Lift Tek 35DV-MQ Service Manual Download Page 1

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SERVICE MANUAL

35DV/45DV/55DV-MQ

Four Stage

Full Freeli

Mast

LTI

263920

Lift

Technologies,

Inc.

Summary of Contents for 35DV-MQ

Page 1: ...SERVICE MANUAL 35DV 45DV 55DV MQ Four Stage Full Freeli Mast LTI 263920 Lift Technologies Inc...

Page 2: ...647 7302 Toll Free 877 430 6302 Email parts lift tek com Lift Technologies Inc 7040 South Highway 11 Westminster SC 29693 USA Tel 864 647 1119 Fax 864 647 5406 Toll Free 888 946 3330 Website www lift...

Page 3: ...val Main Lift Cylinders Description PERIODIC MAINTENANCE Section 3 TROUBLESHOOTING Section 4 INTRODUCTION Section 1 Introduction Special Definitions Mounting Bracket Installation INSTALLATION INSTRUCT...

Page 4: ...ation that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine dama...

Page 5: ...If fire resistant hydraulic oil must be used contact Lift Tek Relief Pressure Hose Size Fitting Size 2600 psi No 8 min No 8 min 13 32 in Orifice FigFigure 2 Valve inlet Port MA0022 eps Valve Inlet Po...

Page 6: ...connecting the tilt cylinders to the mast make sure the cylinders bottom evenly Adjust the tilt cylinders to prevent the mast from racking during tilting Refer to your truck service manual for procedu...

Page 7: ...howing correct position for uprights and carriage 2 4 1 Chain Lubrication The main and free lift chains have been factory lubricated using heat and pressure to force the lubrication thoroughly into th...

Page 8: ...Rails Lubrication Figure 7 Lubricating upright channels Inspect the upright channels for lubrication If necessary lubricate the full length of each upright channel with chassis lube or Kendall SR 12X...

Page 9: ...s finger tight Double Function Install the fittings to the left and right side location Tighten the fittings finger tight 4 Install the lower IHR bracket and plastic inserts to the block at the bottom...

Page 10: ...nnect the hose ends to the fittings leaving the hose ends finger tight 35DV Double Function The No 4 hoses connect to the two right fittings viewed from the driver s seat 2 4 2 Internal Reeving STANDA...

Page 11: ...and hardware Tighten the capscrews to 30 ft lbs 41 Nm 15 Route the hoses up toward the top of the mast following the inner lift chains Bend the hoses over the inner intermediate upright sheave and ins...

Page 12: ...Nm 23 Align the hoses by twisting the hose ends to travel centered in the crosshead on the natural curve of the hose The hoses should travel parallel to each other Hold the hoses while tightening the...

Page 13: ...Mast is extended inspect the upright rails for lubrication Refer to Section 5 5 5 Step 1 for lubrication 4 Make sure the internal reeving hoses if equipped travel evenly in the hose guides Adjust the...

Page 14: ...the upright upper crossmembers see Figure 14 Clearance should be 1 16in 1 5 mm max If thrust plug block replacement is required refer to Section 5 5 3 Upright Disassembly 3 Check the chains for wear a...

Page 15: ...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 ch...

Page 16: ...mast anchor brackets For reassembly tighten the pin capscrews to the truck manufacture s torque specifications 5 Disconnect the Mast lower mounts For reassembly tighten the capscrews to the truck manu...

Page 17: ...retainer seals provide a high pressure hydraulic seal against the plunger The retainer also limits the upward stroke of the plunger A piston is attached to the bottom end of the plunger The piston sea...

Page 18: ...des a high pressure seal against the shell A check valve located in the bottom of the piston allows residual oil between the shell and plunger to escape when the cylinder is extending except for figur...

Page 19: ...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 plung...

Page 20: ...es from the cylinder inlet ports Using a 1 in socket remove the special long fittings from the cylinder ports and install plugs 5 Remove the snap ring from the top of the LH cylinder rod and the tube...

Page 21: ...4 Remove the snap ring fastening the crosshead to the cylinder rod 5 Pull the crosshead with chains and hoses if equipped of the cylinder rod 6 Roll the carriage above the free lift cylinder 7 Using...

Page 22: ...he lower carriage bar and the floor 3 Remove the snap ring fastening the crosshead to the cylinder rod 4 Pull the crosshead with chains and hoses if equipped off the cylinder rod 5 Using a 1 in wrench...

Page 23: ...n 1 Remove the cylinder from the Mast as described in Sec on 5 2 4 2 Make sure disassembly area tools and cylinder are clean before dissembling This will help reduce the amount of contaminants that ma...

Page 24: ...while it is a ached 11 Replace check valves in piston if applicable Tighten to 10 12 lbs 12 Slide retainer back onto rod Verify the orienta on is correct 13 Push pipe securely back into piston cavity...

Page 25: ...ver and cut the seal to remove it CAUTION Do not scratch the seal groves 4 Inspect the plunger piston retainer and cylinder bore for nicks and burrs Minor nicks and burrs can be removed with 400 grit...

Page 26: ...engagement is needed The piston will not enter the shell if the loader contacts the thread relief chamfer 8 Apply a thick film of petroleum jelly or hydraulic oil to the inside of the cylinder shell...

Page 27: ...iston seals back up rings O rings and bearing Lubricate the new seals with petroleum jelly prior to installation Note the correct seal directions The seal lip always points toward the pressure side of...

Page 28: ...the plunger 5 For reassembly reverse the above procedures except as follows Install a new snap wire when installing the piston Figure 26 Removing piston from plunger MA0069 eps 3 2 2 5 3 Valve 5 3 1 V...

Page 29: ...ithin the upright There are four side thrust rollers to transfer carriage side loading to the inner rails These rollers are held in place by a capscrew and are adjustable via their eccentric mounting...

Page 30: ...Section 5 4 4 Lubricate the inner upright rails with chassis lube or Kendall SR 12X where indicated by the heavy line for the full length of the upright see Figure 29 Assemble shims and load rollers o...

Page 31: ...llows Inspect the carriage as described in Section 5 4 4 Lubricate the inner upright rails with chassis lube or Kendall SR 12X where indicated by the heavy line for the full length of the upright see...

Page 32: ...plates and the carriage fork bars If any welds are cracked replace the carriage 4 Inspect the roller stub shafts If they are damaged or if there are cracks at the base of the stub shafts the carriage...

Page 33: ...telescopes within the outer intermediate upright assembly A pair of shim adjustable load rollers are attached to stub shafts located at the top and bottom of the upright A pair of chain sheaves are lo...

Page 34: ...causes the free lift cylinder on the inner upright to raise which moves the carriage to the top of the inner upright Full Extension When the free lift cylinder reaches the end of its stroke the main...

Page 35: ...upright center crossmember and tag for reassembly 8 Disconnect the free lift cylinder hose from the tube and remove the stop hose bracket tube assembly 9 Disconnect the inner main chain anchors from...

Page 36: ...through the top end of the inner intermediate upright NOTE The stub shafts on the lower end of the inner upright come out of the inner intermediate upright between the rail cutout and the stub shaft...

Page 37: ...uter intermediate upright 16 Remove the chain sheaves from the outer intermediate upright 17 Roll the inner intermediate upright downward and remove the lower rollers Remove the upper rollers and thru...

Page 38: ...oving outer intermediate upright 1 Inspect the load for excessive wear or damage Rollers with visible flat spots or cracks should be replaced 2 Inspect the load roller bearings by turning the rollers...

Page 39: ...earance for the pair of rollers at the XXX shown Use an equal number of shims on each side NOTE Roll the uprights past installed thrust plugs blocks before checking load roller clearance Thrust Plug B...

Page 40: ...Page 40 263920...

Page 41: ...and thrust plugs to the upper end of the inner intermediate upright Refer to Step 3 for roller shimming and thrust plug clearance measurement 15 Install the inner main lift chain anchors long anchors...

Page 42: ...10 cm wood block between the outer and outer intermediate lower crossmembers to prevent upright movement 22 Turn the Mast over face down rotating it on its lower end Make sure the Mast is re blocked...

Page 43: ...linder rod down past the outer intermediate s top crossmember Install or remove shim s on the cylinder rod below the crossmember see Figure 46 Shim are listed below Shim Thickness Part No 010 in 25 mm...

Page 44: ...ge shown see Figure 48 If inspection reveals that one strand of a pair of chains requires replacement both strands of the pair should be replaced Check for rust Check for cracked side plates If damage...

Page 45: ...2 for the inner main lift chain pair to achieve a flush inner upright position with the Mast intermediate uprights Tighten the chain anchor nuts to 50 70 ft lbs 68 95 Nm see Figure 49 4 Raise and lowe...

Page 46: ...st the outer main lift chains as described in Section 5 6 3 1 Raise the inner upright and place a 2ft 60 cm long block under the free lift cylinder support casting Lower the upright onto the block The...

Page 47: ...ld be slack see Figure 53 2 Remove the cotter pins and chain pins from the chain anchors Remove the chains 3 Inspect the chain anchors for cracks or other damage as described in Section 5 6 1 4 For re...

Page 48: ...Manual Change Summary R0 10 20 08 Release R1 12 17 08 Update IHR illustrations R2 Cylinder service right left hand added...

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