Two-Stage Mast
4000 SRM 764
Two-Stage Mast
REMOVE
WARNING
Fully lower all the mast weldments.
Weld-
ments, operator platform, and forks can move
suddenly and cause an injury as hydraulic
lines are disconnected.
NOTE:
If the mast assembly will be disassembled, re-
move the operator platform before the mast assembly
is removed. See Operator Platform, Remove in this
section.
1.
Disconnect and remove the battery. Refer to the
correct procedure in the Operating Manual or
the section Periodic Maintenance 8000 SRM
924 or Periodic Maintenance 8000 SRM 1472.
2.
Install blocks under the main frame near the
mast to support the main frame without chang-
ing the height. Make sure the mast, base arms,
and load wheels do not support any weight so the
mast capscrews can be removed. Use chains to
fasten the mast channels together at the top of
the mast.
3.
Open the door and remove the access cover over
the electrical compartment.
Remove the hy-
draulic tube at the cylinder port of the solenoid
valve. Put caps on the port, the mast hose, and
both ends of the tube to prevent dirt from enter-
ing the system. Use wire to fasten the hose in
a position to prevent damage during removal of
the mast.
4.
Disconnect the electrical cable for the operator
platform. Push the cable and connectors through
the holes in the lift truck frame to prevent dam-
age to the cable during removal of the mast. Use
wire to fasten the hoses and cable in a position to
prevent damage.
5.
Use chains to connect a crane to the top of the
mast.
Make sure the chains will not damage
the sheaves or other parts of the mast assembly.
Make sure the chains and crane have the capac-
ity to lift approximately 2000 kg (4500 lb). Use
other chains to fasten all the mast weldments to-
gether so they cannot move. Operate the crane
until it gives support to the weight of the mast.
Move the crane to a position so the mast assem-
bly will be lifted vertically.
6.
Remove the four large capscrews and washers
that fasten the bottom of the mast to the lift truck
frame. Hold the spacers and remove the four
large capscrews and washers that fasten the top
of the mast. Remove all the spacers.
WARNING
Lift chains and cables can roll over the sheaves
to fall and possibly cause an injury if the ends
are not fastened. Keep control of the ends of
the lift chains and cables as they are discon-
nected.
7.
Use a ladder to disconnect the lift chains at the
top of the outer mast weldment. Remove the pins
in the chain anchors to remove the chains with-
out changing the adjustment. Carefully lower
the lift chains. Disconnect the electrical wires
from the limit switches and remove the cables.
8.
Remove the cross tube (horizontal) at the battery
side of the bottom of the mast.
9.
Operate the crane and carefully move the mast
assembly away from the lift truck. Do not dam-
age any hydraulic lines or the electrical cable.
10. Put the mast assembly on the floor so the back
(battery side) of the mast is toward the floor.
DISASSEMBLE
NOTE:
This procedure does NOT include the removal
of the operator platform. Remove the operator plat-
form before starting this procedure. See Operator
Platform, Remove in this section to remove the op-
erator platform. See Figure 3 and Figure 4.
WARNING
Make sure the battery side of the mast is to-
ward the floor so the front of the mast is up for
easier disassembly. Make sure the mast weld-
ments are fastened together so the weldments
will only slide when being moved during disas-
sembly.
1.
If necessary, remove the lift chains by removing
the pin in the chain anchor. Removing the pin
will allow chain removal without changing the
adjustment.
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