ep ICE301B, Service Manual

Page: 53 / 54

REV. 09/2020 REV. 09/2020
MAST MAST
8 8
96 97
8.3.4 Lift Cylinder
8.3.4.1 Cylinder Removal
Left Cylinder Removal (with mast down)
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Remove the mast from the chassis according
to Section 8.3.1 ;
Lay down the mast with lifting tools (with
outer mast underneath the inner mast), place
sleepers at both ends for supporting;
Disconnect the connections between the tub-
ing (1, Fig3131-60020SM ) and three-pass
assembly (2);
Remove the tubing (4) from the three-pass
component (2);
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 (6, Fig3131-60019SM ) and
remove the cylinder clamp (7);
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.
Right Cylinder Removal(with mast down)
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Remove the mast from the chassis according
to Section 8.3.1 ;
Lay down the mast with lifting tools (with
outer mast underneath the inner mast), place
sleepers at both ends for supporting;
Remove the tubing (1, Fig3131-60020SM) to
make it separate from the direct 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 (6, Fig3131-60019SM) and
remove the cylinder clamp (7);
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.
Full Free Middle Cylinder
(with mast on the vehicle)
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.
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
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Lower the mast to the bottom, press the
emergency stop switch and disconnect the
key switch;
Remove retaining shelf (
see Section 8.1.5.1 );
Block the truck wheels with wooden wedges,
raise the fork carriage for 500mm with lifting
tools, insert wooden block between it and the
ground for supporting;
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Loosen the joints (6, Fig3131-60020SM) to
separate the middle cylinder and rigid pipe
assembly (5);
Disconnect the connections between the
tubings (2, Fig3131-60021SM) around the
middle cylinder and rigid pipe assembly (3);
Remove the fork carriage chains according to
Section 8.3.2.2 ;
- Remove the three-pass component (2,
Fig3131-60020SM ) from the left cylinder.
-
- Unscrew the mounting bolt (8) from the
bottom of the cylinder;
Unscrew bolt (3) and remove the cylinder (4)
from the mast.
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- Unscrew the mounting bolt (8) from the
bottom of the cylinder;
Unscrew bolt (3) and remove the cylinder (5)
from the mast.
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Unscrew bolt (18, Fig3131-60019SM ) and
remove the middle cylinder roller guard (16);
Unscrew the nut (19), remove the middle
cylinder tube shaft (12) and middle cylinder
tube roller (11);
Unscrew the bolt (9) and remove the middle
cylinder fixing plate (10) and sprocket seat
(13) from the cylinder (14);
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.
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Unscrew the bolt (15) and separate the
cylinder (14) from the inner mast (2);
Remove the cylinder (14) from the truck.
8.3.4.2 Cylinder Maintenance
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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.
Lifting Side Cylinder
CAUTION
CAUTION
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Secure the cylinder to hose clamp and gently
clamp the cylinder bottom;
Unscrew the cylinder cap (3,Fig3131-
60022SM) with cylinder wrench;
Remove the dust ring (1), seal (2), O-ring (4)
and bushing (5) from the cylinder cap;
Pull out the piston rod (6) from the cylinder
tube (16), then remove the shaft sleeve (8)
from the piston rod;
Remove the piston (10) from the piston rod;
Remove the O-ring (9), bushing (11), rataining
ring (12) and seal (13) from the piston;
Remove the round wire (15) and the bushing
(14) from the piston;
Clean with hydraulic oil of the same specific-
ations;
Replace the problem parts and assembly in
reverse steps.