4.
Make sure there is no slack in the lifting
device or chains. Remove the metric screw,
lock washer, and retainer washer (Item 12, Fig
7.6) from the tilt cylinder rod end.
5.
Support the tilt cylinder while removing the
front cylinder pin. Rest the tilt cylinder on the
frame of the truck being careful not to
damage the cylinder rods.
6.
Repeat Steps 4 and 5 for the other tilt
cylinder.
7.
Make sure the mast is vertical. Remove the
mast mount plates and use the lifting device
to raise the mast and separate it from the
truck. Put the mast on the floor so that the
back of the mast is down.
Disassembly
NOTE
If the carriage has already been removed, start
with Step 3.
Hoses are installed under tension.
1.
Disconnect all hydraulic connections from the
carriage. Loosen chain anchor bolts and
disconnect the chains from the carriage and
middle crossbar of the inner rail and remove.
Remove the chain and hose sheaves from the
center cylinder.
2.
Remove the two carriage stop bolts at the top
of the inner rail. Attach a lifting device to the
carriage. Slide the carriage out the top of the
inner rail. Lay the carriage on the floor face
down. Remove the load rollers, noting the
number and location of shims at each load
roller. The shim arrangement will be
approximately the same during reassembly.
3.
Disconnect and remove the hydraulic hoses
for the center cylinder and auxiliary (sideshift)
attachment back to the outer rail. Remove
the tube connecting the center cylinder to the
distributor block. Remove the snap ring at the
bottom of the center cylinder and the center
cylinder strap. Remove the center cylinder.
4.
Loosen the chain anchor bolts and disconnect
the lift chains at the bottom of the inner rail
and the top of the outer rail and remove.
Remove the chain sheaves at the top of the
middle rail. Push the inner rail half way out
the top of the middle rail and connect a lifting
device to the inner rail. Now push the inner
rail out of the middle rail until the load rollers
on the inner rail are visible in the notches at
the top of the middle rail.
5.
Lift the inner rail out of the middle rail.
Remove the load rollers at the bottom of the
inner rail and the top of the middle rail. Make
a note of the shim arrangement at each load
roller location. The shim arrangement will be
approximately the same during assembly.
6.
Remove the screws, washers, and spacer
sleeves at the top of the outer cylinders (do
not allow the cylinder rod to spin). Make a
note of all shims at the top of either cylinder
rod.
7.
Push the middle rail half way out of the outer
rail and connect a lifting device to it. Now
push the middle rail out until the load rollers at
the bottom of the middle rail are visible in the
notches at the top of the outer rail.
8.
Lift the middle rail out of the outer rail.
Remove the load rollers at the bottom of the
middle rail and the top of the outer rail. Make
a note of the shim arrangement at each load
roller location. The shim arrangement will be
approximately the same during assembly.
9.
If the outer cylinders need repair, disconnect
the hydraulic tubes at the bottom of the outer
cylinders, remove the roll pin from the base,
remove them from the outer rail and mark
them as right and left. Retain any shims
noted in Step 6 with the cylinder. Remove
hydraulic tubes, manifold and fittings from the
rails as necessary.
Cleaning and Inspection
1.
Inspect the chain sheaves and load rollers for
wear or damage. DO NOT use steam to
clean the lift chains, sheaves, or load rollers.
The bearings in the sheaves and load rollers
are lubricated and sealed.
WARNING
When using cleaning solvents, always follow
the manufacturer’s recommended safety
precautions.
2.
Clean the lift chains with solvent. Remove all
dirt and grease. Inspect the lift chains for
wear or damage. The lift chains must be
installed on the mast before they can be
checked for length. A lift chain becomes
longer when it is worn. Most wear occurs in
the section that goes over a sheave. If a
chain is 3% longer than a new lift chain, a new
E
lectric
C
ounterbalance
H
igh
O
utput
Elevating
3/10/00
7.6
