain tension by reducing internal friction in the chain system.

Laboratory wear test indicate that #40 oil has theability to prevent wear better than #10 oil. Generally,the heaviest (highest viscosity) oil that will penetratethe joint is best.

Whatever method is used, the oil must penetrate thechain joint to prevent wear. Applying oil to externalsurfaces will prevent rust, but oil must flow into thelive bearing surfaces for maximum wear life.

To prepare the chain for oil. The leaf chain platesshould be brushed with a stiff brush or wire brush toclear the space between the plates so that oil maypenetrate the live bearing areas.

Oil may be applied with a narrow paint brush ordirectly poured on. Chain should be well flooded to besure the oil penetrates the joint.

In locations difficult to reach, it may be necessary touse a good quality oil under pressure such as anaerosol can or pump pressure spray.

General Guidelines

*

*

**

*

*

Chain Movement - Make sure that the chain operat-ingpath is clear and that the chain articulates freelythrough its full range of operation.

Lubrication - Assure that the chain is well lubricatedwith the heaviest oil that will penetrate the voidbetween the link plate apertures and the pins.

Paint - Make sure the chain does not get paintedover at any time.

Protection - Where necessary, as a protection fromatmosphere or sliding wear, the chain may becovered with a layer of grease. It should be noted,however, that the grease will have to be removed at alater date for chain inspection and relubrication.

Chain Mountings - Double check to be sure all chainfastening devises are secures and all adjustmentshave been made to assure uniform loading of multiplechain applications. Check chain anchors and pins forwear, breakage and misalignment. Damaged anchorsand pins should be replaced.

Sheaves - Sheaves with badly worn flanges andoutside diameter should be replaced. This wear maybe due to chain misalignment or frozen bearings.

Chain Lubrication7.2


To remove and replace the lift cylinder and/orcarriage chain set on standard and triple-stageuprights (TSU):

1. Attach a hoist strap on the carriage of thestandard upright or inner of the TSU.

2. Lift the carriage or inner rail slightly to createslack in the chains. Block the carriage or innerrail up for safety.

3. Remove the chain anchor pins on the outer railand pull the chains off of the sheaves on theinner or intermediate rails.

4. Remove the chain anchor pins from the carriageon the standard upright or the inner rail on theTSU. On the TSU, the inner rails must belowered to the floor to access the chain anchorpins.

Lift Chains (Standard & TSU)

5. Use the steps in reverse order to replace the liftchain set.

NOTEIf a hose adapter is used, the chainsheaves must be loosened and re-moved to prevent the hoses fromstretching when the inner rails of theTSU are lowered to access the chainanchor pins.

Primary Cylinder/CarriageChains (TSUs)

1. Tilt the upright forward, lower it and completelycollapse the primary cylinder to create slack inthe chains. The carriage may also be lifted andblocked in position and the primary cylindercompletely collapsed to create slack in thechains.

2. Remove the chain anchor pins from the back ofthe primary cylinder. Pull the chains through thechain sheave and lay them over the carriageload backrest.

3. Remove the chain anchor pins from the back ofthe carriage.

4. Use these steps in reverse order to replace theprimary cylinder/carriage chain.

Perform the chain length adjustment and chaintension check before returning the truck to service.

Other Chain Service Notes* Use lengths of factory assembled chain. Do not

build lengths from individual components.

* Do not attempt to rework damaged chains byreplacing only the components obviously faulty.The entire chain may be compromised andshould be discarded.

* Never electroplate assembled leaf chain of itscomponents. Plating will result in failure fromhydrogen embrittlement. Plated chains areassembled from modified, individually platedcomponents.

* Welding should not be performed on any chainor components. Welding splatter should never beallowed to come in contact with chain or compo-nents.

* Leaf chains are manufactured exclusively fromheat treated steels and therefore must beannealed. If heating a chain with a cutting torchis absolutely necessary for remove, the chainshould not be used.

* Always replace chains in sets,Failure to do so may damage newchain.

WARNING:

Chain Removal and Re-placement

The procedures for removing and replacing chain setinvolve hoisting and blocking components.

* Do not walk or stand under raised forks.* Keep your arms and fingers away from moving parts of

the upright.* Do not reach through open areas of the upright.

Failure to follow these warnings can result in serious injury.

7.3 7.3-2


7.3-1

UCylindersMain Lift Cylinder Description

Figure 8-1. Main Lift Cylinders.

The main lift cylinders (see Figure8-1) are single stage displacementtype cylinders consisting of a shelland a telescoping plunger/pistonassembly. During extensionhydraulic pressure is actingagainst the plunger outer diameterdue to the internal porting throughthe piston. The piston seals do notaffect cylinder extension. Thetruck hoist control valve holds thecylinders in place once extensionhas stopped.

The shell is internally threaded atthe top end to hold the retainer.The retainer seals provide a high-pressure hydraulic seal againstthe plunger. The retainer alsolimits the upward stroke of theplunger.

A piston is attached to the bottomend of the plunger. The pistonseal provides a high-pressurehydraulic seal against the shellthat engages the cushion valvewhen the cylinder is fully lowered.

A hydraulic fuse/cushion valve islocated in the left hand cylinder’s inletport. In case of a hose failurebetween the lowering control valveand the cylinders, the fuse limitsthe lowering speed of thecylinder. The valve also cushionsthe piston when the cylinder nearsthe fully lowered position.

MA2974.eps

Spacer

Retainer

RetainerSeals

O-Ring

Back-Up

Shell

Rod

Retainer

Wear Ring

Piston Seal

pright Cylinders Section 8

8.0

8.1

Free Lift Cylinder Description

The free lift cylinder (see Figure 8-2) is a single stage pistontype cylinder consisting of a shell and plunger/pistonassembly. During extension hydraulic pressure is actingagainst the fill piston area. The truck hoist control valveholds the cylinder in place once extension has stopped.

The shell is internally threaded at the top end to hold theretainer. The retainer seals provide a high-pressurehydraulic seal against the plunger. The retainer also limitsthe upward stroke of the plunger.

A piston is attached to the bottom end of the plunger. Thepiston seal provides a high-pressure seal againstthe shell. A check valve located in the bottom of the pistonallows residual oil between the shell and plunger to escapewhen the cylinder is extending.

A hydraulic fuse/cushion valve is located in the cylinderinlet port. In case of hose failure between the loweringcontrol valve and the cylinder, the fuse limits the loweringspeed of the cylinder.

MA2975.eps

Retainer

Set Screw

Retainer Seals

Back-Up

O-Ring

Rod

Shell

Back-Up

Piston

Piston SealW/O-Ring

Wear Ring

Retainer

Plug

Figure 8-2. Free Lift Cylinder.

8.2

U pright Cylinders Section 8

Shell

Inlet Port

To Truck Valve

Free Lift Cylinder

Plunger

Check Valve

Piston

Hydraulic Fuse/Cushion Valve

LoweringControl Valve

Triple Mast (MT) Hydraulic Schematic

R.H. Main Lift Cylinder L.H. Main Lift Cylinder

Plunger

CkeckValve

Piston

Shell

Cylinder Operation

1. Actuating the truck hoist control valve to raise causes hydraulic fluid to enter the lowering control valve through the inlet port where it flows unrestricted through the lowering control cartridge.

2. Hydraulic fluid 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 cylinders raise first.

3. Hydraulic fluid flows through the free lift cylinder 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. Hydraulic fluid in the areas between the plunger and the shell is allowed to escape through the Check valve in the piston as the plunger raises to the end of its stroke.

4. Hydraulic fluid flows through the hydraulic fuse/ cushion valve to the bottom of the pistons as the free lift cylinder has fully extended, lifting force is created against the bottom of the main lift cylinder pistons causing their plungers to raise. Hydraulic fluid in the area between the plunger and the shell is allowed to escape through the check valve in the piston as the plunger raises.

5. When hydraulic fluid flow from the truck hoist control valve is discontinued, the cylinders are held in position by the closed center spool of the truck valve.

Cylinder Raising Cylinder Lowering1. Actuating the truck hoist control valve to lower the mast causes the main lift cylinder plungers then free lift cylinder plunger to lower, forcing hydraulic fluid out through the hydraulic fuse/cushion valves.

Note: The restriction setting of each hydraulic fuse is lower (allows more flow) than the setting of the lowering control valve. The hydraulic fuses restrict flow only during failure of a lowering control valve or hose.

2. Hydraulic fluid flows to the lowering control valve where it is restricted 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 developed between the piston and the shell which engages the cushion valva to restrict flow. This allows the plunger/piston just prior to bottoming, providing a smooth transition to free lift cylinder lowering.

Figure 8-3. Mast Hydraulic Schematic.

8.3


Cleaning and Inspection

MA2974.eps

Spacer

Retainer

RetainerSeals

O-Ring

Back-Up

Shell

Rod

Retainer

Wear Ring

Piston Seal

1. Discard old seals, O-Rings, back-up rings, wiper and lockwasher.

2. Wash remaining parts in a stoddard type cleaning solventand dry with a clean shop rag.

3. Inspection threaded parts for damage.

4. Examine the piston rod, inner surfaces of the retainer assem-bly and cylinder barrel for scoring, nicks or scratches. Acrocus cloth may be used to clean up light scratches, etc.. Becareful no to remove the chrome plating when polishingsurfaces.

Main Lift Cylinder Disassembly

Main Lift Cylinder Service

Figure 8-4

8.4

1. Wash the exterior surface of the cylinderthoroughly before dissembling.

*A soft fiber brush should be used to remove debris andforeign objects from grooves and threaded areas, etc.

*A Stoddard type cleaning solvent should be used to washthe cylinder.

2. Place retainer end of cylinder in a vise equipped with softjaws. Do not over tighten.

3. Using a spanner wrench or a bronze (brass) drift, remove theretainer assembly from the cylinder barrel.

*Remove back-up ring and O-Ring from cylinder retainer.

*Remove rod wiper and seal from cylinder retainer.

4. Pull piston rod from barrel assembly.

*Remove spacer and split piston from piston rod.

5. Remove snap ring, retaining washer, plunger, ball and springfrom base end of piston rod.

8.4-2


8.4-1

Main Lift Cylinder Reassembly

Piston Rod and Piston1. Lubricate all parts with clean hydraulic fluid.

2. Lubricate and install the spring, plunger, washer,snap ring and ball into base end of the pistonrod.

Refer to Figure 8-4.

3. Lubricate and install spacer onto the piston rod. Refer to Figure 8-4.

4. Now, lubricate and place split piston onto thepiston rod. Start piston rod into cylinder barreland gently push rod inward until it bottoms out.Be careful no to nick or scratch the chromesurfaces.

Retainer / Retainer Assembly

1. Lubricate new seals, wiper ring and retainerassembly with clean hydraulic fluid.

2. Install the inner seal into the retainer groove. Becertain the sealing lip faces inward. Use a sealinstallation tool for best results. Be careful not tonick or scratch the chrome surfaces.

3. Install a new wiper ring into the retainer.

4. Lubricate and install a new O-Ring and back-upring into the outer groove on the retainer. Installlock washer on outside of retainer.

NOTEPlacing a plastic parts bag over theretainer threads when installing theO-Ring and back-up ring will helpprotect parts against damage,cutting, etc.

5. Carefully start the retainer assembly over thepiston rod and screw it into the barrel finger tight.Do not cut or nick sealing lips upon installation.

6. Using a spanner, tighten the retainer against theshell assembly.

8.4-3


Free Lift Cylinder Service

1. Wash the exterior surface of the cylinder thor-oughly before disassembly

*A soft fiber brush should be used to removedebris and foreign objects from grooves andthreaded areas, etc.

*A stoddard type cleaning solvent should beused to wash the cylinder.

2. Place retainer end of cylinder in a vise equippedwith soft jaws. Do not over tighten vise.

3. Using a spanner wrench or a bronze (brass) drift,remove retainer assembly from cylinder barrel.

4. Remove and discard lock washer, back-up ringand O-Ring located inside cylinder retainer.

5. Remove and discard both O-Rings and back-upring located on the outside of the cylinderretainer.

6. Pull piston rod from barrel assembly.

7. Remove wear ring (ring bearing) from piston rod.

Free Lift Cylinder Disassembly

MA2975.eps

Retainer

Set Screw

Retainer Seals

Back-Up

O-Ring

Rod

Shell

Back-Up

Piston

Piston SealW/O-Ring

Wear Ring

Retainer

Plug

1. Discard old seals, O-Rings, back-up rings, wiperand lock washer

2. Wash remaining parts in a Stoddard type clean-ing solvent and dry with a clean shop rag.

3. Inspect threaded parts for damage.

4. Examine the piston rod, inner surfaces of theretainer assembly and cylinder barrel for scoring,nicks or scratches. A crocus cloth may be usedto clean up light scratches, etc.. Be careful thatyou do not remove the chrome plating whenpolishing surfaces.


Figure 8-5

8.5

8.5-2


8.5-1

Figure 19

1. Lubricate all parts with clean hydraulic fluid.

2. Lubricate and install wear ring onto the pistonrod. Refer to figure 8-5.

3. Now, start piston rod into cylinder barrel andgently push rod inward until it bottoms out. Becareful that you do not nick or scratch chromesurface.

Reassembly

1. Lubricate new seals, O-rings, back-up rings,wiper ring and retainer assembly with clean hy-draulic fluid.

2. Install back-up ring and the inner seal into theretainer groove. Be certain the sealing lip facesinward. Use a seal installation tool. Be carefulthat you do not cut or nick the sealing lip uponinstallation.

3. Lubricate and install (large) O-Ring into the outergroove nearest to end of retainer.

NOTEPlacing a plastic parts bag over theretainer threads when installing the O-Rings and back-up rings will help pro-tect parts against damage, cutting, etc..

4. Next, lubricate and install a new back-up ring andO-Ring into the outer groove at the base end ofthe retainer.

5. Install a new wiper into the retainer.

6. Now, carefully place the retainer assembly overthe piston rod and after applying lube to threads,screw it into the barrel finger tight. Do not cut ornick sealing lip(s) upon installation.

7. Using a spanner wrench, tighten retainer againstbarrel assembly.

8. Next, using drift as shown in opposite illustration,deform lock washer into groves provided in boththe retainer and barrel to securely lock themtogether.

Retainer Assembly

Piston Rod and Piston

8.5-3


Upright Rail to Roller Clearance

U

The following procedure explains how to:

* 1st - Measure rail-to-roller clearance.

* 2nd - Adjust rail-to-roller clearance.

Point ofroller

Contact

Roller

OuterRail

IntermediateRail

InnerRail

MA1060.eps

IMPORTANTWith age and wear, clearances

between the upright rails and the rollerscan increase and cause excessivelooseness between rails and rollers.Upright rollers become worn, rail sur-faces wear, and stress relieving due tohandling heavy loads over a period oftime may cause slight dimensionalchanges between upright rails. Theillustration shows clearance betweenrails and rollers.

A roller clearance inspection shouldbe performed if, during normal opera-tional checks of the upright, noticeablelooseness or binding between rails sets,or if scoring is evident on the rails.

Proper roller clearance should bemaintained because the mast is de-signed to nest the rails snugly whileproviding smooth operation.

Figure 9-1

9.0

pright Shimming Section 9

MA1062.eps

Check Clearance Here


Pry Here

Pry Here

FeelerGauge(0.020)

InnerRail

IntermediateRail

OuterRail

Point ofroller

Contact

Roller

OuterRail

IntermediateRail

InnerRail

MA1060.eps

CheckClearance

Here

Use "C" clampto force rollers

to one side.Torque on "C"

clamp should notexceed 20 ft.lbs.

Figure 9-2

U pright Shimming Section 9

CAUTIONWatch for overhead clearancewhen extending upright.

WARNINGUse extreme care when work-ing on the upright to avoid plac-ing hands or fingers into poten-tial pinch points. Unexpectedmovement of the upright cancause serious injury.

Evaluation of shim requirements generallydictates the a specific roller is acceptable until 0.040”clearance is exceeded, meaning adjustment requiresone standard 1/32” shims to reduce rail-to-rollerclearance to proper tolerances.

ROLLERS SHOULD BE INSTALLED“LINE-TO-LINE”

0.020” MINIMUM CLEARANCE

Refer to adjustment reference chart when using feelergauges.

Roller Clearance Inspection

Before checking the roller clearances, place theintermediate rail approximately 6 inches out of theouter rail and the inner approximately 6 inches out ofthe intermediate rail as illustrated on the previouspage. If the upright is mounted and the rails are beingelevated hydraulically, the inner rail will automaticallyassume it’s correct position. Note the procedure forchecking the clearance is basically the same whetherthe upright is mounted or has been removed from thetruck.

There ate two methods presented, one using apry bar to position the rails and rollers and the otherusing a “C” clamp.

If the upright is mounted to the truck,, the use ofan approved safety platform or step ladder is recom-mended when making inspections and checkingclearances at the upper levels.

If the upright has been removed and placed onthe flat floor, proper blocking of hardwood (Oak) orsteel supports must be used to keep the uprighthorizontal with the floor. This is especially importantwhen fully extending the intermediate and inner rails.

Step Feeler Gauge will Shimmed ShimGauge Pass / Not Pass Correctly QTY0.020" PASS Check with a 0.050" NOT PASS YES0.050" PASS Check with a 0.080" NOT PASS No, ADD0.080" PASS Check with a 0.120" NOT PASS No, ADD3 2

1 0

2 1

Checking Lower RollerClearance with upright 6”from fully retracted posi-tion

9.1


When using a pry bar: “C” Clamp Method:*Insert the pry bar between the outer and intermediate

upright rail on the right side ( as shown on page 37 ).Pry with moderate pressure moving the intermediateand inner rails to the left top end of the upright.

*Using a 0/020” feeler gauge, see if you can insert ashim between the roller and rail. There needs to besome clearance but it is not to exceeds 0.040”. If theclearance between the roller and the rail is two ormore shims, record the number of shims that will fit inthe space between the roller and rail. Refer to thechart on page 35.

*Pry the intermediate rail away from the inner rail.Check the clearance between the intermediate railroller and the inner rail.

*Record the number of shims needed to fit in the spacebetween the roller and the rail for the outer andintermediate rail.

*Install “C” clamp at the location shown on page 37. Itmay be necessary to use a block on the inside of thechannel as shown.

*Tighten the “C” clamp to displace the roller clearanceon that side of the upright. Now, check roller clear-ance on the opposite side of the upright.

*Using a 0.020” feeler gauge, try to insert it betweenthe roller and the rail at the point of contact as shownon page 37.

*If a 0.020” will pass between the roller and the rail,and 0.040” will not fit between the rail and roller, itdoes not require adjustment. If clearance exceeds0.040”, refer to the chart on page 38.

*Record the number of shims needed to fill the spacebetween the roller and the rail.

IMPORTANTThere needs to be at least 0.020” ofclearance but no more than 0.050”.

9.2 9.3


MA1061.eps

Point ofroller

Contact

Roller

OuterRail

IntermediateRail

InnerRail

MA1060.eps

CheckClearance

Here


FeelerGauge(0.020)

InnerRail

IntermediateRail

OuterRail





Pry Here

Pry Here

PryHere

Checking Lower Roller Clearancewith upright 6” from fully retrac-ted position

Now check the lower rollers in the same manner asfor the upper rollers.

Record the number of shim needed for the outerand inner rails opposite the rollers checked.

Figure 9-3


Point ofroller

Contact

Roller

OuterRail

IntermediateRail

InnerRail

MA1060.eps

CheckClearance

Here

PryHere

FeelerGauge(0.020)

InnerRail

IntermediateRail

OuterRail




Pry Here



Pry Here

MA1063.eps

Checking Upper Roller ClearanceWith upright extended Approx-imately 1/2 of full extension

Now check the roller clearance in the same manneras before.



1 0

2 1




Figure 9-4


Checking Lower Roller ClearanceWith upright extended Approx-imately 1/2 of full extension




1 0

2 1




Point ofroller

Contact

Roller

OuterRail

IntermediateRail

InnerRail

MA1060.eps

CheckClearance

Here

PryHere

FeelerGauge(0.020)

InnerRail

IntermediateRail

OuterRail



clamp should notexceed 20 ft.lbs.Pry Here

Pry Here



MA1064.eps

Figure 9-5


Checking Upper Roller ClearanceWith upright extended Approx-imately to full extension




1 0

2 1




Point ofroller

Contact

Roller

OuterRail

IntermediateRail

InnerRail

MA1060.eps

CheckClearance

Here

PryHere

FeelerGauge(0.020)


Pry Here

InnerRail

IntermediateRail

OuterRail




MA1065.eps


Pry Here

Figure 9-6


Checking Lower Roller ClearanceWith upright extended Approx-imately within 6” of full extension


1 0

2 1




Point ofroller

Contact

Roller

OuterRail

IntermediateRail

InnerRail

MA1060.eps

CheckClearance

Here

PryHere

FeelerGauge(0.020)


Pry Here

InnerRail

IntermediateRail

OuterRail




MA1066.eps

Pry Here




Figure 9-7


Determining the Number of Shims neededto make roller adjustments

InnerRail

IntermediateRail

OuterRail

MA1067.eps

022

023

023

022

Step 3

0.020 - 0.040"

0.040 - 0.060"

0.080 - 0.100"

Rail extended towithin 6 - 10" offull extension.

InnerRail

IntermediateRail

OuterRail

Step 2

Rail extended towithin one half of

full extension.

13

11

23

11

Step 1

InnerRail

IntermediateRail

OuterRail

Rail extended towithin 6 - 10" offully retracted.

1

3

1

3

Exampleof GaugeReadings

# of Shims Dimension Dimensionper Shim (in) (decimal - in)

one 0.031two 0.062

three 0.093

1/32"

Figure 9-8

*Refer to step 3. Look at the three numbers thatwere recorded at each roller on the rails. Thesmallest of these is the total number of shimsthat need to be added. “0” means DO NOTadd shims.

*If any of the rollers require adjustment, referto adjustment procedures on next page.

*If the upright roller clearance was checkedwith the upright mounted to the truck, androller adjustment is required, remove theupright from the truck as described at thebeginning of this section.

*Do not attempt to adjust roller with the uprightmounted to the truck.

9.4


Shim AdjustmentWith the upright laying horizontal on blocking.

*Expose the rollers by pulling the rails part wayout of the bottom as shown.

*Pull rollers (one set at a time) from theirstubshaft. Count the number of shim(s)currently used on each shaft. Add shims asindicated in the roller clearance check.

*If the check indicates that an even number ofshims are needed (2 etc..), split the numberbetween the right and left sides. If the checkindicates an odd number of shims (3, etc..),place the odd shim on the right hand sideshaft. Always keep the odd number of shimson to one side.

*The target for adjustment is to have the samenumber of shims on each roller set (right andleft per rail assembly). An odd or extra shimmust be placed on the same side as the onebefore.

*Reposition each roller on it’s shaft using arubber or plastic mallet. Gently tap the rollerto seat it evenly and snugly on the shaft.

Left

Right

Right

Left

UpperRollers

LowerRollers

Pull Rails part way out the bottomexposing rollers at both ends.

MA1068.eps

Figure 9-9

9.5


PUpright & PantographRemoval & ReplaceRoller Shim Adjustments

It is recommended that the panto-graph carriage assembly be removedbefore attempting to remove theuprights.

Support Block

Hardwood (Oak) BlockingMA1028.eps

Figure 10-2

Pantograph RemovalPreparation

1. Truck should be parked on a level surface.

Extend the pantograph fully.

Lower the pantograph onto hardwood (oak)blocks. Refer to figure 10-2.

2. Place a support (2 X 4 or 4 X 4) between the frontand rear members of the pantograph to preventthe pantograph from retracting once the hydraulicsupply is disconnected. Refer to figure 10-2.

3. Actuate the lowering control long enough for theprimary cylinder to collapse and slacken thechains. Release the control.

4. Turn the key to the “OFF” position and removethe key.

NOTEIf the upright is to be removed, a 5-ton

chain hoist equipped with safety hooks isrequired.

10.0

10.1

Figure 10-1

antograph Removal Section 10

10.1-1

5

4

67

3

Lift Chain

Tubing

HydraulicHose

MA1029.eps

Figure 10-3

5. Disconnect electrical plug (3).

6. Remove both harness clamp bolts (4).

7. Disconnect hydraulic hoses from tube connec-tions (5) using two wrenches. One wrench tohold the tube connection(s) while loosening thehose connection(s). There will be some hydraulicfluid leakage upon disconnecting fittings.

8. Remove cotter pins (6).

9. Remove chain anchor pins (7) securing the liftchains to the carriage chain anchors.

NOTELift chains mat be disconnectedat the primary lift cylinder cross-

head (see next page) or fromthe carriage as shown.

Pantograph Removal (continued)(Refer to figure 10-3)

10.1

P antograph Removal Section 10

MA1031.eps

Cotter Pin

Chain Anchor

Lift Chain

Primary Cylindercrosshead

NOTECarriage chains may be discon-nected at the primary cylinder.

Remove cotter pins securing lift chains to the chainanchors. Remove lift chains one at a time from thechain anchors.

NOTEOnce a lift chain has been discon-nected, lay it over the pantograph.Then, using wire, tie the chain endto the load backrest. This will keepthe chains out of the way and from

falling to the ground.

*

Pantograph Removal (continued)

Figure 10-4

10.1


Support Block


Raise both inner andintermediate rails until theinner rail channels areclear of the carriagerollers.

Safety Hook

Lifting StrapsorChains

5 Ton Chain Hoist

MA2195.eps

Inner Rail

Carriage Roller

MA2183.eps

13. Using a 5-ton chain hoist, attach hoist to the innerand intermediate rail assemblies, See Figure 10-5above. Be sure hoist is equipped with safetyhook(s).

*Remove the secondary cylinder snap rings locatedon the top of each secondary cylinder.

14. Raise both inner and intermediate rails until the innerrails clear the upper carriage rollers.

Step 13.

Step 14.

Figure 10-5

Pantograph Removal (continued)10.1


15. Move truck away from pantograph just far enough toallow the intermediate and inner rails to clear thepantograph. See figure 10-6.

16. Completely lower the intermediate and inner railassemblies.

17. Disconnect hoist and move truck away from panto-graph.

NOTEIf the upright rail lift cylinders areto be removed, refer to the fol-lowing pages.

The free lift (center) cylinder maybe removed without removingthe upright.

Truck

Support Block


Support Block


Clearance

Truck

Pantograph

Backup truck just enough to provide clearanceBetween pantograph and upright rails.

Fully lower intermiate and inner rails.

Disconnect hoist safety hook from lifting device.

Move truck away from pantograph.

Safety Hook

Lifting StrapsorChains

MA2196.eps

Pantograph Removal (continued)

Figure 10-6

10.1


PThe Pantograph Assembly may be serviced while installed in the upright with two exceptions:

the carriage rollers and the inner and outer arm bushings must be servicedwith the pantograph removed from the upright.

Pantograph & Fork Carriage Assembly Service11.0

*Move truck to service area.

*Park truck on a flat level surface.

*Extend and lower pantograph.

*Turn key switch OFF.

1. Remove Load Back Rest Extension.

Remove bolts from load backrest Extension and liftthe extension free of the fork carriage.

2. Elevate and Block Pantograph.

*Turn key switch ON and elevatepantograph approximately 3 to 4feet.

*Place an oak block (hardwood)between pantograph carriage andground. Lower pantograph untilcarriage rests on 4X4 blocking asshown in figure 11-1.

*Tilt forks forward.

*Turn key OFF and remove key.

*Disconnect truck battery.

Preparation

MA2189.eps

Figure 11-1

DisconnectBattery

MA1035.eps

Figure 11-2

antograph Service Section 11

11.0-1

Remove forks.Refer to illustration 11-3.

Remove fork by releasing thelocking pin on the top forkhanger and sliding the fork tothe center of the carriage forkbar. Lift the fork up anddisengage the fork hanger fromthe carriage bar.

Standard ITA Models Only

WARNING:

Forks are heavy. Caremust be taken toavoid personal injury.

*

MA2201.eps

Figure 11-3

P antograph Service Section 11

11.0-2

MA2192.eps

Upright

Block

Pantograph

2

MA2207.eps

3

1

Fork Carriage RemovalSide Shift Models Only

1. Remove hose hold down cap.

2. Disconnect electrical plug (1) fromthe main harness connector.

3. Disconnect both hydraulic connec-tions at the connector fitting (2). Capthe open ports and connections.

Figure 11-4

Figure 11-5

11.1P antograph Service Section 11

Fork Carriage RemovalModels Equipped with Tilt Only

1. Remove both cable and hose covers (4),See below.

2. Disconnect hydraulic connection (a)from tilt cylinders.

All Models

3. Install lifting straps as shown to chainhoist equipped with safety hook.

4. Remove retainer bolts and pins (C)securing scissor arms to the forkcarriage.

5. Slowly elevate carriage until free ofarms. Continue to elevate until lowerscissor rollers are free to one side.

.MA2193.eps

C

B

4

C

C

Arms

Lift Straps&Safety Hook

A

Figure 11-6

MA2218.eps

5 1

4

2

3


Allen Screw

Nylon Thrust Pad

Shims

Worn Out3.5 mm

New Pads6.3mm

Scissor Arm Roller "B and C'

When pad is worn near "flush"with carriage roller, new padsshould be installed

MA1017.eps

B

A

C

1. Disconnect reach arm cylin-ders. See figure 11-6. Removeretainer bolts and pins (item“B”) securing reach cylinder topantograph arms.

2. Lift reach arms (A) upwardwhile pivoting arm (B) indirection shown in figure 11-7.This allows access to armroller and thrust pad withoutremoving scissor assemblyfrom carriage.

3. Inspect the thrust pads forfurther service as shown infigure 11-8. Pads that aredamaged or worn to their wearlimit should be removed andnew pads installed.

4. Remove Allen screw and pad.Install new pad. Be certainsame number of shims areinstalled on the shaft if theywere removed.

Servicing Pantograph Arm RollersThrust Pads (Scissor Arm Roller “B” & “C”)

Figure 11-7

Figure 11-8

To Remove Arm Roller “B” (or ”C”):

Slowly move Arm “A” (up as required) whilerotating Arm “B” (as shown) to move arm rollerupward and out of the carriage channel.

Be extremely carefulthat you do not“pinch” your hands orfingers.


5. Disassemble the outer arm assembly.

6. Replace seals with new ones.

7. Wash bearings (cups and Cones) in aStoddard type solvent. Inspect parts forfurther serviceability. Replace any partthat is nicked or having rough spots inthe cones or cups. Cones and cupsmust be replaced together. Do notinstall a new cone in an old cup.

8. Check grease fitting for damage and tomake certain none are missing.

Figure 11-9

Grease Fitting

Pivot Bearing

Outer Arm

Snap Ring

Cup

Cone

Shield

Cup

Cone

Lock Nut

Nut (*)

O-Ring

HousingSnap Ring

Grease Fitting

CylinderBearing

Allen ScrewWear Pad

Shims

Roller

Grease Fitting

Allen ScrewWear Pad

Shims

Roller

Inner Arm Pivot Bearings

Grease Fitting

MA1019.eps

MA1019.epsNut (*)

Install with chamfer towards nut lock.Torque to: 27 - 41 Nm (20 - 30 ft. lb.)

NOTEIf the Inner Arm Pivot Bearings

need to be replaced, thepantograph carriage must be

removed from the upright.

9. Reassemble to the reverse of disas-sembly.

Lubricate parts with cleanchassis grease prior toassembly.

ImportantPrepack bearing cup and cone assemblies

prior to installation


ImportantPrepack bearing cup and cone assemblies

prior to installation



Tilt Cylinder ServiceCylinder Removal

WARNING:

Forks are heavy. Caremust be taken toavoid personal injury.

Figure 11-10

MA2201.eps

11.4


Figure 11-11

MA2202.eps

Capscrew

CapscrewHose Clamp

Carrier AssemblyCarriage Pin

Dowel Pin

Shim

Snap RingShim

Upper Wear PadBushing

Tilt Cylinder Carriage Weldment

Fitting

Tilt Pin

Tilt Pin Bushing

Snap Ring

Grease Fitting

LowerWear Pad

CapscrewLockwasher

Guard

Capscrew

Capscrew

Valve Assembly

Coil

FittingCarriage Claw

RetainerSS Rod

WiperSeal

Fitting

Tilt PivotBushing

Carriage BarAssembly

Cap

Seal

Wear Pad Shim

Shim

ITA Pantograph Carriage With Side Shifter


ITA Pantograph Carriage Without Side Shifter

5

MA2219.eps

Carriage Frame Assembly

Dowel Pin

Shim

ShimSnap Ring

Snap Ring

Shaft

Carrier Assembly

Cap

Bushing

Capscrew

Capscrew

Hose Clamp

Shim

Figure 11-12


Cylinder removal:Remove the fork carriage by removing the lowerclaws and lifting the carriage bars off the car-riage frame.

Refer to figure 11-11 and 11-12.

1. Extend the tilt cylinder completely.

2. Secure the carriage frame using an overhead hoistand a lifting strap.

3. Remove snap rings from the tilt pin.

4. Using the hoist, take the slack out of the strap.

5. Using a brass drift, drive shaft out.

6. Using the hoist, rotate the carriage section up to gainaccess to the tilt cylinder from below the carriageweldment.

7. Disconnect the hydraulic hoses from the tilt cylinder.

8. Remove the capscrews holding the tilt cylinder pivotcaps in place.

9. Remove the tilt cylinder.

The exterior surface of a cylinder should bethoroughly washed before disassembly.

A soft fiber brush should be used to removedebris and foreign objects from grooves andthreaded areas, etc.

A Stoddard type cleaning solvent should be usedto wash the cylinder.

Any part unfit for further service should bereplaced with new part.

Preparation Cleaning andInspection

11.4-1


Wash exterior of the tilt cylinder in a Stoddard typecleaning solvent before disassembly. Use a brush toremove grease and grime from the cylinder tube,anchor and rod ends.

1. Place cylinder in a vise equipped with soft jaws.Do not overtighten - distortion of the shell willresult.

2. Push piston rod all the way into cylinder.

3. Using a narrow blade screwdriver, remove thecapscrew securing the pull wire / retaining ring.

4. Remove the pull wire by rotating the uppersection of the shell clockwise while gently pryingthe pull wire out of it’s groove.

5. Remove the upper section of the shell whilepushing the piston rod through the upper shellsection.

6. Remove the piston / rod assembly.

Disassembly(Refer to Illustration Below)

Figure 11-13

1. Remove wiper ring.

2. Remove rod seal from inner groove.Be careful that you do not nick orscratch surface of retainer assembly.

3. Remove outer O-Ring and backupring from the retainer assembly.

4. Discard seals, wiper and backuprings.

1. Separate the inner shell from the rodassembly.

2. Remove the back rings and o-ringsfrom the inner shell and discard.

3. Remove the piston retaining ring.

4. Remove piston seal with O-Ring frompiston and discard.

5. Remove the piston.

6. Discard O-Ring, sealing ring andenergizer. Always install new seals.

Retainer Assembly


MA2209.epsPivot Shaft

FittingWiper

RodSeal

Outer Shell

O-ring

RetainingRing

Base

Seal w/O-Ring

Piston

Inner ShellCapscrew

Retaining RingBack-Up

O-Ring

Rod

Piston

11.4-2


1. Using only new seals and O-Rings, lubricate all partswith clean hydraulic fluid.

2. Lubricate and install the energizer O-ring into thegroove in the piston. Refer to figure 11-13.

3. Lubricate and install the piston seal over the ener-gizer. Be careful not to nick or cut the seals.

4. Install new o-rings and back-up rings onto the innershell.

5. Lubricate the seals of the inner shell and insert theinner shell into the outer shell.

6. Lubricate the piston and piston rod with cleanhydraulic fluid.

10. Start piston into cylinder tube while gently pushingand rotating piston rod. Be careful not to damageseal.

11. Shove the piston rod all the way into the cylindertube until it bottoms.

Cleaning and Inspection Retainer Assembly

Reassembly

1. Discard old seals, wiper and shear ring.

2. Wash all parts in a Stoddard type cleaning solventand dry with a clean lint free shop rag.

3. Inspect cylinder mounting bushings for damage. If thebushings show signs of wear and/or damage, theyshould be replaced with new bushings.

4. Examine cylinder barrel for scoring, nicks orscratches. The cylinder barrel may be sanded withcrocus cloth to remove minor scratches, etc.. Becareful not to remove the chrome plating whenpolishing the surface. Replace all damaged orunserviceable parts.

5. Inspect surfaces of the piston and piston rod to besure they are clean, smooth and free of damage.

1. Lubricate new seals, wiper ring and retainer assemblywith clean hydraulic fluid.

2. Install the inner seal, with the sealing lip facinginward, into the retainer groove. Be careful not to nickthe sealing lip upon installation.

3. Install a new wiper into retainer.

4. Lubricate and install a new backup ring into the outergroove on the retainer.

5. Lubricate and install a new O-Ring in the groove nextto the backup ring. Note the position of the backupand O-Ring per figure 11-13.

6. Push retainer as far as it will go into the housing.

7. Insert the new pull wire in the pull wire pushing on thewire with your fingers. Rotate the top section of theouter shell counter clock wise while pushing the pullwire into the groove.

8. Once the pull wire is installed, insert and tighten thecapscrew to secure the pull wire.

11.4-4

11.4-3


Reach Cylinder Service

WARNING:

MA2201.eps

Figure 11-14

Support forks asforkbar is removed sothey cannot fall.

11.5

Cylinder Removal




MA1089.eps

A

B

C

C

Arms

ReachCylinder

Lift Straps&Safety Hook

Cylinder removal:Remove the fork carriage as described in section11.1.

Refer to figure 11-15.

1. Extend the reach cylinder completely.

2. Using an overhead crane, secure the scissorarms (C) to keep the scissor arms from fallingonce the reach cylinder has been disconnected.See figure 11-15.

3. Disconnect the hydraulic connectors and plug allopen lines.

4. Remove retainer bolt and pin(B) securing cylinder shaftends in position. See figure 11-15. It may be necessary to usea brass drift to gently tap thepins loose.

5. Remove the reach cylinder andplace on a clean work bench.

Figure 11-15

11.5-1


Wash exterior of the reach cylinder in a Stoddardtype cleaning solvent before disassembly. Use abrush to remove grease and grime from the cylindertube, anchor and rod ends. Remove rod end and jamnut.

1. Place cylinder in a vise equipped with soft jaws.Do not overtighten - distort shell.

2. Push piston rod all the way into cylinder.

3. Using snap ring pliers, remove the snap ring fromthe cylinder retainer.

4. Remove O-Ring.

5. Using a bronze drift, gently tap retainer assemblyinto cylinder housing clear of the shear ring.

6. Using a screwdriver, carefully lift end of shearring from it’s groove. Be careful not to nick orscratch the piston rod.

7. With a pair of pliers, carefully pull shear ring fromcylinder tube. Again, be careful not to nick orscratch the piston rod.

8. Pull outward on piston rod until rod and retainerare free of cylinder housing. Remove retainer.

1. Remove wiper.

2. Remove seal from inner groove. Be careful thatyou do not nick or scratch surface of retainerassembly.

3. Remove outer O-Ring and backup ring from theretainer assembly.

4. Discard seals, wiper and backup rings.

1. Using a 3/4” wrench, hold the rod using the “flats”provided just below threaded area of piston rod.Now install a 2-2/8 in. socket onto the piston rodnut.

2. Remove nut from piston rod while holding thepiston rod.

3. Pull piston free of piston rod.

4. Remove sealing ring and the energizer from piston.Use care not to nick or scratch piston surfaces.

5. Discard O-Ring, sealing ring and energizer. Alwaysinstall new seals.

Figure 11-16

MA2208.eps

Typical Illustration

Rod EndNut

Wiper

RetainingRing

ShearRing

Rod Seal

O-Ring w/ Back-up

Retainer

ShellRod

Piston

PistonSeal Nut

A

ARight HandReach Cylinder

Left HandReach Cylinder

A

A

Disassembly(Refer to Illustration Above)

Retainer Assembly


11.5-2


MA1027.eps

PORT "B"PORT "A"

Bushing

Grease Fitting

Grease Fitting

Bushing

1. Lubricate all parts with clean hydraulic fluid.

2. Lubricate and install the energizer ring into the groovein the piston. Refer to figure 11-16.

3. Lubricate and install the piston seal over the ener-gizer. Be careful not to nick or cut the seals.

4. Place a plastic parts bag over the threaded area ofthe piston rod (to protect seal). Slide a new O-Ringover the bag and into the groove in the piston rod.

5. Remove bag and install piston onto rod. Carefullyslide the piston over and up against the rod shoulder.

6. Install nut onto piston rod finger tight against thepiston.

7. Install the 3/4” wrench back into the “Flats” provided inthe piston rod.

8. Using a torque wrench and 1-1/8 in. socket, torquenut to 115 - 132 ft. lbs. (156 - 179 Nm).

9. Now, lubricate the piston and piston rod with cleanhydraulic fluid.

10. Start piston into cylinder tube while gently pushingand rotating piston rod until piston and seal havepassed the shear ring groove in the cylinder tube. Becareful not to damage seal.


11. Push the piston rod all the way into the cylinder tubeuntil it bottoms.

Retainer Assembly1. Lubricate new seals, wiper ring and retainer assembly

with clean hydraulic fluid.



4. Lubricate and install a new backup ring into the outergroove on the retainer.

5. Lubricate and install a new O-Ring in the groove nextto the backup ring. Note the position of the backupand O-Ring per above diagram.

6. Place a plastic parts bag over the threaded end of therod (to protect seals) and carefully slide the retainerover the rod and into the cylinder housing.


8. Insert the open end of a new shear ring into thecylinder housing while pushing on the ring with yourfingers. Push ring inward as far as you can.

Reassembly

1. Discard old seals, wiper and shear ring.

2. Wash all parts in a Stoddard type cleaning solventand dry with a clean lint free shop rag.

3. Inspect cylinder mounting bushing for damage. If thebushings show signs of wear and/or damage, theymay be pressed out and new bushing installed. ASleeve to fit over spherical inner bushing will beneeded. Do not press out by prying on the innerbushing. Refer to figure 11-17.

4. Inspect threaded parts for damage. Examine cylinderbarrel for scoring, nicks or scratches. A The cylinderbarrel may be sanded with crocus cloth to removeminor scratches, etc.. Be careful not to remove thechrome plating when polishing the surface. Replaceall damaged or unserviceable parts.

5. Inspect surfaces of the piston and piston rod to besure they are clean, smooth and free of damage.

Figure 11-17

11.5-3

11.5-4


1. Using a bronze punch, gently tap ring the rest of theway into the tube and groove. Be sure the shear ringis fully seated in it’s groove.

2. Pull the piston rod out as far as it will come. This willposition the retainer so that the retainer ring grooveand into the housing on top of the retainer.

3. Lubricate a new backup ring and place it over the O-Ring just installed.

4. Install the washer over the retainer and next to thebackup ring previously installed.

5. Install a new split retainer into it’s groove in theretainer assembly. Be sure it is completely seated init’s groove.

6. Install jam nut and rod end to the same location it waswhen removed from the piston rod.

7. Cap cylinder ports until the cylinder is installed on thetruck.

8. Check fluid level of truck once cylinder have beeninstalled.

9. Purger air from hydraulic system by cycling cylindersseveral times to force air from the lines into the sumptank.

Retainer Assembly (Continued)

MA2208.eps


Rod EndNut

Wiper

RetainingRing

ShearRing

Rod Seal

O-Ring w/ Back-up

Retainer

ShellRod

Piston

PistonSeal Nut

A

ARight HandReach Cylinder

Left HandReach Cylinder

A

A

Figure 11-18


Side Shift Cylinder ServiceCylinder Removal:

Figure 11-19

WARNING:

MA2201.eps


1. Remove fork by releasing the lockingpin on the top fork hanger andsliding the fork to the center of thecarriage fork bar. Lift the fork up anddisengage the fork hanger from thecarriage bar.

2. Loosen fittings at the bottom of theside shifter cylinder, catching any oilthat may escape.

3. Using a pry bar, push the side shifterrods into the cylinder body catchingany oil be leaks from the cylinder.

4. Remove the capscrews securing thecarriage claws to the back of thelower carriage bar.

5. Rotate the front of the carrier frameup and remove the carriage bars.

6. Remove all wear pads and discard.

Support forks asforkbar is removed sothey cannot fall.

11.6


1. The exterior surface of a cylinder should bethoroughly washed before disassembly.

2. A soft fiber brush should be used to removedebris and foreign objects from grooves andthreaded areas, etc.

3. A Stoddard type cleaning solvent should beused to wash the cylinder.

4. Any part unfit for further service should bereplaced with new part.

Wash exterior of the side shift cylinder in aStoddard type cleaning solvent before disassem-bly. Use a brush to remove grease and grimefrom the cylinder tube, anchor and rod ends.

5. Using a spanner wrench in the holes locatedin the top of the retainer, rotate the retainerassembly counter clockwise to loosen theretainer.

6. Remove retainer and rod.

7. Remove rod from retainer.

1. Remove the piston rod seal and wiper. Be carefulthat you do not nick or scratch surface of retainerassembly.

2. Remove outer O-Ring from the retainer assembly.

3. Discard seals, wiper and backup rings.

Disassembly (Refer to Figure 11-20)

Preparation Cleaning andInspection

Retainer Assembly11.6-1

11.6-2

11.6-3


Figure 11-20

MA2202.eps

Capscrew

CapscrewHose Clamp


Dowel Pin

Shim

Snap RingShim



Fitting

Tilt Pin

Tilt Pin Bushing

Snap Ring

Grease Fitting

LowerWear Pad

CapscrewLockwasher

Guard

Capscrew

Capscrew

Valve Assembly

Coil


RetainerSS Rod

WiperSeal

Fitting

Tilt PivotBushing


Cap

Seal

Wear Pad Shim

Shim


1. Lubricate new seals, wiper ring and retainer assemblywith clean hydraulic fluid.



4. Lubricate and install a new O-Ring in the groove.


6. Using a spanner wrench, tighten the retainer.

7. Start rod into cylinder tube while gently pushing androtating the rod. Be careful not to damage seal.

8. Push the rod all the way into the cylinder shell until itbottoms out.

9. Purger air from hydraulic system by cycling cylindersseveral times to force air from the lines into the sumptank.

a. Reinstall new wear pads and lubricate wearpads.

b. Reinstall front carrier on cylinder body.

c. Reinstall carriage claws and capscrews toback face of the lower bar.

Cleaning and Inspection1. Discard old seals and wiper.

2. Wash all rods and retainers in a Stoddard typecleaning solvent and dry with a clean lint free shoprag.

3. Inspect surfaces of the rod to be sure they are clean,smooth and free of damage.

Reassembly11.6-4 11.6-5



For PIDs 40HR-MT-001 Through 40HR-MT-111.

AND

For PIDs 45HR-MT-001 Through 45HR-MT-102.

For all other PIDS see Page 88.

Reach and TiltSelector Valve Service

antograph Service Section 11P

Preparation

Reach and Tilt Selector Valve

MA1069.eps

1. Move the truck to a service area.

*Move truck to a flat level surface.

*Extend pantograph.

*Fully lower pantograph.

*Tilt (if so equipped) forks forward until thefork tips touch the ground.

2. Turn key switch off.

*Remove key.


3. If equipped, control circuit capacitors must bedischarged to avoid possibly being shockedwhen working on the solenoid valve.

DisconnectBattery

MA1035.eps

Figure 11-21

11.7


MA2216.eps

ReachCylinder

Selector ValveReach and Tilt

Selector Valve Mounting Fastener

Hardwood (Oak)Blocking

Floor

Before working on PantographBe Certain it is Blocked as Shown

Figure 11-22


Figure 11-23


B

To Tilt CylindersorSide Shifter Selector Valve

A

Mounting Bolts

To R.H.Hand ReachCylinder To

L.H. Hand ReachCylinder

HydraulicSupply

S5S6

1

2

3

4

6 7

11 12

9 10

5 8

Guard

MA2492.eps

To TruckAuxiliarySwitches

To Truck HydraulicSupply

CAUTION

The solenoid valve stemis very fragile. Be verycareful when handling

the valve that you do notdent or bend the stem.

Over torquing the coil nutor the valve at installationwill cause damage to the

valve.

Figure 11-24


9 10

8

6 7

5

Mounting Bolts



MA2493.eps

B

A

To L.H. ReachCylinder

To R.H. ReachCylinder

To Tilt CylinderorSide Shifter Selector Valve

Figure 11-25



WARNINGBe sure the pantograph isblocked as shown on figure 11-22.

Removal

WARNINGHydraulic lines may havetrapped pressure. “Crack” thefittings to bleed pressure beforedisconnecting.

WARNINGWhen trapped pressure is bled,the pantograph may settle.Beware.

Loosen guard mounting bolts and remove the guard.

Unplug connect (#1) from coil (S6) and unplugconnectors (#2) from coil (S5).

Remove fasteners (#4) from clamp (#3).

Tag hoses and disconnect hydraulic connections (#5)and (#8) from valve (A). Cap both hose ends.

CAUTIONResidual pressure will be

present when disconnectinghydraulic lines. Use cautionwhen disconnecting fittings.

Tag tubes and disconnect fittings (#11) and (#12)from bottom side of valve (A). Cap both hose ends.

Remove both mounting fasteners from pantographframe (B) and valve (A).

Remove valve from pantograph. Place componentson a clean work bench.

DisassemblyRemove nuts, coils and solenoid valves (S5) and (S6)from the valve body.

NOTEThe valve body and valves arenot serviceable. If the unit is notfunctioning properly, it must bereplaced.

1.

2.

3.

4.

6.

7.

5.

*

*


B


A

Mounting Bolts



HydraulicSupply

S5S6

1

2

3

4

6 7

11 12

9 10

5 8

Guard

MA2492.eps



9 10

8

6 7

5

Mounting Bolts



MA2493.eps

B

A




Figure 11-26

Figure 11-27


Installing clamps, connectwire, tighten nuts andbolts

7. Be sure the valve guard is located properly andsecurely tighten both solenoid valve mounting bolts.

8. Install wire clamps (#3) and bolts (#4).

9. Connect coil plugs to their respective receptacles.

IMPORTANTAll electrical plugs and their receptacles arematched labeled for easy connection. Check to besure each plug and receptacle match beforeattempting to make connections.

CAUTION

The system must be purged of air before putting truckback into service or damage to the hydraulic systemmat occur.

10. Install and tighten clamp bolts (#4).

1. Position the valve to the pantograph frame aligningholes in frame with those in the valve. Refer toillustration on previous page.

2. Install mounting fasteners finger tight. Do not tightenfasteners until after the hydraulic hoses are installed.

Connecting Hydraulic Plumbing

3. Remove cap, hose tag and install connection (#11) tothe valve finger tight.

4. Remove cap, hose tag and install (#12) connectionfinger tight.

5. Install connections (#5) and (#8). Install connections(#6, 7, 8, 9 and 10) to the reach cylinders finger tight.

6. Securely tighten each hydraulic connection to thevalve body and the reach cylinder.

IMPORTANTBe sure the hoses are routed correctly beforeattempting to connect them to the valve. Refer topage 94.

Mounting Selector ValveRefer to Figure 11-26 and 11-27

11.8-2

antograph Service Section 11PSide Shifter Solenoid Control Valve



*Extend pantograph.




*Remove key.



a. Remove guard lockwashers andcapscrews.

DisconnectBattery

MA1035.eps

Figure 11-28

11.9

Mounting Selector Valve

MA2202.eps

Capscrew

CapscrewHose Clamp


Dowel Pin

Shim

Snap RingShim



Fitting

Tilt Pin

Tilt Pin Bushing

Snap Ring

Grease Fitting

LowerWear Pad

CapscrewLockwasher

Guard

Capscrew

Capscrew

Valve Assembly

Coil


RetainerSS Rod

WiperSeal

Fitting

Tilt PivotBushing


Cap

Seal

Wear Pad Shim

Shim

Figure 11-29


Removal

*Unplug Connectors from each coil.

*Label each hose with it’s location.

*Disconnect hydraulic connections (V1, V2, C6, C5, C2,and C4) from the side shifter selector valve.


Cap each hose when disconnected.

NoteThere will be some fluid leakagewhen hydraulic fittings are discon-nected. Place a rag beneath thefitting to be removed.

*Remove mounting bolts securing the selector valve tothe pantograph.

*Remove valve and place on a clean work bench.

*The valve assembly is not serviceable, if unit is notfunctioning properly, it must be replaced.

*Inspect hoses and connectors for further serviceability.

*Replace defective parts.

Refer to Figure 11-30

Figure 11-30

2

MA2207.eps

3

1

NOTEThe valve body and valves arenot serviceable. If the unit is notfunctioning properly, it must bereplaced.


Figure 11-31


InstallationMount Selector Valve

*Line up mounting holes in selector valve with those inthe mounting bracket. Install mounting bolts fingertight. See Figure 94.

Install Hoses

*Wipe hose ends and connectors clean. Remove hosecaps just prior to installation. Be certain all connec-tions are tight.

Connect Coils

*Plug connectors to each coils. See illustration on page96.

*Tighten all mounting fasteners.

*Install guard.

MA2216.eps

ReachCylinder




Floor


Figure 11-32

11.9-1


Figure 11-33

MA2202.eps

Capscrew

CapscrewHose Clamp


Dowel Pin

Shim

Snap RingShim



Fitting

Tilt Pin

Tilt Pin Bushing

Snap Ring

Grease Fitting

LowerWear Pad

CapscrewLockwasher

Guard

Capscrew

Capscrew

Valve Assembly

Coil


RetainerSS Rod

WiperSeal

Fitting

Tilt PivotBushing


Cap

Seal

Wear Pad Shim

Shim


11.10 Servicing a Double Reach PantographThe Double Reach Pantograph is serviced the same as the Single Reach Pantograph with oneexception. The Double Pantograph has two scissor assemblies. Follow service proceduresoutlined in Sections 11-7 through 11-9. Refer to Figures 11-34 through 1137.

MA2312.eps

Rear FrameScissor Pin

Grease Fitting

Pivot Bushing

Rear Scissor Frame

Scissor Arm

Bearing CupBearing ConeLock Nut

NutO-Ring

HousingSnap Ring

Grease Fitting

CylinderBearing

Washer

Grease FittingScissor Arm

Shield

Bearing Cone

Bearing Cup

Snap Ring

Bushing

Washer

Cotter Pin

Flat Washer

Nut

Grease Fitting

Scissor Arm

Pivot Bushing

Shield

Bearing Cone

Bearing Cup

Snap Ring

Bearing Cup

Bearing ConeLock Nut

Nut

O-Ring

HousingSnap Ring

Grease FittingCarriageScissor Arm

Shims

Bearing

Flat Washer

Capscrew

Figure 11-34Double Reach Assembly


C2

CONNECT TO PLUG ONMAST WIRE HARNESS

MA2313.eps

Sideshifting Models Only

Sleeve

Clamp

Capscrew

Wire Harnessto Sideshifter

Scissor Pin Roll Pin

Reach Cylinder

Fitting

Tube

O-Ring

Guard

Hose Guard

Clamp

Cylinder Pin

Nut

Tube Assembly

Capscrew

Wire Harness

Fitting

Clamp

Fitting

SolenoidCoil

Fitting

Fitting

SolenoidValve Block

Couter Balance Valve



MA2310.eps

Inner Reach Cylinder Hose

Outer Reach Cylinder Hose

Cover

Cable Tie

Tilt Cylinder Hoses

Double Reach Without Sideshifter

MA2311.eps



Cover

Cable Tie

Tilt Cylinder Hoses and Cable

Double Reach With Sideshifter

Figure 11-36 HoseRouting.


11.10 Servicing a Double Reach Pantograph (continued)


For PIDs 40HR-MT-112 Through Present.

AND

For PIDs 45HR-MT-103 Through Present.

Reach and TiltSelector Valve Service



MA1069.eps



*Extend pantograph.




*Remove key.



DisconnectBattery

MA1035.eps

Figure 11-21

Preparation11.7


MA2216.eps

ReachCylinder




Floor


Figure 11-22


A1

B1

A Lift

Figure 11-23


B


A

Mounting Bolts



HydraulicSupply

S5S6

1

2

3

4

6 7

11 12

9 10

5 8

Guard

MA2492.eps



CAUTION

The solenoid valve stemis very fragile. Be verycareful when handling

the valve that you do notdent or bend the stem.

Over torquing the coil nutor the valve at installationwill cause damage to the

valve.

Figure 11-24


9 10

8

6 7

5

Mounting Bolts



MA2493.eps

B

A




Figure 11-25



WARNINGBe sure the pantograph isblocked as shown in figure 11-22.

Removal


WARNINGWhen trapped pressure is bled,the pantograph may settle.Beware.

Loosen guard mounting bolts and remove the guard.

Unplug connect (#1) from coil (S6) and unplugconnectors (#2) from coil (S5).

Remove fasteners (#4) from clamp (#3).

Tag hoses and disconnect hydraulic connections (#5)and (#8) from valve (A). Cap both hose ends.

CAUTIONResidual pressure will be

present when disconnectinghydraulic lines. Use cautionwhen disconnecting fittings.

Tag tubes and disconnect fittings (#11) and (#12)from bottom side of valve (A). Cap both hose ends.

Remove both mounting fasteners from pantographframe (B) and valve (A).

Remove valve from pantograph. Place componentson a clean work bench.


NOTEThe valve body and valves areserviceable. If the unit is notfunctioning properly, Seesection 13 for valve service.

1.

2.

3.

4.

6.

7.

5.

*

*

11.8

11.8-1

11.8-2


B


A

Mounting Bolts



HydraulicSupply

S5S6

1

2

3

4

6 7

11 12

9 10

5 8

Guard

MA2492.eps



9 10

8

6 7

5

Mounting Bolts



MA2493.eps

B

A




Figure 11-26

Figure 11-27


Installing clamps, connectwire, tighten nuts andbolts

7. Be sure the valve guard is located properly andsecurely tighten both solenoid valve mounting bolts.

8. Install wire clamps (#3) and bolts (#4).

9. Connect coil plugs to their respective receptacles.

IMPORTANTAll electrical plugs and their receptacles arematched labeled for easy connection. Check to besure each plug and receptacle match beforeattempting to make connections.

CAUTION

The system must be purged of air before putting truckback into service or damage to the hydraulic systemmat occur.

10. Install and tighten clamp bolts (#4).

1. Position the valve to the pantograph frame aligningholes in frame with those in the valve.

2. Install mounting fasteners finger tight. Do not tightenfasteners until after the hydraulic hoses are installed.

Connecting Hydraulic Plumbing

3. Remove cap, hose tag and install connection (#11) tothe valve finger tight.

4. Remove cap, hose tag and install (#12) connectionfinger tight.

5. Install connections (#5) and (#8). Install connections(#6, 7, 8, 9 and 10) to the reach cylinders finger tight.

6. Securely tighten each hydraulic connection to thevalve body and the reach cylinder.

IMPORTANTBe sure the hoses are routed correctly beforeattempting to connect them to the valve. Refer topage 94.

Mounting Selector ValveRefer to Figure 11-26 and 11-27

11.8-2

11.8-3


Side Shifter Solenoid Control Valve



*Extend pantograph.




*Remove key.



a. Remove guard lockwashers andcapscrews.

DisconnectBattery

MA1035.eps

Figure 11-28

Removal

MA2202.eps

Capscrew

CapscrewHose Clamp


Dowel Pin

Shim

Snap RingShim



Fitting

Tilt Pin

Tilt Pin Bushing

Snap Ring

Grease Fitting

LowerWear Pad

CapscrewLockwasher

Guard

Capscrew

Capscrew

Valve Assembly

Coil


RetainerSS Rod

WiperSeal

Fitting

Tilt PivotBushing


Cap

Seal

Wear Pad Shim

Shim

Figure 11-29

11.9


Removal

*Unplug Connectors from each coil.

*Label each hose with it’s location.

*Disconnect hydraulic connections (V1, V2, C6, C5, C2,and C4) from the side shifter selector valve.


Cap each hose when disconnected.

NoteThere will be some fluid leakagewhen hydraulic fittings are discon-nected. Place a rag beneath thefitting to be removed.

*Remove mounting bolts securing the selector valve tothe pantograph.

*Remove valve and place on a clean work bench.

*Inspect hoses and connectors for further serviceability.

*Replace defective parts.

Refer to Figure 11-30.

Figure 11-30

2

MA2207.eps

3

1

11.9

NOTEThe valve body and valves areserviceable. If the unit is notfunctioning properly, Seesection 13 for valve service.


Figure 11-31


InstallationMounting Selector Valve

*Line up mounting holes in selector valve with those inthe mounting bracket. Install mounting bolts fingertight. See Figure 11-33.

Installing Hoses

*Wipe hose ends and connectors clean. Remove hosecaps just prior to installation. Be certain all connec-tions are tight.

Connecting Coils

*Plug connectors to each coils. See illustration on page96.

*Tighten all mounting fasteners.

*Install guard.

MA2216.eps

TiltCylinder


Floor


TiltSelector

Valve

MA2569.eps

Figure 11-32

11.9-1


Figure 11-33

MA2202.eps

Capscrew

CapscrewHose Clamp


Dowel Pin

Shim

Snap RingShim



Fitting

Tilt Pin

Tilt Pin Bushing

Snap Ring

Grease Fitting

LowerWear Pad

CapscrewLockwasher

Guard

Capscrew

Capscrew

Valve Assembly

Coil


RetainerSS Rod

WiperSeal

Fitting

Tilt PivotBushing


Cap

Seal

Wear Pad Shim

Shim


11.10 Servicing a Double Reach PantographThe Double Reach Pantograph is serviced the same as the Single Reach Pantograph with oneexception. The Double Pantograph has two scissor assemblies. Follow service proceduresoutlined in Sections 11-1 through 11-9. Refer to Figures 11-34 through 11-37.

MA2312.eps

Rear FrameScissor Pin

Grease Fitting

Pivot Bushing

Rear Scissor Frame

Scissor Arm

Bearing CupBearing ConeLock Nut

NutO-Ring

HousingSnap Ring

Grease Fitting

CylinderBearing

Washer

Grease FittingScissor Arm

Shield

Bearing Cone

Bearing Cup

Snap Ring

Bushing

Washer

Cotter Pin

Flat Washer

Nut

Grease Fitting

Scissor Arm

Pivot Bushing

Shield

Bearing Cone

Bearing Cup

Snap Ring

Bearing Cup

Bearing ConeLock Nut

Nut

O-Ring

HousingSnap Ring

Grease FittingCarriageScissor Arm

Shims

Bearing

Flat Washer

Capscrew



C2

CONNECT TO PLUG ONMAST WIRE HARNESS

MA2313.eps

Sideshifting Models Only

Sleeve

Clamp

Capscrew

Wire Harnessto Sideshifter

Scissor Pin Roll Pin

Reach Cylinder

Fitting

Tube

O-Ring

Guard

Hose Guard

Clamp

Cylinder Pin

Nut

Tube Assembly

Capscrew

Wire Harness

Fitting

Clamp

Fitting

SolenoidCoil

Fitting

Fitting

SolenoidValve Block

Couter Balance Valve



MA2310.eps



Cover

Cable Tie

Tilt Cylinder Hoses

Double Reach Without Sideshifter

MA2311.eps



Cover

Cable Tie

Tilt Cylinder Hoses and Cable

Double Reach With Sideshifter


Figure 11-37 Hose Routing.

11.10 Servicing a Double Reach Pantograph (continued)

P

Outside Spanner Tool

2"

Inside Spanner Tool

1 1/2" 700

4 1/2"

200

400

3 1/2"

9"

4 1/2"

9"

1 1/2"

MA1046.eps

1"

1"

1"

1"

1/2" Thick Material

1/2" Thick Material

1/4" Fine Thread

Figure 12-1

antogragh Shimming Section 12

Shim

HandleShim Set

Side View

Carpenter Square

Top View

Front View

MA1047.eps

Protractor

Sliding T Bevel

450

4 3/4"

7/8"

Figure 12-2

P antogragh Shimming Section 12

AllenHeadScrew

Load RollerAdjustmentShims

Carriage

Scissors

MA2190.eps

Lift Fork Carriage

Pantograph Assembly

Figure 12-3


Truck Side


MA1038.eps

Inner Rail Assembly


Rail Assembly

Outrigger(s)

TopBottom

PANTOGRAPH CARRIAGE ROLLERS

The clearance between the upright inner rails and the pantograph carriage rollers must be checked and adjusted.

Checks and Adjustments

NOTE: Roller clearance and adjustment may accomplished withthe upright mounted to the truck or removed and laying onthe floor as shown above.

1. Span inner rail with inside spanner tool.

Find the smallest distance between rails.

After finding the smallest distance, place a roller shim between the spanner tool and the inner rail. Lock the tool inposition.

Inner Rail

MA1048.eps

**

Step 1Span Railto findnarrowestpoint.

Inside Spanner Tool

Figure 12-4

Figure 12-5

12.0

12.0-1


Lock

Lock

Lock

Lock

Outside Spanning Tool

Inside Spanning Tool

MA1050.eps

MA1051.eps

UpperCarriageRoller

OuterSpanningTool

AllenHeadScrew

Load RollerAdjustmentShims

Carriage

Scissors

MA1052.eps

2. Set outside spanning tool to match the adjusted insidespanning tool.

3. Lock the outside spanning tool in the adjustedposition.

4. Span the upper carriage rollers at their outer mostcamber point. Add or remove shims at the roller shaftto match tool size.

5. Center carriage rollers by counting the shims andusing equal numbers of shims on both sides. If thereis an odd number of shims, place the odd shim on theright hand side.

IMPORTANTWhen upright is fully extended, the uppercarriage rollers extend beyond the inner railassembly. To allow the rollers to retractsmoothly back into the rail, one shim shouldbe removed from each side.

6. Install upper carriage rollers and securely tighten theAllen head retaining capscrews.

Figure 12-6

Figure 12-7

Figure 12-8


7. Span center carriage rollers at their outer mostcamber point. Add or remove shims to match toolsize.

8. Center carriage rollers by using equal amounts ofshims on both sides. If an odd number is used, placethe odd shim on the right hand side.

MA1053.eps

CenterCarriageRoller

OuterSpanningTool

9. Place a carpenters square at the outer most camberpoint of the center and lower rollers. Hold the squaretight against rollers and take the following measure-ments.

*Measure the distance between the top of thesquare and the straight edge at point (A).

*Take a measurement at point (B). These mea-surements should be the same. If they are not,add or remove shims from the lower rollersshaft(s) until the distance measured at eachpoint is equal.

Figure 12-9

Figure 12-10


10. Span lower rollers. Add or remove shims to (the rollerthat has not be squared) match the size of the outsidespanning tool.

MA1055.eps

BottomCarriageRoller

OuterSpanningTool

11. Check and adjust rollers on the opposite side ofcarriage. Place square at the outer most camber ofthe center and lower rollers. Take measurements asbefore. This side will be square within 1/32:, if not ,return to step 9 and repeat procedure. Make surerollers are center as previously described.

Figure 12-11

Figure 12-12


13. Check opposite roller in use the same procedure,adjusting if necessary.

NOTEUpper Rollers are retained only withthe Allen head capscrews. Center

and lower rollers are always captivewithin the rails.

Carriage

Scissors

MA1057.eps

1/32" Shim

Carriage

Scissors

MA1058.eps

1/32" Shim

12. The top rollers are checked last. Remember that thetop carriage rollers extend out of the inner rails whenthe mast uprights are at full extension. To makereentry of these rollers into the inner rails easier,additional clearance is required for the top rollers.(Refer to steps 4,5 and 6).

*Place the square directly through the center ofthe rollers as shown in the illustration to theright.

*The rollers are shimmed properly when a 1/32”shim can be fit between the outer most camberpoint of top roller and the square. The clearanceshould not exceed 1/32”.

*If adjustments are necessary, remove the Allenhead capscrew and the roller. Add or removeshims to correct the adjustment.

*Install Allen head capscrew and check adjust-ment.

Figure 12-13

Figure 12-13


Reach and Tilt Selector Valve Service

S ervice


Remove both counter balance valves from the valvebody.

NOTEIt will not be necessary to sepa-rate the valve bodies unlessthere was leakage between thetwo bodies. If the valve is leak-ing between the bodies, thenremove four 1/4-20 screws andsperate the bodies. Replace thevalve bodies with new ones.

Wash all parts except the coils in a Stoddard typecleaning solution. Wipe the coils with a clean cloth.

Wipe all parts dry with a clean lint-free cloth. Allowcomponents to air dry before reassembly.

Cleaning

*

*

*

*

Section 13Pantograph Valve Service

MA2580.eps

Typical Solenoid Valves

Typical Counterbalance Valve

CAUTION

Cleanliness is of extreme importance. Before discon-necting hydraulic components, clean exterior ofplumbing and solenoid valve to prevent dirt and otherforeign material from entering hydraulic system.

Figure 13-1

S ervice

MA1073.eps

Back-Up Ring(s)

O-Ring(s)

Solenoid Valve


Leads

Nut

Coil

Valve Body

Torque to 5 lb.ft.(6.8 Nm) Max.

Typical Cartridge Kit

Lubricate all parts in clean hydraulic fluid prior toinstallation.

If the O-Rings are damaged, replace the valve.

Install the solenoid valves back into their respectiveports on the valve body. Be certain the solenoid valveis torqued correctly to the body. Torque to 8 - 10 lb. ft.(11 - 14 Nm.).

Install the coil over the solenoid valve.

Install the coil retainer nut and torque to 25 lft.lb.(33.9 Nm) maximum. This allows the coil to becorrectly positioned during installation to the truck.

1.

2.

3.

4.

Reassembly - Solenoid Valves

Figure 13-2

Figure 13-3

Pantograph Valve Service Section 13

5.

Lubricate all parts in clean hydraulic fluid prior toinstallation. Use only new seals.


Install the counterbalance valves back into theirrespective ports on the valve body. Torque to 35 ft.lb. (47 Nm) maximum.

S ervice

1.

MA2581.eps

Counterbalance Valve(NON-ADJUSTABLE)If the valve has been tampered with,it must be replace with a new one.

O-RINGS

BACK-UP RINGS

BODYCAUTION

Cleanliness is of extreme importance. Before discon-necting hydraulic components, clean exterior ofplumbing and solenoid valve to prevent dirt and otherforeign material from entering hydraulic system.

Reassembly - Counter-balance Valves

InstallationIMPORTANT

Inspect hoses, hydraulic connections and their sealsfor damage. Replace defective parts.

Wipe hose ends and connections clean prior toinstalling them to the solenoid valve.

Remove hose caps just prior to installation.

2.

3.

Figure 13-4


S ervice

MA2582.eps

Valve Body

Solenoid Stem Valve

Check Valve

Solenoid Coil

Figure 13-5



Side Shift Selector Valve Service

S ervice

MA1073.eps

Back-Up Ring(s)

O-Ring(s)

Solenoid Valve


Leads

Nut

Coil

Valve Body

Torque to 5 lb.ft.(6.8 Nm) Max.

Typical Cartridge Kit

DisassemblyRemove nut and coil from each solenoid valve.

Remove both solenoid valves from the valve body.

Wash all parts except the coils in a Stoddard typecleaning solution. Wipe the coils with a clean cloth.

Wipe all parts dry with a clean lint-free cloth. Allowcomponents to air dry before reassembly.


Cleaning*

*

*

*

*

ReassemblyLubricate all parts in clean hydraulic fluid prior toinstallation.

Install the solenoid valves back into their respectiveports on the valve body. Be certain the solenoid valveis torqued correctly to the body. Torque to 8 - 10 ft. lb.(11 - 14 Nm.).

Install the coil over the solenoid valve.

Install the coil retainer nut and torque to 25 lft.lb.(33.9 Nm) maximum. This allows the coil to becorrectly positioned during installation to the truck.

*

Figure 13-7

Pantograph Valve Service

Figure 13-6

Section 13

*

*

*

M anual Changes Section 14

R3 - Update manual for four valve reach valve and new SS seal kit.Update illustrations for SS kit on pages 56, 68, 78, 82.Update illustrations for new valve on pages 70, 72, 73, 74, 76, 84.Break Manual into sections and reorganize sections.

R4 - 04/08/04Section 6Add page 18, for Tri-Line Cable Service.

Section 11Revise schematic on page 73.Revise note on pages 76 and 80.Revise schematic on page 80.

Section 13Create valve assembly service section.

R5 - 06/28/04Revise Section 11 to show two valve and 4 valve configurations.

R6 - Revise cylinder illusrtations in Cylinder Service Section.

R7 - 11/12/07Revise chain adjustment instructions on page 23.

R8 - 12/15/07Revise hydraulic schematic on pages 74, 82, 91 and 99.

Lift Technologies, Inc.7040 South Highway 11Westminster, SC 29693USATel: +1(864) 647-1119Fax: +1(864) 647-5406

Lift Technologies Inc.Corporate Head Office251 Woodlawn Road W., Unit 217Guelph, ON N1H 8J1 CanadaTel: +1-519-823-4545

Lift -Tek Elecar Srl29015 Castel. San. Giovanni (PC)Via G. GalileiItaly

Do you have any questions that need to be answered right now?

Other Lift Technologies Locations

Customer Service(North America Toll Free)

1-888-946-3330

© Lift Technoloies Inc. 02-2007 www.lift-tekelecar.com

30_35!40!45HR MT Reach Truck Mast R8

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Transcript of 30_35!40!45HR MT Reach Truck Mast R8