ep ICE301B, Service Manual

Page: 43 / 54

REV. 09/2020 REV. 09/2020
MAST MAST
8 8
76 77
8.1.4 Lift Cylinder
8.1.4.1 Cylinder Removal (with mast on
the vehicle)
Left Cylinder Removal
-
-
-
Lower the mast to the bottom, press the em-
ergency stop switch and disconnect the key
switch;
Block the truck wheels with wooden wedges,
raise the inner mast (2, Fig3530-60002SM)
for 500mm with lifting tools, insert wooden
block between inner mast and the ground for
supporting;
Disconnect the connection between the tubing
(5) and straight coupling (3);
Hydraulic oil may damage truck parts and
contaminate the environment. When removing
joints or tubings, place a clean container under
it for discharge of hydraulic oil.
-
Unscrew the bolt (3, Fig3530-60002SM) and
remove the cylinder clamp (4);
-
- Unscrew the mounting bolt (7) from the bott-
om of the cylinder;
Unscrew the bolt (6), lift the cylinder (5) up
and remove it from the truck.
-
supporting;
Remove the tubing (5, Fig3131-60005SM)
to make it separate from the three-pass
component (2);
Right Cylinder Removal
- Lower the mast to the bottom, press the em-
ergency stop switch and disconnect the key
switch;
- Block the truck wheels with wooden wedges,
raise the inner mast (2, Fig3530-60002SM) for
500 mm with lifting tools, insert wooden block
between inner mast and the ground for
Hydraulic oil may damage truck parts and cont-
aminate the environment. When removing joints
or tubings, place a clean container under it for
discharge of hydraulic oil.
- Unscrew the bolt (3, Fig3530-60002SM) and
remove the cylinder clamp (4);
CAUTION
CAUTION
Before going on with the next step, please fix
the cylinder properly first. Be sure to avoid the
falling of cylinder during removal, resulting in
personal injury.
CAUTION
- Remove the regulator (6) from the three-pass
component (2);
-
-
Unscrew the mounting bolt (7) from the bott-
om of the cylinder;
Unscrew the bolt (6), lift the cylinder (5) up
and remove it from the truck;
- Remove the three-pass component (2,
Fig3131-60005SM) from the right cylinder.
8.1.4.2 Cylinder Maintenance
If the piston rode or cylinder tube is damaged,
please replace the entire cylinder.
If the seals are aged or damaged, please
replace the complete set of seals.
-
-
-
-
-
-
-
-
-
Secure the cylinder to hose clamp and gently
clamp the cylinder bottom;
Unscrew the cylinder cap (3) with cylinder
wrench;
Remove the dust ring (1), seal (2), O-ring (4)
and bushing (5) from the cylinder cap (3);
Pull out the piston rod (6) from the cylinder
tube (15);
Remove the support ring (8) and the piston (9)
from the piston rod;
Remove the O-ring (7), bushing (10),
rataining ring (11) and seal (12) from the
piston;
Remove the O-ring (14) and bushing (13)
from the piston;
Clean with hydraulic oil of the same specific-
ations;
Replace the problem parts and assembly in
reverse steps.
-
-
-
Use suitable hose clamps to avoid cylinder
deformation caused by severely tight hose
clamp.
Carry out the maintenance work in a clean
environment to prevent impurities from
entering into cylinder, causing cylinder
damage.
During the installation, hydraulic oil of
the same specifications must be used for
cleaning or lubrication.
8.1.4.3 Cylinder Installation
-
-
-
-
-
Install the cylinder according to the reverse
order of removal according to 8.1.4.1 ;
Add hydraulic oil of the same specifications
into the tank, see Section 2.2.3 ;
Pull out emergency stop switch and turn on
the key switch;
Repeat Lift - Lower cylinder to discharge the
air within the tubings and cylinder;
Check the hydraulic oil level and make sure
that the liquid is at standard level.
CAUTION
CAUTION