Two-Stage Mast With Limited Free-Lift Repair
REMOVE
WARNING
The mast is heavy. The mast can weigh approxi-
mately 907 kg (2000 lb). Make sure all lifting devi-
ces (hoists, cables, chains, slings, etc.) are suita-
ble and of adequate capacity to lift the mast. Seri-
ous injury can occur if the mast falls.
CAUTION
Make sure all the mast weldments are fastened to-
gether. Make sure the safety chains will not dam-
age the sheaves, tubing, or other parts of the
mast.
NOTE:
If the mast needs to be disassembled, re-
move the forks and carriage. See the sections Fork
Replacement and Carriages Repair for procedures.
If only the main lift cylinders or tilt cylinders need
to be repaired, the mast does not need to be re-
moved from the lift truck. See the section Cylinder
Repair (Mast S/N A270-72, A551, A555, A559,
A626, A627, A751-52, B551, B555, B586-91,
B749-54, C661-63, C665, D507-09, D515,
D562-64, E509, E564) 2100SRM1382 for proce-
dures. For header hose installation and adjust-
ment, see the section Header Hose Installation and
Adjustment.
1.
Fully lower all mast weldments. Tilt the mast
fully forward. Connect a crane or lifting device,
with a capacity of at least 907 kg (2000 lb), to
all top crossmembers of the mast weldments
using chains to support the mast in an upright
position when the tilt cylinders are disconnec-
ted. See the section Safety Procedures When
Working Near Mast.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic hoses until the oil in the system has
cooled.
Completely lower forks to relieve hydraulic pres-
sure before disconnecting any hoses.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when disconnecting hydraulic hoses
from the mast. If hydraulic system becomes con-
taminated, damage to hydraulic system can oc-
cur.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
2.
Position a drip pan with a capacity of 21 li-
ter (22.5 qt) under the area of the hydraulic fit-
tings.
3.
Remove the floor mat. Lift the floor plate up
enough to disconnect the electrical connectors
from the accelerator pedal or pedal, and remove
floor plate with accelerator pedal or still at-
tached. See Figure 14.
4000 SRM 1386
Two-Stage Mast With Limited Free-Lift Repair
19
