30_35!40!45hr mt reach truck mast r8
TRANSCRIPT
S ERVICE MANUAL
Manual Number 246552 R8 ORION
30/35/40/45HR MTOrion Triple Stage
Full FreeliftPantograph Mast
12/15/07
246552R R8 Orion 12/15/07 Page 3
ContentsIntroduction Section 1 ..................................................................................................................................................4
Introduction ................................................................................................................................................. 4Special Definitions ....................................................................................................................................... 4
Installation Section 2 ....................................................................................................................................................5Truck System Requirements .......................................................................................................................5Mast Installation .......................................................................................................................................... 5Mast Inspection ........................................................................................................................................... 6Chain Lubrication ........................................................................................................................................ 6Upright and Carriage ...................................................................................................................................6Position, Chain Tension .............................................................................................................................. 6Channel Lubrication .................................................................................................................................... 7Mast Skewing .............................................................................................................................................. 7
Periodic Maintenance Section 3 ..................................................................................................................................8Daily Inspection ........................................................................................................................................... 8100 - Hour Inspection .................................................................................................................................. 8200 - Hour Inspection .................................................................................................................................. 8500 - Hour Inspection .................................................................................................................................. 9
Trouble Shooting Section 4 .......................................................................................................................................10Troubleshooting Chart ............................................................................................................................... 10
Mast Uprights Section 5 .............................................................................................................................................11Upright Description .................................................................................................................................... 11
Upright Removal Section 6 ........................................................................................................................................ 12Upright Removal ....................................................................................................................................... 12Upright Disassembly ................................................................................................................................. 14
Upright Chain Inpection Section 7 ............................................................................................................................ 20Upright Chain Inspection ........................................................................................................................... 20Chain Length Adjustment .......................................................................................................................... 22Chain Lubrication ...................................................................................................................................... 25Chain Removal and Replacement ............................................................................................................. 26Other Chain Service Notes ........................................................................................................................ 26
Upright Cylinders Section 8 .......................................................................................................................................27Main Lift Cylinder Description .................................................................................................................... 27Free Lift Cylinder Description .................................................................................................................... 28Cylinder Operation .................................................................................................................................... 29Main Lift Cylinder Service .......................................................................................................................... 30Free Lift Cylinder Service .......................................................................................................................... 32
Upright Shimming Section 9......................................................................................................................................34Upright Rail to Roller Clearance ................................................................................................................ 34Determining the Number of Shims needed to make roller adjustments ..................................................... 43Shim Adjustment ....................................................................................................................................... 44
Pantograph Removal Section 10 ............................................................................................................................... 45Preparation ................................................................................................................................................ 45Pantograph Removal ................................................................................................................................. 45
Pantograph Service Section 11 .................................................................................................................................50Pantograph & Fork Carriage Assembly Service ........................................................................................ 50Fork Carriage Removal ............................................................................................................................. 52Servicing Pantograph Arm Rollers ............................................................................................................ 54Tilt Cylinder Service .................................................................................................................................. 56Reach Cylinder Service ............................................................................................................................. 62Side Shift Cylinder Service ........................................................................................................................ 67Reach and Tilt Selector Valve ................................................................................................................... 71Side Shifter Solenoid Control Valve ........................................................................................................... 79Servicing a Double Reach Pantograph ...................................................................................................... 84
Pantograph Shimming Section 12 ............................................................................................................................ 87Checks and Adjustments ........................................................................................................................... 90
Pantograph Valve Service Section 13 ......................................................................................................................... 96Reach / Tilt Valve Service ........................................................................................................................... 96Side Shifter Valve Service ........................................................................................................................... 99
Page 4
This manual provides the installation Instructions, periodicmaintenance requirements, troubleshooting and serviceprocedures for the Lift Tek Series masts.
These masts provide excellent visibility for the lift truckdriver. The mast carriage and upright channels are allroller-mounted which provides smooth operation and longservice life.In any communication about the mast, refer to the mastserial number stamped on the nameplate. If the nameplateis missing, these numbers are also stamped on theleft-hand lower outer rail. See Figure 1-1.
Special DefinitionsWARNING
1.2
A statement preceded by is informationthat should be acted upon to prevent bodily injury. AWARNING is always inside a ruled box.
CAUTIONA statement preceded by CAUTION is information thatshould be acted upon to prevent machine damage.
IMPORTANTA statement preceded by IMPORTANT thatpossesses special significance.
NOTEA statement preceded by NOTE is information that is handy
Figure 1-1. Serial Mast Number Location
I
MA0974.eps
StampedSerial Number
Example:40HR-MT-001-00025-M
1.1
WARNING
ntroduction Section 1
Introduction
Page 5
Mast Installation
I
1. Raise and block the front end of the truck 1ft. (30 cm) per ANSI B56.1 or drive the truck over a service pit.
2. Disconnect the truck power supply.
3. Lift the mast using an overhead hoist with a sling looped under the upper upright crossmembers. Position the mast on the truck. Install the mounting blocks and capscrews. Tighten the capscrews to the truck manufacturer’s torque specifications.
4. Connect the lift truck hydraulic supply hose to the mast valve.
NOTE: Use as few fittings as possible and always use 45o
fittings instead of 90o fittings. Keep the hose lengths to aminimum. Avoid sharp bends or pinch points when routingthe hose.
5. Connect all electrical connections to the mast.
6. Connect the truck power supply.
7. Check the hydraulic fluid level in the truck hydraulic tank when the Mast is fully lowered. Fill if required.
MA0975.eps
2
4
2
Figure Figure 2-1. Mast Installation.
Contact Lift Tek ifadditional fittings arerequired. See backcover.
nstallation Section 2
2.1 Truck System Requirements
WARNING: For proper truck stability or toprevent interference, tilt restriction may berequired. Contact the truck manufacturer.
IMPORTANT: Lift Tek Masts are compatible with SAE 10Wpetroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104B only. Use of synthetic or aqueous base hydraulic oil is notrecommended. If fire resistant hydraulic oil must be used,contact Lift Tek.
2.2
Page 6
I nstallation
Mast InspectionCheck each of the following before using the Mast for thefirst time.
CAUTION: The factory-set adjustments may not becorrect for your truck.
1. Inspect all chains for lubrication.
2. Inspect all chains for any visible damage.
3. Inspect the main lift chain adjustment for proper tension and upright position.
4. Inspect the free lift chain adjustment for proper tension and carriage position.
5. Inspect for lubrication in the Mast upright channels.
6. Check for Mast skewing.
Chain LubricationThe main and free lift chains have been factory lubricatedusing heat and pressure to force the lubrication thoroughlyinto the chain links. Avoid removal or contamination ofthis factory-applied lubrication. Do not wash, sand blast,etch, steam clean, or paint the chains for initial Mastinstallation. If chains need lubrication, refer toSection 7.2. Chain Lubrication
Upright and CarriagePosition, Chain TensionThe main lift chains should be adjusted so that when theunloaded Mast is fully lowered, the uprights are flush atthe bottom. The free lift chains should beadjusted so that when the unloaded Mast is fully lowered,the carriage is properly positioned depending on the trucktype.
CONTINUED ON NEXT PAGE
MA0977.eps
Free Lift ChainsAdjusting Nuts
Outer MainLift ChainAdjusting Nuts
Figure 2-2. Adjusting Chain AnchorLocation (driver’s view).
Section 2
2.3
2.3-2
2.3-1
Page 7
Upright and CarriagePosition, Chain Tension
( Continued )
I nstallation
All chains should also be adjusted for equal tension of thepairs to ensure proper load distribution and mast opera-tion. Chains are adjusted at the chain anchors (seeFigure 2-2). To determine equal tension, extend theunloaded mast to put the chains under tension. Then pressthe center of the strand with your thumb. Then pressat the same place on the other chain of the pair. Eachchain in a pair should have equal “give”.
If the uprights or carriage are not in correct adjust-ment, of if the chain pairs do not have equal tension,perform the Main Lift and Free Lift Chain Adjustmentsas described in section 7.1.
Channel Lubrication
MA0978.eps
OuterUpright
Lubrication
Figure 2-4. Lubricating upright channels.
Inspect the upright channels for lubrication. If necessary,lubricate the full length of each upright channel withchassis lube or Kendall SR-12X (see Figure 2-4).
Mast SkewingTo adjust the Mast to eliminate skewing, perform the MastSkewing Adjustment as described below.
Extend the mast to full lift height and inspect for mastskewing (see Figure 2-5).
* If the mast bends to the right at full extension, a shim(s) needs to be removed from the left main lift cylinder rod.
* If the mast bends to the left at full extension, a shim(s) needs to be installed on the left main lift cylinder rod.
MA0979.eps
Left HandMain LiftCylinder
Three StageMast shown
FreeliftCylinder
Right HandMain LiftCylinder
1
11
Figure 2-5. Extending Mast to checkfor skewing (driver’s view).
AlignmentPin
AlignmentPin Tab
Cylinder
Shim
WasherSnap Ring
IntermediateUpright
MA0980.eps
Figure 2-3. Shimming ML cylinders.
Section 2
2.3-2
2.3-3
2.3-4
Page 8
P3.1 Periodic Maintenance
For proper operation and an extended service lift, theMast should be inspected and serviced regularly as part ofyour normal lift truck maintenance schedule according tothe following outlines and ANSI B56.1 procedures.
The recommended intervals are for Masts operating undernormal conditions. If operation is in severe conditions orcorrosive atmospheres, inspect the Mast more frequently,
WARNING: Never work on a raised mast witha load without supports, or while anyone is nearthe lift truck control handles per ANSI B56.1.
3.1-1 Daily InspectionPerform the following at the beginning of each work shift:
3.1-2 100 - Hour InspectionAfter each 100 hours of lift truck operation, and in addition tothe Daily inspection:
1. Inspect and lubricate the full length of the chains with SAE 40 wt. oil or Bowman Heavy Load Red Grease.
CAUTION: The chains must be coated with a film oflubricant at all times.
Pry from topof Mast - Here
Check ClearanceHere
Roller
MA0981.eps
Figure 3-1. Measuring Load Roller andThrust Plug Clearances.
1. Check cylinder rods and retainer for obvious damage ,nicks, marring,scratches that might damage the cylinder packings. Check the conditionof hydraulic plumbing and connections. Tighten connections if loose.
2. Check lift chains for damage.3. Check the chain anchor pins. Be sure the cotter pins (6) are in place
and not damaged.4. Examine the hydraulic plumbing and connections. Tighten loose
connections.5. Check harness hold-down clamps, brackets, and connectors for security
of mounting and damage.
3.1-3 200 - Hour Inspection1. Clean and lubricate pantograph assembly.
2. Inspect and lubricate the full length of the chains with SAE 40 wt. oil or Bowman Heavy Load Red Grease.
CAUTION: The chains must be coated with a film oflubricant at all times.
3. Lubricate the full length of each mast upright rail.
eriodic Maintenance Section 3
Page 9
500 - Hour InspectionP eriodic Maintenance
3.1-4
After each 500 hours of lift truck operation, and in addition to the Daily and 100 - Hour Inspections:
1. Measure load roller clearances in the carriage/pantograph and Mast uprights. Pry between the upright and load roller so that the opposite load roller is tight against the upright (see Figure 9 ). Total side-to-side clearance should be 0.020 in. (.5 mm) max. across the tightest point throughout the travel of the upright. If shimming is required.
2. Check chains for wear and stretch.
3. Check the backrest capscrews for tightness. Tighten capscrews to 145 ft.-lbs. ( 195 Nm ).
Section 3
Page 10
T
PROBLEM PROBABLE CAUSE SOLUTION
Empty a) Plugged inlet hose a) Unplug hose or replace.b) Insufficient oil. b) Check the truck hydraulic system for
correct oil level in tank, defective pump or pump drive, leaks in the lines or disconnect control valve linkage. Repair or replace as necessary.
c) Bent or jammed plunger. c) Repair or replace as necessary.
Loaded a) Plugged piston check valve. a) Unplug check valve or replace.b) Truck relief valve setting low. b) Raise truck relief setting to specified levelc) Over capacity. c) Reduce load to specified capacity.d) Mechanical bind due to bent plunger d) Remove mechanical bind by or bad rollers. replacing/freeing plunger and rollers.
Cylinders drift- a) External leak in pressure line. a) Tighten or replace as necessary.b) Truck valve defective-cycle to full b) Repair or replace truck valve. lift height to verify.c) External leaks at retainer. c) Replace all cylinder seals.d) Piston check valve leaking. d) Replace check valve.
Spongy or jerky action- a) Sticky or defective truck relief valve. a) remove and check the truck relief valve. If contaminated oil caused the malfunction, drain and flush the system, change the filter and refill with fresh oil.
b) Bent or damaged cylinder plunger. b) 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 charge. e) Charge battery.f) Low pump volume. f) Install accumulator.g) Low oil level. g) Fill oil reservoir.h) Insufficient hydraulic tank capacity h) Install larger tank baffles or baffles.Other. Contact Lift Technologies
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position.
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position.
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position.
Cylinders don’t lift load or won't move
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position.
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position.
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position.
The Following Table lists problems that may be encountered on your Mast, the probable causes, and the recommendedcorrective action that should be taken to restore the Mast to normal operating condition.
Troubleshooting Chart
rouble Shooting Section 4
4.0
Page 11
OuterUprightRollers
IntermediateUprightRollers
InnerUprightRollers Intermediate
UprightRollers
PantographRollers
PantographRollers
MA2191.eps
Upright Description
Outer Upright AssemblyThe outer upright assembly is mounted to the truck. A pairof shim adjustable load rollers are attached to stub shaftslocated near the top of the upright. A pair of adjustablehoist chain anchors are located in the top crossmember. Thesecondary cylinders rest on an integral lower crossmember.
Intermediate Upright AssemblyThe intermediate upright assembly telescopes within theouter upright assembly. A pair of shim adjustable loadrollers are attached to stub shafts located at the top andbottom of the upright. A pair of chain sheaves are locatednear the top of the upright to provide a rolling surface forthe main lift chains.
Inner Upright AssemblyThe inner upright assembly telescopes within the intermedi-ate upright assembly. A pair of shim adjustable load rollersare attached to stub shafts located at the bottom of theupright. The free lift chain anchors are attached to thecenter crossmember. The free lift cylinder rests on a cradlewhich is integral with the lower crossmember.
5.1
M ast Uprights Section 5
Mast Uprights
Figure 5-1
5.0
Page 12
UUpright Removal
NOTE: It is recommended that thepantograph carriage assembly beremoved before attempting to removethe upright.
Preparation1. Turn key switch off.
*Remove key from switch.
2. Disconnect truck battery at the battery disconnect.
3. Remove battery from truck.
NOTEThe pantograph must be removedbefore attempting to remove theupright.
DisconnectBattery
MA1035.eps
4. Remove any overhead guards and/or screen guards.
5. Elevate and support each side of truck with suitable 3”hardwood (Oak) blocking. See figure 6-2.
6. Disconnect all hydraulic supply lines to the upright.Cap all open lines and fittings.
7. Disconnect all electrical connections to the mast andtie wires out of the way.
MA1036.eps
3" Blocking (Oak) Hardwood Figure 6-2
pright Removal Section 6
6.0
Figure 6-1
6.0-1
Page 13
Upright Removal (Continued)
MA1037.eps
Truck Side
Hardwood (Oak) Blocking
MA1038.eps
Inner Rail Assembly
IntermediateRail Assembly Outer
Rail Assembly
Outrigger(s)
TopBottom
8. Place lifting strap beneath the upper tie bars of theouter, intermediate and inner rail assemblies.Connect strap ends to the chain hoist. Be certain thehoist is equipped with safety hooks. See Figure 6-3.
9. Raise lift to remove slack in the strap. Strap should betaut enough to support the upright after it is discon-nected from the truck.
10. Remove all fasteners securing the upright to thetruck.
11. Use hardwood (Oak) blocks to support the bottomend of the upright and to keep it level when laidhorizontally on the floor. Avoid resting the mast onhydraulic fittings.
12. Lower the upright onto the blocks with the truck sidedown. This will allow the rail assemblies to be pulledout of the outer rail assembly to access rail rollersand secondary cylinders. See figure 6-4.
Figure 6-3
Figure 6-4
6.0
WARNING: Do not stand on or near the Mastwhile it is suspended by an overhead hoist.
WARNING: Do not stand the Mast up verticallyunless it is chained to a support.
U pright Removal Section 6
Page 14
Upright Disassembly
1. Pull the inner and intermediate rail assemblies partway out of the outer rail assembly to provide accessfor secondary cylinder removal. The rail cylindersmust be removed to adjust or replace the lower railrollers. Refer to figure 6-6.
2. Loosen and remove the hydraulic fittings at the baseof the left and right secondary cylinders. Discard oldO-Rings. Install new O-Ring(s) at time of installation.See figure 6-5.
3. Remove the snap ring at the base of each cylinder.
MA1039.eps
Left HandCylinder
Right HandCylinder
Tube
Elbow
FlowRegulator
Fitting
O-Ring
Truck Side
Hardwood (Oak) Blocking
MA1038.eps
Inner Rail Assembly
IntermediateRail Assembly Outer
Rail Assembly
Outrigger(s)
TopBottom
MA1040.epsSnap Ring
CylinderBase
Figure 6-5
Figure 6-6
Rail Cylinders
Rollers and ShimsPulling the rail assemblies part way out of the bottomof the outer rail assembly will allow access to removeand/or replace rollers and shims. The rail cylindersmust be removed to accomplish this.
6.1
U pright Removal Section 6
Page 15
AlignmentPin
AlignmentPin Tab
Cylinder
Shim
WasherSnap Ring
IntermediateUpright
MA0980.eps
NOTERecord the number of shims re-moved for each side. The samenumber of shim should be rein-stalled on each side to prevent“racking” of the upright assem-blies.
4. Remove the external snap ring from the top ofeach cylinder piston rod. See figure 6-7.
5. Remove the washer from each cylinder rod.
6. Support the cylinders, and move the rails outwardfar enough to allow removal of the cylinders.
NOTEEach cylinder is equipped witha weldment near the top end ofeach barrel assembly. Thisweldment fits over an alignmentpin that is part of the chainanchor mount of the outer up-right.
WARNINGRail cylinders are heavy andcare must be taken to avoidpersonal injury.
Upright Disassembly (Continued)
Figure 6-7
6.1
U pright Removal Section 6
Page 16
Cable, Hose and Chain Sheaves (Refer to figure 6-8 6-10, 6-11 and 6-12)
Free Lift Cylinder(Refer to figure 6-8)
* Remove cotter pins (7), jam nuts (11), full nuts (10)and ecentrical washer.
* Remove chain anchors (8) and lift chains (13).
* Remove snap ring (14). Lift cylinder off alignment pin(12) and out of upright.
Installation is reverse of removal.
NOTEThe free lift cylinder may be re-moved with upright attached totruck..
WARNINGThe free lift cylinder is heavyand care must be taken toavoid personal injury.
Free Lift Cylinder
12
3
4
56
15
7
8
9
11
10
12
13
13
14
16
MA1041.eps
Truck Side
Hardwood (Oak) Blocking
MA1038.eps
Inner Rail Assembly
IntermediateRail Assembly Outer
Rail Assembly
Outrigger(s)
TopBottom
Figure 6-8
Figure 6-9
* Remove snap rings (6) and sheaves (5).
* Remove screws (4) securing mounting plates tocrosshead (16) and remove assembly from block.
* Remove pins (15) and crosshead (16) from primarycylinder piston rod.
* Loosen and remove nuts (1), capscrews (3), andspacers (2).
* Disassemble assembly. Replace and worn and/ordamaged components.
Installation is the reverse of removal.
6.2-1
6.2-2
U pright Removal Section 6
Page 17
MA1042.eps
MountingPlate
Capscrew
Allen HeadScrew
Nut
Roller
Block
Roll PinSecures Block to Cylinder Rod
Sheave
Snap Ring
1
2Spacer
11
5
6
10
43
Figure 6-10
U pright Removal Section 6
Page 18
Figure 6-11
Figure 6-12
U pright Removal Section 6
Tri-Line Hose/Cable Routing
MA2583.eps
PantographCable end
MastCable end
PantographTri-Line Hose/Cable
MastTri-Line Hose/Cable
SOCKET (Not Shown)
PIN PLUG
SEAL-INTERMEDIATE
SEAL-PROTECTOR SEAL
CAP
SEAL
SPADE FEMALE
WIRE COLOR:WIRE #1-BLACK W/BROWN STRIPEWIRE #2-GREY W/YELLOW STRIPEWIRE #3-GREY W/GREEN STRIPEWIRE #4-GREYWIRE #5-GREEN
POSITION 1
WIRE #2 (REACH)WIRE #2
WIRE #5
WIRE #1 (POWER)WIRE #1
POSITION 1
WIRE #3WIRE #4
WIRE #5 (TILT IND.)WIRE #4 (TILT)
WIRE #3 (SS)
POSITION 1
(LENGTH TO BE SAME AS WIRE 1-4)
WIRE 4WIRE 5
POSITION 1WIRE 1WIRE 2
WIRE 3
MA2584.eps
Mast to Pantograph Cable Assembly
Mast End Pantograph End
Page 19
Cable and Chain Sheaves (Refer to figure 6-13 and 6-14)
* Loosen and remove retainer bolt from stubshaft.
* Remove washer, sheaves and spacer.
* Replace worn and/or damaged components.
Installation is the reverse of removal.
Removal
Bolt
Washer
Bushing
Sheave
ChainSheave
IntermediateRail Assembly MA1043.eps
Chain SheaveHose Sheave
MA1044.eps
6.2-3
U pright Removal Section 6
Figure 6-13
Figure 6-14
Page 20
Upright Chain Inspection7.0
Each 50-250 hours of operation (more frequently insevere or extreme environments), chains should beinspected and lubricated. Inspection should involvethe following:
ElongationWhen a length of 12.00 inches (305 mm) of a newchain has elongated to a length of 12.360 inches (315mm), it should be discarded and replaced. It isimportant to measure the chain in the section thatmoves over the sheaves because it receives the mostfrequent articulation. Measuring the chain near itsclevis terminals could give an erroneous reading as itwould not have flexed as frequently, if indeed at all,as nearer the middle of the assembly. See figure 7-1.
Chains should be replaced when wear exceeds 3% ofthe pitch or when 12 inches (305 mm) of chain isstretched 3.8 inch (10 mm).
Edge WearCheck the chain for wear on the link plate edgescaused by running back and forth over the sheave.The maximum reduction of the material should notexceed 5%. This can be compared to a normal linkplate height by measuring a portion of chain that doesnot run over the sheave. Distorted or battered plateson the leaf chain can cause tight joints and preventflexing. See figure 7-1.
Worn contours and worn surfaces on the outside linksor pin heads should not exceed 5% of new height.
Turning or Protruding PinsHighly loaded chain operated with inadequatelubrication can generate abnormal friction forcesbetween pin and link plates. In extreme instances, thetorque could surpass the press fit force between thepins and the outside plates, resulting in pin rotation.When chain is allowed to operate in this condition, apin, or series of pins, can begin to twist out of thechain resulting in failure. The pin head rivets shouldbe examined to determine if the “VEE” flats are still incorrect alignment. Chains with rotated/displacedheads or abnormal protrusion should be replacedimmediately. Do not attempt to repair the chain bywelding or driving the pin(s) back into the chain. Oncethe press fit integrity between outside plates and pinshas been altered, it cannot be restored. Any wearpattern on the pin heads or the sides of the link platesindicates misalignment in the system. This conditiondamages the chain and increases frictional loading,and should be corrected. See Figure 7-1.
Figure 7-1
U pright Chain Inspection Section 7
Page 21
Upright Chain Inspection (Continued)
U
Cracked PlatesThe chains should be periodically inspected verycarefully, front and back as well as side to side,for any evidence of cracked plates. If any onecrack is discovered, the chain(s) should bereplaced. It is important, however, to determinethe causes of the crack before installing newchain so the condition does not repeat itself.
Fatigue Cracking - Fatigue cracks are aresult of repeated cyclic loading beyond thechains endurance limit. The magnitude of theload and frequency of its occurrence arefactors which determine when fatigue failurewill occur. The loading can be continuous orintermittent (impulse load).
Fatigue cracks almost always startat the link plate pin hole (point of higheststress) and are perpendicular to the chainpitch line. They are often microscopic in theirearly stage. Unlike a pure tensile failure,there is no noticeable yielding (stretch ) of thematerial.
Stress-Corrosion Cracking - The outsidelink plates which are heavily press fitted tothe pins, are particularly susceptible to stresscorrosion cracking. Like cracks, these initiateat the point of highest stress (pin hole) buttend to extend in an arch-like pattern be-tween the holes on the plate.
More than on e crack can oftenappear on a link plate. In addition to rusting,this condition can be caused by exposure toan acidic or caustic medium or atmosphere.
Stress corrosion is an environmen-tally assisted failure. Two conditions must bepresent: a corrosive agent and static stress.In the chain, static stress is present at the pinhole due to the press fit pin. No cycle motionis required, and the plates can crack duringidle periods. The reaction of many chemicalagents (such as battery acid fumes) withhardened steel can liberate hydrogen whichattacks and weakens the steel grain struc-ture.
For this same reason, never attemptto electroplate a leaf chain or its components.The plating process liberates hydrogen andhydrogen embrittlement cracks will appear.These are similar in appearance to stresscorrosion cracks.
If a plated chain is required, consultLift-Tek. Plated chains are assembled frommodified, individually plated componentswhich may reduce the chain rating.
7.0
MA1002.eps
Figure 7-2. Arc-Like Cracks in plate are asign of stress corrosion.
Corrosion Fatigue - Corrosion fatigue cracks arevery similar (in many cases identical) to normalfatigue cracks in appearance. They generally begin atthe pin hole and move perpendicular (900) to thechain pitch line.Corrosion fatigue is not the same as stress corrosion.Corrosion fatigue is the combined action of anaggressive environment and a cyclic stress (not astatic stress alone, as in stress corrosion).
Ultimate Strength FailureThis type of failure is caused by overloads far inexcess of the design load. See Figure 7-3.
Tight JointsAll joints in leaf chain should flex freely. Tight jointsresist flexure and increase internal friction, thusincreasing chain tension required to fit a given load.Increased tension accelerated wear and fatigueproblems.
MA1003.eps
Figure 7-3
pright Chain Inspection Section 7
Page 22
An upright or carriage can moveunexpectedly:
Do not walk or stand under raised forks.
Keep clear of load and carriagewhen making any check or adjustment.
Keep your arms and fingers away frommoving parts of the upright.
Block the carriage or upright when workingwith the components in a raised position.
Do not reach through open areas of theupright.
Never attempt to move or align the rails byhand. Use a prybar.
Failure to follow these warning canresult in serious injury.
WARNING:
*
*****
Chain Length Adjustment
Threaded chain anchors must be left freeto pivot in mounting hole.
Anchor pis heads must be to the inside ofthe upright.
Torque jam nuts to adjustment nuts to 100- 200 Nm (74 - 148 Ft-Lbs).
Make sure chain anchors are secured sothat no twist is evident in the chains.
IMPORTANT
IMPORTANTThe carriage stop must not be al-lowed to contact the upright stopunder any circumstances during
normal operations.
****
7.1
U pright Chain Inspection Section 7
Page 23
Triple-Stage Upright (TSU) Chain Length AdjustmentsTriple-Stage uprights use two chain set; one set forcarriage lift and one set for rail lift. Adjustmentanchors for the lift cylinder stage are located at theback of the outer rail. Adjustment anchors for theprimary lift stage are behind the primary cylinder.Carriage chain anchors are not intended for adjust-ment.For TSU inner rail lift chains, chain length must beadjusted if the difference between the bottom of theinner rail and the outer rail is greater 10 mm (0.40 in.)
For the TSU primary cylinder lift chain, the chainlength must be adjusted if:
With standard fork setting, the fork clearanceshould be adjusted to provide from 1 3/4” to 2”clearance when the upright is vertical.
With the optional forks to floor setting, the fork tofloor clearance should be adjusted to providefrom 1/4” to 1/2” clearance when the upright isvertical.
The center of the bottom carriage roller comeswithin 20 mm (0.80 in.) of the bottom edge of theinner rail.
The carriage safety stop hit the inner rail stop atfull extension height.
To adjust the secondary cylinder lift chains on a TSUuse the following illustration and procedures:
1. Set the upright in the vertical position.
2. Break the jam nuts loose on the chain anchors.
3. Adjust the chain anchor adjustment nuts until thebottom of the inner rail is within 2.5 mm (0.10 in.)of the bottom of the outer rail.
To adjust the primary cylinder lift chains on a TSU usethe following illustration and procedures:
1. Fork-to-ground clearance:
a. Set the upright to vertical position.
b. Break the jam nuts loose on the chain
anchors.
c. Turn the chain adjustment nuts until clearancebetween forks and ground is 10-20 mm (0.40-0.80 in.).
(Continued on next page)
*
*
*
To Carriage
Adjust Chain Length Here
Adjust chain length here
To inner rail
MA1004.eps
Threaded chain anchors must be left freeto pivot in mounting hole.
Anchor pis heads must be to the inside ofthe upright.
Torque jam nuts to adjustment nuts to 100- 200 Nm (74 - 148 Ft-Lbs).
Make sure chain anchors are secured sothat no twist is evident in the chains.
IMPORTANT****
Figure 7-4
Figure 7-5
7.1-1
U pright Chain Inspection Section 7
*
Page 24
Triple-Stage Upright (TSU) Chain Length Adjustments(Continued)
IMPORTANTThe carriage stop must not be al-lowed to contact the upright stopunder any circumstances during
normal operations.
2. Carriage roller position:
a. Raise carriage about 1M (3.2 ft.) and smear abead of grease on the bottom 75 mm (3 in.) ofthe inner rail in the area of the roller pattern.
b. Tilt upright fully back and completely lower.
c. Measure the distance from where the center ofthe bottom carriage roller stopped to the bottomedge of the inner rail. Distance should not beless than 20 mm (0.80 in.) or chain lengthadjustment is required.
3. Carriage Stop-to-Upright:
a. Lift upright to its full height and check forclearance on the carriage safety stop.
b. If carriage stop hits the upright stop, adjust thechain anchor adjustment nuts out until there is atleast 3 mm (0.12 in.) clearance between thestops.
If all three chain length requirements listed previously cannotbe met, the tire diameter may be out of the design range allow-ance. Also, excessive tire wear will decrease carriage stopclearance.
7.1-1
U pright Chain Inspection Section 7
Page 25
Like all bearing surfaces, the precision manufactured,harden-steel, joint-wearing surfaces of a leaf chainrequire a film of oil between all mating parts toprevent accelerated wear.
Maintaining a lubrication film on all chains surfaceswill:
* Minimize joint wear.* Improve corrosion resistance.* Reduce the possibility of pin turning.* Minimize tight joints.* Lower chain tension by reducing internal friction in the chain system.
Laboratory wear test indicate that #40 oil has theability to prevent wear better than #10 oil. Generally,the heaviest (highest viscosity) oil that will penetratethe joint is best.
Whatever method is used, the oil must penetrate thechain joint to prevent wear. Applying oil to externalsurfaces will prevent rust, but oil must flow into thelive bearing surfaces for maximum wear life.
To prepare the chain for oil. The leaf chain platesshould be brushed with a stiff brush or wire brush toclear the space between the plates so that oil maypenetrate the live bearing areas.
Oil may be applied with a narrow paint brush ordirectly poured on. Chain should be well flooded to besure the oil penetrates the joint.
In locations difficult to reach, it may be necessary touse a good quality oil under pressure such as anaerosol can or pump pressure spray.
General Guidelines
*
*
**
*
*
Chain Movement - Make sure that the chain operat-ingpath is clear and that the chain articulates freelythrough its full range of operation.
Lubrication - Assure that the chain is well lubricatedwith the heaviest oil that will penetrate the voidbetween the link plate apertures and the pins.
Paint - Make sure the chain does not get paintedover at any time.
Protection - Where necessary, as a protection fromatmosphere or sliding wear, the chain may becovered with a layer of grease. It should be noted,however, that the grease will have to be removed at alater date for chain inspection and relubrication.
Chain Mountings - Double check to be sure all chainfastening devises are secures and all adjustmentshave been made to assure uniform loading of multiplechain applications. Check chain anchors and pins forwear, breakage and misalignment. Damaged anchorsand pins should be replaced.
Sheaves - Sheaves with badly worn flanges andoutside diameter should be replaced. This wear maybe due to chain misalignment or frozen bearings.
Chain Lubrication7.2
U pright Chain Inspection Section 7
Page 26
To remove and replace the lift cylinder and/orcarriage chain set on standard and triple-stageuprights (TSU):
1. Attach a hoist strap on the carriage of thestandard upright or inner of the TSU.
2. Lift the carriage or inner rail slightly to createslack in the chains. Block the carriage or innerrail up for safety.
3. Remove the chain anchor pins on the outer railand pull the chains off of the sheaves on theinner or intermediate rails.
4. Remove the chain anchor pins from the carriageon the standard upright or the inner rail on theTSU. On the TSU, the inner rails must belowered to the floor to access the chain anchorpins.
Lift Chains (Standard & TSU)
5. Use the steps in reverse order to replace the liftchain set.
NOTEIf a hose adapter is used, the chainsheaves must be loosened and re-moved to prevent the hoses fromstretching when the inner rails of theTSU are lowered to access the chainanchor pins.
Primary Cylinder/CarriageChains (TSUs)
1. Tilt the upright forward, lower it and completelycollapse the primary cylinder to create slack inthe chains. The carriage may also be lifted andblocked in position and the primary cylindercompletely collapsed to create slack in thechains.
2. Remove the chain anchor pins from the back ofthe primary cylinder. Pull the chains through thechain sheave and lay them over the carriageload backrest.
3. Remove the chain anchor pins from the back ofthe carriage.
4. Use these steps in reverse order to replace theprimary cylinder/carriage chain.
Perform the chain length adjustment and chaintension check before returning the truck to service.
Other Chain Service Notes* Use lengths of factory assembled chain. Do not
build lengths from individual components.
* Do not attempt to rework damaged chains byreplacing only the components obviously faulty.The entire chain may be compromised andshould be discarded.
* Never electroplate assembled leaf chain of itscomponents. Plating will result in failure fromhydrogen embrittlement. Plated chains areassembled from modified, individually platedcomponents.
* Welding should not be performed on any chainor components. Welding splatter should never beallowed to come in contact with chain or compo-nents.
* Leaf chains are manufactured exclusively fromheat treated steels and therefore must beannealed. If heating a chain with a cutting torchis absolutely necessary for remove, the chainshould not be used.
* Always replace chains in sets,Failure to do so may damage newchain.
WARNING:
Chain Removal and Re-placement
The procedures for removing and replacing chain setinvolve hoisting and blocking components.
* Do not walk or stand under raised forks.* Keep your arms and fingers away from moving parts of
the upright.* Do not reach through open areas of the upright.
Failure to follow these warnings can result in serious injury.
7.3 7.3-2
U pright Chain Inspection Section 7
7.3-1
Page 27
UCylindersMain Lift Cylinder Description
Figure 8-1. Main Lift Cylinders.
The main lift cylinders (see Figure8-1) are single stage displacementtype cylinders consisting of a shelland a telescoping plunger/pistonassembly. During extensionhydraulic pressure is actingagainst the plunger outer diameterdue to the internal porting throughthe piston. The piston seals do notaffect cylinder extension. Thetruck hoist control valve holds thecylinders in place once extensionhas stopped.
The shell is internally threaded atthe top end to hold the retainer.The retainer seals provide a high-pressure hydraulic seal againstthe plunger. The retainer alsolimits the upward stroke of theplunger.
A piston is attached to the bottomend of the plunger. The pistonseal provides a high-pressurehydraulic seal against the shellthat engages the cushion valvewhen the cylinder is fully lowered.
A hydraulic fuse/cushion valve islocated in the left hand cylinder’s inletport. In case of a hose failurebetween the lowering control valveand the cylinders, the fuse limitsthe lowering speed of thecylinder. The valve also cushionsthe piston when the cylinder nearsthe fully lowered position.
MA2974.eps
Spacer
Retainer
RetainerSeals
O-Ring
Back-Up
Shell
Rod
Retainer
Wear Ring
Piston Seal
pright Cylinders Section 8
8.0
8.1
Page 28
Free Lift Cylinder Description
The free lift cylinder (see Figure 8-2) is a single stage pistontype cylinder consisting of a shell and plunger/pistonassembly. During extension hydraulic pressure is actingagainst the fill piston area. The truck hoist control valveholds the cylinder in place once extension has stopped.
The shell is internally threaded at the top end to hold theretainer. The retainer seals provide a high-pressurehydraulic seal against the plunger. The retainer also limitsthe upward stroke of the plunger.
A piston is attached to the bottom end of the plunger. Thepiston seal provides a high-pressure seal againstthe shell. A check valve located in the bottom of the pistonallows residual oil between the shell and plunger to escapewhen the cylinder is extending.
A hydraulic fuse/cushion valve is located in the cylinderinlet port. In case of hose failure between the loweringcontrol valve and the cylinder, the fuse limits the loweringspeed of the cylinder.
MA2975.eps
Retainer
Set Screw
Retainer Seals
Back-Up
O-Ring
Rod
Shell
Back-Up
Piston
Piston SealW/O-Ring
Wear Ring
Retainer
Plug
Figure 8-2. Free Lift Cylinder.
8.2
U pright Cylinders Section 8
Page 29
Shell
Inlet Port
To Truck Valve
Free Lift Cylinder
Plunger
Check Valve
Piston
Hydraulic Fuse/Cushion Valve
LoweringControl Valve
Triple Mast (MT) Hydraulic Schematic
R.H. Main Lift Cylinder L.H. Main Lift Cylinder
Plunger
CkeckValve
Piston
Shell
Cylinder Operation
1. Actuating the truck hoist control valve to raise causes hydraulic fluid to enter the lowering control valve through the inlet port where it flows unrestricted through the lowering control cartridge.
2. Hydraulic fluid flows to the cylinder inlet ports. Due to the larger bore diameter of the free lift cylinder compared to both main lift cylinders, the free lift cylinders raise first.
3. Hydraulic fluid flows through the free lift cylinder hydraulic fuse/cushion valve to the bottom of the piston. Lifting force is created against the bottom of the piston causing the plunger to raise. Hydraulic fluid in the areas between the plunger and the shell is allowed to escape through the Check valve in the piston as the plunger raises to the end of its stroke.
4. Hydraulic fluid flows through the hydraulic fuse/ cushion valve to the bottom of the pistons 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 plunger and the shell is allowed to escape through the check valve in the piston as the plunger raises.
5. When hydraulic fluid flow from the truck hoist control valve is discontinued, the cylinders are held in position by the closed center spool of the truck valve.
Cylinder Raising Cylinder Lowering1. Actuating the truck hoist control valve to lower the mast causes the main lift cylinder plungers then free lift cylinder plunger to lower, forcing hydraulic fluid out through the hydraulic fuse/cushion valves.
Note: The restriction setting of each hydraulic fuse is lower (allows more flow) than the setting of the lowering control valve. The hydraulic fuses restrict flow only during failure of a lowering control valve or hose.
2. Hydraulic fluid flows to the lowering control valve where it is restricted at a controlled speed determined by the load being handled.
3. As the main lift cylinder pistons lower over the spear in the bottom of the shell, a high pressure area is developed between the piston and the shell which engages the cushion valva to restrict flow. This allows the plunger/piston just prior to bottoming, providing a smooth transition to free lift cylinder lowering.
Figure 8-3. Mast Hydraulic Schematic.
8.3
U pright Cylinders Section 8
Page 30
Cleaning and Inspection
MA2974.eps
Spacer
Retainer
RetainerSeals
O-Ring
Back-Up
Shell
Rod
Retainer
Wear Ring
Piston Seal
1. Discard old seals, O-Rings, back-up rings, wiper and lockwasher.
2. Wash remaining parts in a stoddard type cleaning solventand dry with a clean shop rag.
3. Inspection threaded parts for damage.
4. Examine the piston rod, inner surfaces of the retainer assem-bly and cylinder barrel for scoring, nicks or scratches. Acrocus cloth may be used to clean up light scratches, etc.. Becareful no to remove the chrome plating when polishingsurfaces.
Main Lift Cylinder Disassembly
Main Lift Cylinder Service
Figure 8-4
8.4
1. Wash the exterior surface of the cylinderthoroughly before dissembling.
*A soft fiber brush should be used to remove debris andforeign objects from grooves and threaded areas, etc.
*A Stoddard type cleaning solvent should be used to washthe cylinder.
2. Place retainer end of cylinder in a vise equipped with softjaws. Do not over tighten.
3. Using a spanner wrench or a bronze (brass) drift, remove theretainer assembly from the cylinder barrel.
*Remove back-up ring and O-Ring from cylinder retainer.
*Remove rod wiper and seal from cylinder retainer.
4. Pull piston rod from barrel assembly.
*Remove spacer and split piston from piston rod.
5. Remove snap ring, retaining washer, plunger, ball and springfrom base end of piston rod.
8.4-2
U pright Cylinders Section 8
8.4-1
Page 31
Main Lift Cylinder Reassembly
Piston Rod and Piston1. Lubricate all parts with clean hydraulic fluid.
2. Lubricate and install the spring, plunger, washer,snap ring and ball into base end of the pistonrod.
Refer to Figure 8-4.
3. Lubricate and install spacer onto the piston rod. Refer to Figure 8-4.
4. Now, lubricate and place split piston onto thepiston rod. Start piston rod into cylinder barreland gently push rod inward until it bottoms out.Be careful no to nick or scratch the chromesurfaces.
Retainer / Retainer Assembly
1. Lubricate new seals, wiper ring and retainerassembly with clean hydraulic fluid.
2. Install the inner seal into the retainer groove. Becertain the sealing lip faces inward. Use a sealinstallation tool for best results. Be careful not tonick or scratch the chrome surfaces.
3. Install a new wiper ring into the retainer.
4. Lubricate and install a new O-Ring and back-upring into the outer groove on the retainer. Installlock washer on outside of retainer.
NOTEPlacing a plastic parts bag over theretainer threads when installing theO-Ring and back-up ring will helpprotect parts against damage,cutting, etc.
5. Carefully start the retainer assembly over thepiston rod and screw it into the barrel finger tight.Do not cut or nick sealing lips upon installation.
6. Using a spanner, tighten the retainer against theshell assembly.
8.4-3
U pright Cylinders Section 8
Page 32
Free Lift Cylinder Service
1. Wash the exterior surface of the cylinder thor-oughly before disassembly
*A soft fiber brush should be used to removedebris and foreign objects from grooves andthreaded areas, etc.
*A stoddard type cleaning solvent should beused to wash the cylinder.
2. Place retainer end of cylinder in a vise equippedwith soft jaws. Do not over tighten vise.
3. Using a spanner wrench or a bronze (brass) drift,remove retainer assembly from cylinder barrel.
4. Remove and discard lock washer, back-up ringand O-Ring located inside cylinder retainer.
5. Remove and discard both O-Rings and back-upring located on the outside of the cylinderretainer.
6. Pull piston rod from barrel assembly.
7. Remove wear ring (ring bearing) from piston rod.
Free Lift Cylinder Disassembly
MA2975.eps
Retainer
Set Screw
Retainer Seals
Back-Up
O-Ring
Rod
Shell
Back-Up
Piston
Piston SealW/O-Ring
Wear Ring
Retainer
Plug
1. Discard old seals, O-Rings, back-up rings, wiperand lock washer
2. Wash remaining parts in a Stoddard type clean-ing solvent and dry with a clean shop rag.
3. Inspect threaded parts for damage.
4. Examine the piston rod, inner surfaces of theretainer assembly and cylinder barrel for scoring,nicks or scratches. A crocus cloth may be usedto clean up light scratches, etc.. Be careful thatyou do not remove the chrome plating whenpolishing surfaces.
Cleaning and Inspection
Figure 8-5
8.5
8.5-2
U pright Cylinders Section 8
8.5-1
Page 33
Figure 19
1. Lubricate all parts with clean hydraulic fluid.
2. Lubricate and install wear ring onto the pistonrod. Refer to figure 8-5.
3. Now, start piston rod into cylinder barrel andgently push rod inward until it bottoms out. Becareful that you do not nick or scratch chromesurface.
Reassembly
1. Lubricate new seals, O-rings, back-up rings,wiper ring and retainer assembly with clean hy-draulic fluid.
2. Install back-up ring and the inner seal into theretainer groove. Be certain the sealing lip facesinward. Use a seal installation tool. Be carefulthat you do not cut or nick the sealing lip uponinstallation.
3. Lubricate and install (large) O-Ring into the outergroove nearest to end of retainer.
NOTEPlacing a plastic parts bag over theretainer threads when installing the O-Rings and back-up rings will help pro-tect parts against damage, cutting, etc..
4. Next, lubricate and install a new back-up ring andO-Ring into the outer groove at the base end ofthe retainer.
5. Install a new wiper into the retainer.
6. Now, carefully place the retainer assembly overthe piston rod and after applying lube to threads,screw it into the barrel finger tight. Do not cut ornick sealing lip(s) upon installation.
7. Using a spanner wrench, tighten retainer againstbarrel assembly.
8. Next, using drift as shown in opposite illustration,deform lock washer into groves provided in boththe retainer and barrel to securely lock themtogether.
Retainer Assembly
Piston Rod and Piston
8.5-3
U pright Cylinders Section 8
Page 34
Upright Rail to Roller Clearance
U
The following procedure explains how to:
* 1st - Measure rail-to-roller clearance.
* 2nd - Adjust rail-to-roller clearance.
Point ofroller
Contact
Roller
OuterRail
IntermediateRail
InnerRail
MA1060.eps
IMPORTANTWith age and wear, clearances
between the upright rails and the rollerscan increase and cause excessivelooseness between rails and rollers.Upright rollers become worn, rail sur-faces wear, and stress relieving due tohandling heavy loads over a period oftime may cause slight dimensionalchanges between upright rails. Theillustration shows clearance betweenrails and rollers.
A roller clearance inspection shouldbe performed if, during normal opera-tional checks of the upright, noticeablelooseness or binding between rails sets,or if scoring is evident on the rails.
Proper roller clearance should bemaintained because the mast is de-signed to nest the rails snugly whileproviding smooth operation.
Figure 9-1
9.0
pright Shimming Section 9
Page 35
MA1062.eps
Check Clearance Here
Check Clearance Here
Pry Here
Pry Here
FeelerGauge(0.020)
InnerRail
IntermediateRail
OuterRail
Point ofroller
Contact
Roller
OuterRail
IntermediateRail
InnerRail
MA1060.eps
CheckClearance
Here
Use "C" clampto force rollers
to one side.Torque on "C"
clamp should notexceed 20 ft.lbs.
Figure 9-2
U pright Shimming Section 9
Page 36
CAUTIONWatch for overhead clearancewhen extending upright.
WARNINGUse extreme care when work-ing on the upright to avoid plac-ing hands or fingers into poten-tial pinch points. Unexpectedmovement of the upright cancause serious injury.
Evaluation of shim requirements generallydictates the a specific roller is acceptable until 0.040”clearance is exceeded, meaning adjustment requiresone standard 1/32” shims to reduce rail-to-rollerclearance to proper tolerances.
ROLLERS SHOULD BE INSTALLED“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Refer to adjustment reference chart when using feelergauges.
Roller Clearance Inspection
Before checking the roller clearances, place theintermediate rail approximately 6 inches out of theouter rail and the inner approximately 6 inches out ofthe intermediate rail as illustrated on the previouspage. If the upright is mounted and the rails are beingelevated hydraulically, the inner rail will automaticallyassume it’s correct position. Note the procedure forchecking the clearance is basically the same whetherthe upright is mounted or has been removed from thetruck.
There ate two methods presented, one using apry bar to position the rails and rollers and the otherusing a “C” clamp.
If the upright is mounted to the truck,, the use ofan approved safety platform or step ladder is recom-mended when making inspections and checkingclearances at the upper levels.
If the upright has been removed and placed onthe flat floor, proper blocking of hardwood (Oak) orsteel supports must be used to keep the uprighthorizontal with the floor. This is especially importantwhen fully extending the intermediate and inner rails.
Step Feeler Gauge will Shimmed ShimGauge Pass / Not Pass Correctly QTY0.020" PASS Check with a 0.050" NOT PASS YES0.050" PASS Check with a 0.080" NOT PASS No, ADD0.080" PASS Check with a 0.120" NOT PASS No, ADD3 2
1 0
2 1
Checking Lower RollerClearance with upright 6”from fully retracted posi-tion
9.1
U pright Shimming Section 9
Page 37
When using a pry bar: “C” Clamp Method:*Insert the pry bar between the outer and intermediate
upright rail on the right side ( as shown on page 37 ).Pry with moderate pressure moving the intermediateand inner rails to the left top end of the upright.
*Using a 0/020” feeler gauge, see if you can insert ashim between the roller and rail. There needs to besome clearance but it is not to exceeds 0.040”. If theclearance between the roller and the rail is two ormore shims, record the number of shims that will fit inthe space between the roller and rail. Refer to thechart on page 35.
*Pry the intermediate rail away from the inner rail.Check the clearance between the intermediate railroller and the inner rail.
*Record the number of shims needed to fit in the spacebetween the roller and the rail for the outer andintermediate rail.
*Install “C” clamp at the location shown on page 37. Itmay be necessary to use a block on the inside of thechannel as shown.
*Tighten the “C” clamp to displace the roller clearanceon that side of the upright. Now, check roller clear-ance on the opposite side of the upright.
*Using a 0.020” feeler gauge, try to insert it betweenthe roller and the rail at the point of contact as shownon page 37.
*If a 0.020” will pass between the roller and the rail,and 0.040” will not fit between the rail and roller, itdoes not require adjustment. If clearance exceeds0.040”, refer to the chart on page 38.
*Record the number of shims needed to fill the spacebetween the roller and the rail.
IMPORTANTThere needs to be at least 0.020” ofclearance but no more than 0.050”.
9.2 9.3
U pright Shimming Section 9
Page 38
MA1061.eps
Point ofroller
Contact
Roller
OuterRail
IntermediateRail
InnerRail
MA1060.eps
CheckClearance
Here
Check Clearance Here
FeelerGauge(0.020)
InnerRail
IntermediateRail
OuterRail
Use "C" clampto force rollers
to one side.Torque on "C"
clamp should notexceed 20 ft.lbs.
Check Clearance Here
Pry Here
Pry Here
PryHere
Checking Lower Roller Clearancewith upright 6” from fully retrac-ted position
Now check the lower rollers in the same manner asfor the upper rollers.
Record the number of shim needed for the outerand inner rails opposite the rollers checked.
Figure 9-3
U pright Shimming Section 9
Page 39
Point ofroller
Contact
Roller
OuterRail
IntermediateRail
InnerRail
MA1060.eps
CheckClearance
Here
PryHere
FeelerGauge(0.020)
InnerRail
IntermediateRail
OuterRail
Use "C" clampto force rollers
to one side.Torque on "C"
clamp should notexceed 20 ft.lbs.
Pry Here
Check Clearance Here
Check Clearance Here
Pry Here
MA1063.eps
Checking Upper Roller ClearanceWith upright extended Approx-imately 1/2 of full extension
Now check the roller clearance in the same manneras before.
Record the number of shim needed for the outerand inner rails opposite the rollers checked.
Step Feeler Gauge will Shimmed ShimGauge Pass / Not Pass Correctly QTY0.020" PASS Check with a 0.050" NOT PASS YES0.050" PASS Check with a 0.080" NOT PASS No, ADD0.080" PASS Check with a 0.120" NOT PASS No, ADD3 2
1 0
2 1
ROLLERS SHOULD BE INSTALLED“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Refer to adjustment reference chart when using feelergauges.
Figure 9-4
U pright Shimming Section 9
Page 40
Checking Lower Roller ClearanceWith upright extended Approx-imately 1/2 of full extension
Now check the roller clearance in the same manneras before.
Record the number of shim needed for the outerand inner rails opposite the rollers checked.
Step Feeler Gauge will Shimmed ShimGauge Pass / Not Pass Correctly QTY0.020" PASS Check with a 0.050" NOT PASS YES0.050" PASS Check with a 0.080" NOT PASS No, ADD0.080" PASS Check with a 0.120" NOT PASS No, ADD3 2
1 0
2 1
ROLLERS SHOULD BE INSTALLED“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Refer to adjustment reference chart when using feelergauges.
Point ofroller
Contact
Roller
OuterRail
IntermediateRail
InnerRail
MA1060.eps
CheckClearance
Here
PryHere
FeelerGauge(0.020)
InnerRail
IntermediateRail
OuterRail
Use "C" clampto force rollers
to one side.Torque on "C"
clamp should notexceed 20 ft.lbs.Pry Here
Pry Here
Check Clearance Here
Check Clearance Here
MA1064.eps
Figure 9-5
U pright Shimming Section 9
Page 41
Checking Upper Roller ClearanceWith upright extended Approx-imately to full extension
Now check the roller clearance in the same manneras before.
Record the number of shim needed for the outerand inner rails opposite the rollers checked.
Step Feeler Gauge will Shimmed ShimGauge Pass / Not Pass Correctly QTY0.020" PASS Check with a 0.050" NOT PASS YES0.050" PASS Check with a 0.080" NOT PASS No, ADD0.080" PASS Check with a 0.120" NOT PASS No, ADD3 2
1 0
2 1
ROLLERS SHOULD BE INSTALLED“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Refer to adjustment reference chart when using feelergauges.
Point ofroller
Contact
Roller
OuterRail
IntermediateRail
InnerRail
MA1060.eps
CheckClearance
Here
PryHere
FeelerGauge(0.020)
Check Clearance Here
Pry Here
InnerRail
IntermediateRail
OuterRail
Use "C" clampto force rollers
to one side.Torque on "C"
clamp should notexceed 20 ft.lbs.
MA1065.eps
Check Clearance Here
Pry Here
Figure 9-6
U pright Shimming Section 9
Page 42
Checking Lower Roller ClearanceWith upright extended Approx-imately within 6” of full extension
Step Feeler Gauge will Shimmed ShimGauge Pass / Not Pass Correctly QTY0.020" PASS Check with a 0.050" NOT PASS YES0.050" PASS Check with a 0.080" NOT PASS No, ADD0.080" PASS Check with a 0.120" NOT PASS No, ADD3 2
1 0
2 1
ROLLERS SHOULD BE INSTALLED“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Refer to adjustment reference chart when using feelergauges.
Point ofroller
Contact
Roller
OuterRail
IntermediateRail
InnerRail
MA1060.eps
CheckClearance
Here
PryHere
FeelerGauge(0.020)
Check Clearance Here
Pry Here
InnerRail
IntermediateRail
OuterRail
Use "C" clampto force rollers
to one side.Torque on "C"
clamp should notexceed 20 ft.lbs.
MA1066.eps
Pry Here
Check Clearance Here
Now check the roller clearance in the same manneras before.
Record the number of shim needed for the outerand inner rails opposite the rollers checked.
Figure 9-7
U pright Shimming Section 9
Page 43
Determining the Number of Shims neededto make roller adjustments
InnerRail
IntermediateRail
OuterRail
MA1067.eps
022
023
023
022
Step 3
0.020 - 0.040"
0.040 - 0.060"
0.080 - 0.100"
Rail extended towithin 6 - 10" offull extension.
InnerRail
IntermediateRail
OuterRail
Step 2
Rail extended towithin one half of
full extension.
13
11
23
11
Step 1
InnerRail
IntermediateRail
OuterRail
Rail extended towithin 6 - 10" offully retracted.
1
3
1
3
Exampleof GaugeReadings
# of Shims Dimension Dimensionper Shim (in) (decimal - in)
one 0.031two 0.062
three 0.093
1/32"
Figure 9-8
*Refer to step 3. Look at the three numbers thatwere recorded at each roller on the rails. Thesmallest of these is the total number of shimsthat need to be added. “0” means DO NOTadd shims.
*If any of the rollers require adjustment, referto adjustment procedures on next page.
*If the upright roller clearance was checkedwith the upright mounted to the truck, androller adjustment is required, remove theupright from the truck as described at thebeginning of this section.
*Do not attempt to adjust roller with the uprightmounted to the truck.
9.4
U pright Shimming Section 9
Page 44
Shim AdjustmentWith the upright laying horizontal on blocking.
*Expose the rollers by pulling the rails part wayout of the bottom as shown.
*Pull rollers (one set at a time) from theirstubshaft. Count the number of shim(s)currently used on each shaft. Add shims asindicated in the roller clearance check.
*If the check indicates that an even number ofshims are needed (2 etc..), split the numberbetween the right and left sides. If the checkindicates an odd number of shims (3, etc..),place the odd shim on the right hand sideshaft. Always keep the odd number of shimson to one side.
*The target for adjustment is to have the samenumber of shims on each roller set (right andleft per rail assembly). An odd or extra shimmust be placed on the same side as the onebefore.
*Reposition each roller on it’s shaft using arubber or plastic mallet. Gently tap the rollerto seat it evenly and snugly on the shaft.
Left
Right
Right
Left
UpperRollers
LowerRollers
Pull Rails part way out the bottomexposing rollers at both ends.
MA1068.eps
Figure 9-9
9.5
U pright Shimming Section 9
Page 45
PUpright & PantographRemoval & ReplaceRoller Shim Adjustments
It is recommended that the panto-graph carriage assembly be removedbefore attempting to remove theuprights.
Support Block
Hardwood (Oak) BlockingMA1028.eps
Figure 10-2
Pantograph RemovalPreparation
1. Truck should be parked on a level surface.
Extend the pantograph fully.
Lower the pantograph onto hardwood (oak)blocks. Refer to figure 10-2.
2. Place a support (2 X 4 or 4 X 4) between the frontand rear members of the pantograph to preventthe pantograph from retracting once the hydraulicsupply is disconnected. Refer to figure 10-2.
3. Actuate the lowering control long enough for theprimary cylinder to collapse and slacken thechains. Release the control.
4. Turn the key to the “OFF” position and removethe key.
NOTEIf the upright is to be removed, a 5-ton
chain hoist equipped with safety hooks isrequired.
10.0
10.1
Figure 10-1
antograph Removal Section 10
10.1-1
Page 46
5
4
67
3
Lift Chain
Tubing
HydraulicHose
MA1029.eps
Figure 10-3
5. Disconnect electrical plug (3).
6. Remove both harness clamp bolts (4).
7. Disconnect hydraulic hoses from tube connec-tions (5) using two wrenches. One wrench tohold the tube connection(s) while loosening thehose connection(s). There will be some hydraulicfluid leakage upon disconnecting fittings.
8. Remove cotter pins (6).
9. Remove chain anchor pins (7) securing the liftchains to the carriage chain anchors.
NOTELift chains mat be disconnectedat the primary lift cylinder cross-
head (see next page) or fromthe carriage as shown.
Pantograph Removal (continued)(Refer to figure 10-3)
10.1
P antograph Removal Section 10
Page 47
MA1031.eps
Cotter Pin
Chain Anchor
Lift Chain
Primary Cylindercrosshead
NOTECarriage chains may be discon-nected at the primary cylinder.
Remove cotter pins securing lift chains to the chainanchors. Remove lift chains one at a time from thechain anchors.
NOTEOnce a lift chain has been discon-nected, lay it over the pantograph.Then, using wire, tie the chain endto the load backrest. This will keepthe chains out of the way and from
falling to the ground.
*
Pantograph Removal (continued)
Figure 10-4
10.1
P antograph Removal Section 10
Page 48
Support Block
Hardwood (Oak) Blocking
Raise both inner andintermediate rails until theinner rail channels areclear of the carriagerollers.
Safety Hook
Lifting StrapsorChains
5 Ton Chain Hoist
MA2195.eps
Inner Rail
Carriage Roller
MA2183.eps
13. Using a 5-ton chain hoist, attach hoist to the innerand intermediate rail assemblies, See Figure 10-5above. Be sure hoist is equipped with safetyhook(s).
*Remove the secondary cylinder snap rings locatedon the top of each secondary cylinder.
14. Raise both inner and intermediate rails until the innerrails clear the upper carriage rollers.
Step 13.
Step 14.
Figure 10-5
Pantograph Removal (continued)10.1
P antograph Removal Section 10
Page 49
15. Move truck away from pantograph just far enough toallow the intermediate and inner rails to clear thepantograph. See figure 10-6.
16. Completely lower the intermediate and inner railassemblies.
17. Disconnect hoist and move truck away from panto-graph.
NOTEIf the upright rail lift cylinders areto be removed, refer to the fol-lowing pages.
The free lift (center) cylinder maybe removed without removingthe upright.
Truck
Support Block
Hardwood (Oak) Blocking
Support Block
Hardwood (Oak) Blocking
Clearance
Truck
Pantograph
Backup truck just enough to provide clearanceBetween pantograph and upright rails.
Fully lower intermiate and inner rails.
Disconnect hoist safety hook from lifting device.
Move truck away from pantograph.
Safety Hook
Lifting StrapsorChains
MA2196.eps
Pantograph Removal (continued)
Figure 10-6
10.1
P antograph Removal Section 10
Page 50
PThe Pantograph Assembly may be serviced while installed in the upright with two exceptions:
the carriage rollers and the inner and outer arm bushings must be servicedwith the pantograph removed from the upright.
Pantograph & Fork Carriage Assembly Service11.0
*Move truck to service area.
*Park truck on a flat level surface.
*Extend and lower pantograph.
*Turn key switch OFF.
1. Remove Load Back Rest Extension.
Remove bolts from load backrest Extension and liftthe extension free of the fork carriage.
2. Elevate and Block Pantograph.
*Turn key switch ON and elevatepantograph approximately 3 to 4feet.
*Place an oak block (hardwood)between pantograph carriage andground. Lower pantograph untilcarriage rests on 4X4 blocking asshown in figure 11-1.
*Tilt forks forward.
*Turn key OFF and remove key.
*Disconnect truck battery.
Preparation
MA2189.eps
Figure 11-1
DisconnectBattery
MA1035.eps
Figure 11-2
antograph Service Section 11
11.0-1
Page 51
Remove forks.Refer to illustration 11-3.
Remove fork by releasing thelocking pin on the top forkhanger and sliding the fork tothe center of the carriage forkbar. Lift the fork up anddisengage the fork hanger fromthe carriage bar.
Standard ITA Models Only
WARNING:
Forks are heavy. Caremust be taken toavoid personal injury.
*
MA2201.eps
Figure 11-3
P antograph Service Section 11
11.0-2
Page 52
MA2192.eps
Upright
Block
Pantograph
2
MA2207.eps
3
1
Fork Carriage RemovalSide Shift Models Only
1. Remove hose hold down cap.
2. Disconnect electrical plug (1) fromthe main harness connector.
3. Disconnect both hydraulic connec-tions at the connector fitting (2). Capthe open ports and connections.
Figure 11-4
Figure 11-5
11.1P antograph Service Section 11
Page 53
Fork Carriage RemovalModels Equipped with Tilt Only
1. Remove both cable and hose covers (4),See below.
2. Disconnect hydraulic connection (a)from tilt cylinders.
All Models
3. Install lifting straps as shown to chainhoist equipped with safety hook.
4. Remove retainer bolts and pins (C)securing scissor arms to the forkcarriage.
5. Slowly elevate carriage until free ofarms. Continue to elevate until lowerscissor rollers are free to one side.
.MA2193.eps
C
B
4
C
C
Arms
Lift Straps&Safety Hook
A
Figure 11-6
MA2218.eps
5 1
4
2
3
11.2P antograph Service Section 11
Page 54
Allen Screw
Nylon Thrust Pad
Shims
Worn Out3.5 mm
New Pads6.3mm
Scissor Arm Roller "B and C'
When pad is worn near "flush"with carriage roller, new padsshould be installed
MA1017.eps
B
A
C
1. Disconnect reach arm cylin-ders. See figure 11-6. Removeretainer bolts and pins (item“B”) securing reach cylinder topantograph arms.
2. Lift reach arms (A) upwardwhile pivoting arm (B) indirection shown in figure 11-7.This allows access to armroller and thrust pad withoutremoving scissor assemblyfrom carriage.
3. Inspect the thrust pads forfurther service as shown infigure 11-8. Pads that aredamaged or worn to their wearlimit should be removed andnew pads installed.
4. Remove Allen screw and pad.Install new pad. Be certainsame number of shims areinstalled on the shaft if theywere removed.
Servicing Pantograph Arm RollersThrust Pads (Scissor Arm Roller “B” & “C”)
Figure 11-7
Figure 11-8
To Remove Arm Roller “B” (or ”C”):
Slowly move Arm “A” (up as required) whilerotating Arm “B” (as shown) to move arm rollerupward and out of the carriage channel.
Be extremely carefulthat you do not“pinch” your hands orfingers.
11.3P antograph Service Section 11
Page 55
5. Disassemble the outer arm assembly.
6. Replace seals with new ones.
7. Wash bearings (cups and Cones) in aStoddard type solvent. Inspect parts forfurther serviceability. Replace any partthat is nicked or having rough spots inthe cones or cups. Cones and cupsmust be replaced together. Do notinstall a new cone in an old cup.
8. Check grease fitting for damage and tomake certain none are missing.
Figure 11-9
Grease Fitting
Pivot Bearing
Outer Arm
Snap Ring
Cup
Cone
Shield
Cup
Cone
Lock Nut
Nut (*)
O-Ring
HousingSnap Ring
Grease Fitting
CylinderBearing
Allen ScrewWear Pad
Shims
Roller
Grease Fitting
Allen ScrewWear Pad
Shims
Roller
Inner Arm Pivot Bearings
Grease Fitting
MA1019.eps
MA1019.epsNut (*)
Install with chamfer towards nut lock.Torque to: 27 - 41 Nm (20 - 30 ft. lb.)
NOTEIf the Inner Arm Pivot Bearings
need to be replaced, thepantograph carriage must be
removed from the upright.
9. Reassemble to the reverse of disas-sembly.
Lubricate parts with cleanchassis grease prior toassembly.
ImportantPrepack bearing cup and cone assemblies
prior to installation
P antograph Service Section 11
ImportantPrepack bearing cup and cone assemblies
prior to installation
Page 56
Remove forks.Refer to illustration 11-10.
Remove fork by releasing thelocking pin on the top forkhanger and sliding the fork tothe center of the carriage forkbar. Lift the fork up anddisengage the fork hanger fromthe carriage bar.
Tilt Cylinder ServiceCylinder Removal
WARNING:
Forks are heavy. Caremust be taken toavoid personal injury.
Figure 11-10
MA2201.eps
11.4
P antograph Service Section 11
Page 57
Figure 11-11
MA2202.eps
Capscrew
CapscrewHose Clamp
Carrier AssemblyCarriage Pin
Dowel Pin
Shim
Snap RingShim
Upper Wear PadBushing
Tilt Cylinder Carriage Weldment
Fitting
Tilt Pin
Tilt Pin Bushing
Snap Ring
Grease Fitting
LowerWear Pad
CapscrewLockwasher
Guard
Capscrew
Capscrew
Valve Assembly
Coil
FittingCarriage Claw
RetainerSS Rod
WiperSeal
Fitting
Tilt PivotBushing
Carriage BarAssembly
Cap
Seal
Wear Pad Shim
Shim
ITA Pantograph Carriage With Side Shifter
P antograph Service Section 11
Page 58
ITA Pantograph Carriage Without Side Shifter
5
MA2219.eps
Carriage Frame Assembly
Dowel Pin
Shim
ShimSnap Ring
Snap Ring
Shaft
Carrier Assembly
Cap
Bushing
Capscrew
Capscrew
Hose Clamp
Shim
Figure 11-12
P antograph Service Section 11
Page 59
Cylinder removal:Remove the fork carriage by removing the lowerclaws and lifting the carriage bars off the car-riage frame.
Refer to figure 11-11 and 11-12.
1. Extend the tilt cylinder completely.
2. Secure the carriage frame using an overhead hoistand a lifting strap.
3. Remove snap rings from the tilt pin.
4. Using the hoist, take the slack out of the strap.
5. Using a brass drift, drive shaft out.
6. Using the hoist, rotate the carriage section up to gainaccess to the tilt cylinder from below the carriageweldment.
7. Disconnect the hydraulic hoses from the tilt cylinder.
8. Remove the capscrews holding the tilt cylinder pivotcaps in place.
9. Remove the tilt cylinder.
The exterior surface of a cylinder should bethoroughly washed before disassembly.
A soft fiber brush should be used to removedebris and foreign objects from grooves andthreaded areas, etc.
A Stoddard type cleaning solvent should be usedto wash the cylinder.
Any part unfit for further service should bereplaced with new part.
Preparation Cleaning andInspection
11.4-1
P antograph Service Section 11
Page 60
Wash exterior of the tilt cylinder in a Stoddard typecleaning solvent before disassembly. Use a brush toremove grease and grime from the cylinder tube,anchor and rod ends.
1. Place cylinder in a vise equipped with soft jaws.Do not overtighten - distortion of the shell willresult.
2. Push piston rod all the way into cylinder.
3. Using a narrow blade screwdriver, remove thecapscrew securing the pull wire / retaining ring.
4. Remove the pull wire by rotating the uppersection of the shell clockwise while gently pryingthe pull wire out of it’s groove.
5. Remove the upper section of the shell whilepushing the piston rod through the upper shellsection.
6. Remove the piston / rod assembly.
Disassembly(Refer to Illustration Below)
Figure 11-13
1. Remove wiper ring.
2. Remove rod seal from inner groove.Be careful that you do not nick orscratch surface of retainer assembly.
3. Remove outer O-Ring and backupring from the retainer assembly.
4. Discard seals, wiper and backuprings.
1. Separate the inner shell from the rodassembly.
2. Remove the back rings and o-ringsfrom the inner shell and discard.
3. Remove the piston retaining ring.
4. Remove piston seal with O-Ring frompiston and discard.
5. Remove the piston.
6. Discard O-Ring, sealing ring andenergizer. Always install new seals.
Retainer Assembly
Piston Rod and Piston
MA2209.epsPivot Shaft
FittingWiper
RodSeal
Outer Shell
O-ring
RetainingRing
Base
Seal w/O-Ring
Piston
Inner ShellCapscrew
Retaining RingBack-Up
O-Ring
Rod
Piston
11.4-2
P antograph Service Section 11
Page 61
1. Using only new seals and O-Rings, lubricate all partswith clean hydraulic fluid.
2. Lubricate and install the energizer O-ring into thegroove in the piston. Refer to figure 11-13.
3. Lubricate and install the piston seal over the ener-gizer. Be careful not to nick or cut the seals.
4. Install new o-rings and back-up rings onto the innershell.
5. Lubricate the seals of the inner shell and insert theinner shell into the outer shell.
6. Lubricate the piston and piston rod with cleanhydraulic fluid.
10. Start piston into cylinder tube while gently pushingand rotating piston rod. Be careful not to damageseal.
11. Shove the piston rod all the way into the cylindertube until it bottoms.
Cleaning and Inspection Retainer Assembly
Reassembly
1. Discard old seals, wiper and shear ring.
2. Wash all parts in a Stoddard type cleaning solventand dry with a clean lint free shop rag.
3. Inspect cylinder mounting bushings for damage. If thebushings show signs of wear and/or damage, theyshould be replaced with new bushings.
4. Examine cylinder barrel for scoring, nicks orscratches. The cylinder barrel may be sanded withcrocus cloth to remove minor scratches, etc.. Becareful not to remove the chrome plating whenpolishing the surface. Replace all damaged orunserviceable parts.
5. Inspect surfaces of the piston and piston rod to besure they are clean, smooth and free of damage.
1. Lubricate new seals, wiper ring and retainer assemblywith clean hydraulic fluid.
2. Install the inner seal, with the sealing lip facinginward, into the retainer groove. Be careful not to nickthe sealing lip upon installation.
3. Install a new wiper into retainer.
4. Lubricate and install a new backup ring into the outergroove on the retainer.
5. Lubricate and install a new O-Ring in the groove nextto the backup ring. Note the position of the backupand O-Ring per figure 11-13.
6. Push retainer as far as it will go into the housing.
7. Insert the new pull wire in the pull wire pushing on thewire with your fingers. Rotate the top section of theouter shell counter clock wise while pushing the pullwire into the groove.
8. Once the pull wire is installed, insert and tighten thecapscrew to secure the pull wire.
11.4-4
11.4-3
P antograph Service Section 11
Page 62
Reach Cylinder Service
WARNING:
MA2201.eps
Figure 11-14
Support forks asforkbar is removed sothey cannot fall.
11.5
Cylinder Removal
P antograph Service Section 11
Remove forks.Refer to illustration 11-14.
Remove fork by releasing thelocking pin on the top forkhanger and sliding the fork tothe center of the carriage forkbar. Lift the fork up anddisengage the fork hanger fromthe carriage bar.
Page 63
MA1089.eps
A
B
C
C
Arms
ReachCylinder
Lift Straps&Safety Hook
Cylinder removal:Remove the fork carriage as described in section11.1.
Refer to figure 11-15.
1. Extend the reach cylinder completely.
2. Using an overhead crane, secure the scissorarms (C) to keep the scissor arms from fallingonce the reach cylinder has been disconnected.See figure 11-15.
3. Disconnect the hydraulic connectors and plug allopen lines.
4. Remove retainer bolt and pin(B) securing cylinder shaftends in position. See figure 11-15. It may be necessary to usea brass drift to gently tap thepins loose.
5. Remove the reach cylinder andplace on a clean work bench.
Figure 11-15
11.5-1
P antograph Service Section 11
Page 64
Wash exterior of the reach cylinder in a Stoddardtype cleaning solvent before disassembly. Use abrush to remove grease and grime from the cylindertube, anchor and rod ends. Remove rod end and jamnut.
1. Place cylinder in a vise equipped with soft jaws.Do not overtighten - distort shell.
2. Push piston rod all the way into cylinder.
3. Using snap ring pliers, remove the snap ring fromthe cylinder retainer.
4. Remove O-Ring.
5. Using a bronze drift, gently tap retainer assemblyinto cylinder housing clear of the shear ring.
6. Using a screwdriver, carefully lift end of shearring from it’s groove. Be careful not to nick orscratch the piston rod.
7. With a pair of pliers, carefully pull shear ring fromcylinder tube. Again, be careful not to nick orscratch the piston rod.
8. Pull outward on piston rod until rod and retainerare free of cylinder housing. Remove retainer.
1. Remove wiper.
2. Remove seal from inner groove. Be careful thatyou do not nick or scratch surface of retainerassembly.
3. Remove outer O-Ring and backup ring from theretainer assembly.
4. Discard seals, wiper and backup rings.
1. Using a 3/4” wrench, hold the rod using the “flats”provided just below threaded area of piston rod.Now install a 2-2/8 in. socket onto the piston rodnut.
2. Remove nut from piston rod while holding thepiston rod.
3. Pull piston free of piston rod.
4. Remove sealing ring and the energizer from piston.Use care not to nick or scratch piston surfaces.
5. Discard O-Ring, sealing ring and energizer. Alwaysinstall new seals.
Figure 11-16
MA2208.eps
Typical Illustration
Rod EndNut
Wiper
RetainingRing
ShearRing
Rod Seal
O-Ring w/ Back-up
Retainer
ShellRod
Piston
PistonSeal Nut
A
ARight HandReach Cylinder
Left HandReach Cylinder
A
A
Disassembly(Refer to Illustration Above)
Retainer Assembly
Piston Rod and Piston
11.5-2
P antograph Service Section 11
Page 65
MA1027.eps
PORT "B"PORT "A"
Bushing
Grease Fitting
Grease Fitting
Bushing
1. Lubricate all parts with clean hydraulic fluid.
2. Lubricate and install the energizer ring into the groovein the piston. Refer to figure 11-16.
3. Lubricate and install the piston seal over the ener-gizer. Be careful not to nick or cut the seals.
4. Place a plastic parts bag over the threaded area ofthe piston rod (to protect seal). Slide a new O-Ringover the bag and into the groove in the piston rod.
5. Remove bag and install piston onto rod. Carefullyslide the piston over and up against the rod shoulder.
6. Install nut onto piston rod finger tight against thepiston.
7. Install the 3/4” wrench back into the “Flats” provided inthe piston rod.
8. Using a torque wrench and 1-1/8 in. socket, torquenut to 115 - 132 ft. lbs. (156 - 179 Nm).
9. Now, lubricate the piston and piston rod with cleanhydraulic fluid.
10. Start piston into cylinder tube while gently pushingand rotating piston rod until piston and seal havepassed the shear ring groove in the cylinder tube. Becareful not to damage seal.
Cleaning and Inspection
11. Push the piston rod all the way into the cylinder tubeuntil it bottoms.
Retainer Assembly1. Lubricate new seals, wiper ring and retainer assembly
with clean hydraulic fluid.
2. Install the inner seal, with the sealing lip facinginward, into the retainer groove. Be careful not to nickthe sealing lip upon installation.
3. Install a new wiper into retainer.
4. Lubricate and install a new backup ring into the outergroove on the retainer.
5. Lubricate and install a new O-Ring in the groove nextto the backup ring. Note the position of the backupand O-Ring per above diagram.
6. Place a plastic parts bag over the threaded end of therod (to protect seals) and carefully slide the retainerover the rod and into the cylinder housing.
7. Push retainer as far as it will go into the housing.
8. Insert the open end of a new shear ring into thecylinder housing while pushing on the ring with yourfingers. Push ring inward as far as you can.
Reassembly
1. Discard old seals, wiper and shear ring.
2. Wash all parts in a Stoddard type cleaning solventand dry with a clean lint free shop rag.
3. Inspect cylinder mounting bushing for damage. If thebushings show signs of wear and/or damage, theymay be pressed out and new bushing installed. ASleeve to fit over spherical inner bushing will beneeded. Do not press out by prying on the innerbushing. Refer to figure 11-17.
4. Inspect threaded parts for damage. Examine cylinderbarrel for scoring, nicks or scratches. A The cylinderbarrel may be sanded with crocus cloth to removeminor scratches, etc.. Be careful not to remove thechrome plating when polishing the surface. Replaceall damaged or unserviceable parts.
5. Inspect surfaces of the piston and piston rod to besure they are clean, smooth and free of damage.
Figure 11-17
11.5-3
11.5-4
P antograph Service Section 11
Page 66
1. Using a bronze punch, gently tap ring the rest of theway into the tube and groove. Be sure the shear ringis fully seated in it’s groove.
2. Pull the piston rod out as far as it will come. This willposition the retainer so that the retainer ring grooveand into the housing on top of the retainer.
3. Lubricate a new backup ring and place it over the O-Ring just installed.
4. Install the washer over the retainer and next to thebackup ring previously installed.
5. Install a new split retainer into it’s groove in theretainer assembly. Be sure it is completely seated init’s groove.
6. Install jam nut and rod end to the same location it waswhen removed from the piston rod.
7. Cap cylinder ports until the cylinder is installed on thetruck.
8. Check fluid level of truck once cylinder have beeninstalled.
9. Purger air from hydraulic system by cycling cylindersseveral times to force air from the lines into the sumptank.
Retainer Assembly (Continued)
MA2208.eps
Typical Illustration
Rod EndNut
Wiper
RetainingRing
ShearRing
Rod Seal
O-Ring w/ Back-up
Retainer
ShellRod
Piston
PistonSeal Nut
A
ARight HandReach Cylinder
Left HandReach Cylinder
A
A
Figure 11-18
P antograph Service Section 11
Page 67
Side Shift Cylinder ServiceCylinder Removal:
Figure 11-19
WARNING:
MA2201.eps
Remove forks.Refer to illustration 11-19.
1. Remove fork by releasing the lockingpin on the top fork hanger andsliding the fork to the center of thecarriage fork bar. Lift the fork up anddisengage the fork hanger from thecarriage bar.
2. Loosen fittings at the bottom of theside shifter cylinder, catching any oilthat may escape.
3. Using a pry bar, push the side shifterrods into the cylinder body catchingany oil be leaks from the cylinder.
4. Remove the capscrews securing thecarriage claws to the back of thelower carriage bar.
5. Rotate the front of the carrier frameup and remove the carriage bars.
6. Remove all wear pads and discard.
Support forks asforkbar is removed sothey cannot fall.
11.6
P antograph Service Section 11
Page 68
1. The exterior surface of a cylinder should bethoroughly washed before disassembly.
2. A soft fiber brush should be used to removedebris and foreign objects from grooves andthreaded areas, etc.
3. A Stoddard type cleaning solvent should beused to wash the cylinder.
4. Any part unfit for further service should bereplaced with new part.
Wash exterior of the side shift cylinder in aStoddard type cleaning solvent before disassem-bly. Use a brush to remove grease and grimefrom the cylinder tube, anchor and rod ends.
5. Using a spanner wrench in the holes locatedin the top of the retainer, rotate the retainerassembly counter clockwise to loosen theretainer.
6. Remove retainer and rod.
7. Remove rod from retainer.
1. Remove the piston rod seal and wiper. Be carefulthat you do not nick or scratch surface of retainerassembly.
2. Remove outer O-Ring from the retainer assembly.
3. Discard seals, wiper and backup rings.
Disassembly (Refer to Figure 11-20)
Preparation Cleaning andInspection
Retainer Assembly11.6-1
11.6-2
11.6-3
P antograph Service Section 11
Page 69
Figure 11-20
MA2202.eps
Capscrew
CapscrewHose Clamp
Carrier AssemblyCarriage Pin
Dowel Pin
Shim
Snap RingShim
Upper Wear PadBushing
Tilt Cylinder Carriage Weldment
Fitting
Tilt Pin
Tilt Pin Bushing
Snap Ring
Grease Fitting
LowerWear Pad
CapscrewLockwasher
Guard
Capscrew
Capscrew
Valve Assembly
Coil
FittingCarriage Claw
RetainerSS Rod
WiperSeal
Fitting
Tilt PivotBushing
Carriage BarAssembly
Cap
Seal
Wear Pad Shim
Shim
P antograph Service Section 11
Page 70
1. Lubricate new seals, wiper ring and retainer assemblywith clean hydraulic fluid.
2. Install the inner seal, with the sealing lip facinginward, into the retainer groove. Be careful not to nickthe sealing lip upon installation.
3. Install a new wiper into retainer.
4. Lubricate and install a new O-Ring in the groove.
5. Push retainer as far as it will go into the housing.
6. Using a spanner wrench, tighten the retainer.
7. Start rod into cylinder tube while gently pushing androtating the rod. Be careful not to damage seal.
8. Push the rod all the way into the cylinder shell until itbottoms out.
9. Purger air from hydraulic system by cycling cylindersseveral times to force air from the lines into the sumptank.
a. Reinstall new wear pads and lubricate wearpads.
b. Reinstall front carrier on cylinder body.
c. Reinstall carriage claws and capscrews toback face of the lower bar.
Cleaning and Inspection1. Discard old seals and wiper.
2. Wash all rods and retainers in a Stoddard typecleaning solvent and dry with a clean lint free shoprag.
3. Inspect surfaces of the rod to be sure they are clean,smooth and free of damage.
Reassembly11.6-4 11.6-5
P antograph Service Section 11
Page 71
P antograph Service Section 11
For PIDs 40HR-MT-001 Through 40HR-MT-111.
AND
For PIDs 45HR-MT-001 Through 45HR-MT-102.
For all other PIDS see Page 88.
Reach and TiltSelector Valve Service
Page 72
antograph Service Section 11P
Preparation
Reach and Tilt Selector Valve
MA1069.eps
1. Move the truck to a service area.
*Move truck to a flat level surface.
*Extend pantograph.
*Fully lower pantograph.
*Tilt (if so equipped) forks forward until thefork tips touch the ground.
2. Turn key switch off.
*Remove key.
*Disconnect truck battery.
3. If equipped, control circuit capacitors must bedischarged to avoid possibly being shockedwhen working on the solenoid valve.
DisconnectBattery
MA1035.eps
Figure 11-21
11.7
Page 73
P antograph Service Section 11
MA2216.eps
ReachCylinder
Selector ValveReach and Tilt
Selector Valve Mounting Fastener
Hardwood (Oak)Blocking
Floor
Before working on PantographBe Certain it is Blocked as Shown
Figure 11-22
Page 74
antograph Service Section 11P
Figure 11-23
Page 75
P antograph Service Section 11
B
To Tilt CylindersorSide Shifter Selector Valve
A
Mounting Bolts
To R.H.Hand ReachCylinder To
L.H. Hand ReachCylinder
HydraulicSupply
S5S6
1
2
3
4
6 7
11 12
9 10
5 8
Guard
MA2492.eps
To TruckAuxiliarySwitches
To Truck HydraulicSupply
CAUTION
The solenoid valve stemis very fragile. Be verycareful when handling
the valve that you do notdent or bend the stem.
Over torquing the coil nutor the valve at installationwill cause damage to the
valve.
Figure 11-24
Page 76
antograph Service Section 11P
9 10
8
6 7
5
Mounting Bolts
To Truck HydraulicSupply
To TruckAuxiliarySwitches
MA2493.eps
B
A
To L.H. ReachCylinder
To R.H. ReachCylinder
To Tilt CylinderorSide Shifter Selector Valve
Figure 11-25
Page 77
P antograph Service Section 11
Reach and Tilt Selector Valve
WARNINGBe sure the pantograph isblocked as shown on figure 11-22.
Removal
WARNINGHydraulic lines may havetrapped pressure. “Crack” thefittings to bleed pressure beforedisconnecting.
WARNINGWhen trapped pressure is bled,the pantograph may settle.Beware.
Loosen guard mounting bolts and remove the guard.
Unplug connect (#1) from coil (S6) and unplugconnectors (#2) from coil (S5).
Remove fasteners (#4) from clamp (#3).
Tag hoses and disconnect hydraulic connections (#5)and (#8) from valve (A). Cap both hose ends.
CAUTIONResidual pressure will be
present when disconnectinghydraulic lines. Use cautionwhen disconnecting fittings.
Tag tubes and disconnect fittings (#11) and (#12)from bottom side of valve (A). Cap both hose ends.
Remove both mounting fasteners from pantographframe (B) and valve (A).
Remove valve from pantograph. Place componentson a clean work bench.
DisassemblyRemove nuts, coils and solenoid valves (S5) and (S6)from the valve body.
NOTEThe valve body and valves arenot serviceable. If the unit is notfunctioning properly, it must bereplaced.
1.
2.
3.
4.
6.
7.
5.
*
*
Page 78
antograph Service Section 11P
B
To Tilt CylindersorSide Shifter Selector Valve
A
Mounting Bolts
To R.H.Hand ReachCylinder To
L.H. Hand ReachCylinder
HydraulicSupply
S5S6
1
2
3
4
6 7
11 12
9 10
5 8
Guard
MA2492.eps
To TruckAuxiliarySwitches
To Truck HydraulicSupply
9 10
8
6 7
5
Mounting Bolts
To Truck HydraulicSupply
To TruckAuxiliarySwitches
MA2493.eps
B
A
To L.H. ReachCylinder
To R.H. ReachCylinder
To Tilt CylinderorSide Shifter Selector Valve
Figure 11-26
Figure 11-27
Page 79
P antograph Service Section 11
Installing clamps, connectwire, tighten nuts andbolts
7. Be sure the valve guard is located properly andsecurely tighten both solenoid valve mounting bolts.
8. Install wire clamps (#3) and bolts (#4).
9. Connect coil plugs to their respective receptacles.
IMPORTANTAll electrical plugs and their receptacles arematched labeled for easy connection. Check to besure each plug and receptacle match beforeattempting to make connections.
CAUTION
The system must be purged of air before putting truckback into service or damage to the hydraulic systemmat occur.
10. Install and tighten clamp bolts (#4).
1. Position the valve to the pantograph frame aligningholes in frame with those in the valve. Refer toillustration on previous page.
2. Install mounting fasteners finger tight. Do not tightenfasteners until after the hydraulic hoses are installed.
Connecting Hydraulic Plumbing
3. Remove cap, hose tag and install connection (#11) tothe valve finger tight.
4. Remove cap, hose tag and install (#12) connectionfinger tight.
5. Install connections (#5) and (#8). Install connections(#6, 7, 8, 9 and 10) to the reach cylinders finger tight.
6. Securely tighten each hydraulic connection to thevalve body and the reach cylinder.
IMPORTANTBe sure the hoses are routed correctly beforeattempting to connect them to the valve. Refer topage 94.
Mounting Selector ValveRefer to Figure 11-26 and 11-27
11.8-2
Page 80
antograph Service Section 11PSide Shifter Solenoid Control Valve
1. Move the truck to a service area.
*Move truck to a flat level surface.
*Extend pantograph.
*Fully lower pantograph.
*Tilt (if so equipped) forks forward until thefork tips touch the ground.
2. Turn key switch off.
*Remove key.
*Disconnect truck battery.
3. If equipped, control circuit capacitors must bedischarged to avoid possibly being shockedwhen working on the solenoid valve.
a. Remove guard lockwashers andcapscrews.
DisconnectBattery
MA1035.eps
Figure 11-28
11.9
Mounting Selector Valve
MA2202.eps
Capscrew
CapscrewHose Clamp
Carrier AssemblyCarriage Pin
Dowel Pin
Shim
Snap RingShim
Upper Wear PadBushing
Tilt Cylinder Carriage Weldment
Fitting
Tilt Pin
Tilt Pin Bushing
Snap Ring
Grease Fitting
LowerWear Pad
CapscrewLockwasher
Guard
Capscrew
Capscrew
Valve Assembly
Coil
FittingCarriage Claw
RetainerSS Rod
WiperSeal
Fitting
Tilt PivotBushing
Carriage BarAssembly
Cap
Seal
Wear Pad Shim
Shim
Figure 11-29
Page 81
P antograph Service Section 11
Removal
*Unplug Connectors from each coil.
*Label each hose with it’s location.
*Disconnect hydraulic connections (V1, V2, C6, C5, C2,and C4) from the side shifter selector valve.
WARNINGHydraulic lines may havetrapped pressure. “Crack” thefittings to bleed pressure beforedisconnecting.
Cap each hose when disconnected.
NoteThere will be some fluid leakagewhen hydraulic fittings are discon-nected. Place a rag beneath thefitting to be removed.
*Remove mounting bolts securing the selector valve tothe pantograph.
*Remove valve and place on a clean work bench.
*The valve assembly is not serviceable, if unit is notfunctioning properly, it must be replaced.
*Inspect hoses and connectors for further serviceability.
*Replace defective parts.
Refer to Figure 11-30
Figure 11-30
2
MA2207.eps
3
1
NOTEThe valve body and valves arenot serviceable. If the unit is notfunctioning properly, it must bereplaced.
Page 82
antograph Service Section 11P
Figure 11-31
Page 83
P antograph Service Section 11
InstallationMount Selector Valve
*Line up mounting holes in selector valve with those inthe mounting bracket. Install mounting bolts fingertight. See Figure 94.
Install Hoses
*Wipe hose ends and connectors clean. Remove hosecaps just prior to installation. Be certain all connec-tions are tight.
Connect Coils
*Plug connectors to each coils. See illustration on page96.
*Tighten all mounting fasteners.
*Install guard.
MA2216.eps
ReachCylinder
Selector ValveReach and Tilt
Selector Valve Mounting Fastener
Hardwood (Oak)Blocking
Floor
Before working on PantographBe Certain it is Blocked as Shown
Figure 11-32
11.9-1
Page 84
antograph Service Section 11P
Figure 11-33
MA2202.eps
Capscrew
CapscrewHose Clamp
Carrier AssemblyCarriage Pin
Dowel Pin
Shim
Snap RingShim
Upper Wear PadBushing
Tilt Cylinder Carriage Weldment
Fitting
Tilt Pin
Tilt Pin Bushing
Snap Ring
Grease Fitting
LowerWear Pad
CapscrewLockwasher
Guard
Capscrew
Capscrew
Valve Assembly
Coil
FittingCarriage Claw
RetainerSS Rod
WiperSeal
Fitting
Tilt PivotBushing
Carriage BarAssembly
Cap
Seal
Wear Pad Shim
Shim
Page 85
P antograph Service Section 11
11.10 Servicing a Double Reach PantographThe Double Reach Pantograph is serviced the same as the Single Reach Pantograph with oneexception. The Double Pantograph has two scissor assemblies. Follow service proceduresoutlined in Sections 11-7 through 11-9. Refer to Figures 11-34 through 1137.
MA2312.eps
Rear FrameScissor Pin
Grease Fitting
Pivot Bushing
Rear Scissor Frame
Scissor Arm
Bearing CupBearing ConeLock Nut
NutO-Ring
HousingSnap Ring
Grease Fitting
CylinderBearing
Washer
Grease FittingScissor Arm
Shield
Bearing Cone
Bearing Cup
Snap Ring
Bushing
Washer
Cotter Pin
Flat Washer
Nut
Grease Fitting
Scissor Arm
Pivot Bushing
Shield
Bearing Cone
Bearing Cup
Snap Ring
Bearing Cup
Bearing ConeLock Nut
Nut
O-Ring
HousingSnap Ring
Grease FittingCarriageScissor Arm
Shims
Bearing
Flat Washer
Capscrew
Figure 11-34Double Reach Assembly
Page 86
antograph Service Section 11P
C2
CONNECT TO PLUG ONMAST WIRE HARNESS
MA2313.eps
Sideshifting Models Only
Sleeve
Clamp
Capscrew
Wire Harnessto Sideshifter
Scissor Pin Roll Pin
Reach Cylinder
Fitting
Tube
O-Ring
Guard
Hose Guard
Clamp
Cylinder Pin
Nut
Tube Assembly
Capscrew
Wire Harness
Fitting
Clamp
Fitting
SolenoidCoil
Fitting
Fitting
SolenoidValve Block
Couter Balance Valve
Figure 11-35Double Reach Assembly
Page 87
P antograph Service Section 11
MA2310.eps
Inner Reach Cylinder Hose
Outer Reach Cylinder Hose
Cover
Cable Tie
Tilt Cylinder Hoses
Double Reach Without Sideshifter
MA2311.eps
Inner Reach Cylinder Hose
Outer Reach Cylinder Hose
Cover
Cable Tie
Tilt Cylinder Hoses and Cable
Double Reach With Sideshifter
Figure 11-36 HoseRouting.
Figure 11-37 HoseRouting.
11.10 Servicing a Double Reach Pantograph (continued)
Page 88
P antograph Service Section 11
For PIDs 40HR-MT-112 Through Present.
AND
For PIDs 45HR-MT-103 Through Present.
Reach and TiltSelector Valve Service
Page 89
P antograph Service Section 11
Reach and Tilt Selector Valve
MA1069.eps
1. Move the truck to a service area.
*Move truck to a flat level surface.
*Extend pantograph.
*Fully lower pantograph.
*Tilt (if so equipped) forks forward until thefork tips touch the ground.
2. Turn key switch off.
*Remove key.
*Disconnect truck battery.
3. If equipped, control circuit capacitors must bedischarged to avoid possibly being shockedwhen working on the solenoid valve.
DisconnectBattery
MA1035.eps
Figure 11-21
Preparation11.7
Page 90
P antograph Service Section 11
MA2216.eps
ReachCylinder
Selector ValveReach and Tilt
Selector Valve Mounting Fastener
Hardwood (Oak)Blocking
Floor
Before working on PantographBe Certain it is Blocked as Shown
Figure 11-22
Page 91
P antograph Service Section 11
A1
B1
A Lift
Figure 11-23
Page 92
P antograph Service Section 11
B
To Tilt CylindersorSide Shifter Selector Valve
A
Mounting Bolts
To R.H.Hand ReachCylinder To
L.H. Hand ReachCylinder
HydraulicSupply
S5S6
1
2
3
4
6 7
11 12
9 10
5 8
Guard
MA2492.eps
To TruckAuxiliarySwitches
To Truck HydraulicSupply
CAUTION
The solenoid valve stemis very fragile. Be verycareful when handling
the valve that you do notdent or bend the stem.
Over torquing the coil nutor the valve at installationwill cause damage to the
valve.
Figure 11-24
Page 93
P antograph Service Section 11
9 10
8
6 7
5
Mounting Bolts
To Truck HydraulicSupply
To TruckAuxiliarySwitches
MA2493.eps
B
A
To L.H. ReachCylinder
To R.H. ReachCylinder
To Tilt CylinderorSide Shifter Selector Valve
Figure 11-25
Page 94
P antograph Service Section 11
Reach and Tilt Selector Valve
WARNINGBe sure the pantograph isblocked as shown in figure 11-22.
Removal
WARNINGHydraulic lines may havetrapped pressure. “Crack” thefittings to bleed pressure beforedisconnecting.
WARNINGWhen trapped pressure is bled,the pantograph may settle.Beware.
Loosen guard mounting bolts and remove the guard.
Unplug connect (#1) from coil (S6) and unplugconnectors (#2) from coil (S5).
Remove fasteners (#4) from clamp (#3).
Tag hoses and disconnect hydraulic connections (#5)and (#8) from valve (A). Cap both hose ends.
CAUTIONResidual pressure will be
present when disconnectinghydraulic lines. Use cautionwhen disconnecting fittings.
Tag tubes and disconnect fittings (#11) and (#12)from bottom side of valve (A). Cap both hose ends.
Remove both mounting fasteners from pantographframe (B) and valve (A).
Remove valve from pantograph. Place componentson a clean work bench.
DisassemblyRemove nuts, coils and solenoid valves (S5) and (S6)from the valve body.
NOTEThe valve body and valves areserviceable. If the unit is notfunctioning properly, Seesection 13 for valve service.
1.
2.
3.
4.
6.
7.
5.
*
*
11.8
11.8-1
11.8-2
Page 95
P antograph Service Section 11
B
To Tilt CylindersorSide Shifter Selector Valve
A
Mounting Bolts
To R.H.Hand ReachCylinder To
L.H. Hand ReachCylinder
HydraulicSupply
S5S6
1
2
3
4
6 7
11 12
9 10
5 8
Guard
MA2492.eps
To TruckAuxiliarySwitches
To Truck HydraulicSupply
9 10
8
6 7
5
Mounting Bolts
To Truck HydraulicSupply
To TruckAuxiliarySwitches
MA2493.eps
B
A
To L.H. ReachCylinder
To R.H. ReachCylinder
To Tilt CylinderorSide Shifter Selector Valve
Figure 11-26
Figure 11-27
Page 96
P antograph Service Section 11
Installing clamps, connectwire, tighten nuts andbolts
7. Be sure the valve guard is located properly andsecurely tighten both solenoid valve mounting bolts.
8. Install wire clamps (#3) and bolts (#4).
9. Connect coil plugs to their respective receptacles.
IMPORTANTAll electrical plugs and their receptacles arematched labeled for easy connection. Check to besure each plug and receptacle match beforeattempting to make connections.
CAUTION
The system must be purged of air before putting truckback into service or damage to the hydraulic systemmat occur.
10. Install and tighten clamp bolts (#4).
1. Position the valve to the pantograph frame aligningholes in frame with those in the valve.
2. Install mounting fasteners finger tight. Do not tightenfasteners until after the hydraulic hoses are installed.
Connecting Hydraulic Plumbing
3. Remove cap, hose tag and install connection (#11) tothe valve finger tight.
4. Remove cap, hose tag and install (#12) connectionfinger tight.
5. Install connections (#5) and (#8). Install connections(#6, 7, 8, 9 and 10) to the reach cylinders finger tight.
6. Securely tighten each hydraulic connection to thevalve body and the reach cylinder.
IMPORTANTBe sure the hoses are routed correctly beforeattempting to connect them to the valve. Refer topage 94.
Mounting Selector ValveRefer to Figure 11-26 and 11-27
11.8-2
11.8-3
Page 97
P antograph Service Section 11
Side Shifter Solenoid Control Valve
1. Move the truck to a service area.
*Move truck to a flat level surface.
*Extend pantograph.
*Fully lower pantograph.
*Tilt (if so equipped) forks forward until thefork tips touch the ground.
2. Turn key switch off.
*Remove key.
*Disconnect truck battery.
3. If equipped, control circuit capacitors must bedischarged to avoid possibly being shockedwhen working on the solenoid valve.
a. Remove guard lockwashers andcapscrews.
DisconnectBattery
MA1035.eps
Figure 11-28
Removal
MA2202.eps
Capscrew
CapscrewHose Clamp
Carrier AssemblyCarriage Pin
Dowel Pin
Shim
Snap RingShim
Upper Wear PadBushing
Tilt Cylinder Carriage Weldment
Fitting
Tilt Pin
Tilt Pin Bushing
Snap Ring
Grease Fitting
LowerWear Pad
CapscrewLockwasher
Guard
Capscrew
Capscrew
Valve Assembly
Coil
FittingCarriage Claw
RetainerSS Rod
WiperSeal
Fitting
Tilt PivotBushing
Carriage BarAssembly
Cap
Seal
Wear Pad Shim
Shim
Figure 11-29
11.9
Page 98
P antograph Service Section 11
Removal
*Unplug Connectors from each coil.
*Label each hose with it’s location.
*Disconnect hydraulic connections (V1, V2, C6, C5, C2,and C4) from the side shifter selector valve.
WARNINGHydraulic lines may havetrapped pressure. “Crack” thefittings to bleed pressure beforedisconnecting.
Cap each hose when disconnected.
NoteThere will be some fluid leakagewhen hydraulic fittings are discon-nected. Place a rag beneath thefitting to be removed.
*Remove mounting bolts securing the selector valve tothe pantograph.
*Remove valve and place on a clean work bench.
*Inspect hoses and connectors for further serviceability.
*Replace defective parts.
Refer to Figure 11-30.
Figure 11-30
2
MA2207.eps
3
1
11.9
NOTEThe valve body and valves areserviceable. If the unit is notfunctioning properly, Seesection 13 for valve service.
Page 99
P antograph Service Section 11
Figure 11-31
Page 100
P antograph Service Section 11
InstallationMounting Selector Valve
*Line up mounting holes in selector valve with those inthe mounting bracket. Install mounting bolts fingertight. See Figure 11-33.
Installing Hoses
*Wipe hose ends and connectors clean. Remove hosecaps just prior to installation. Be certain all connec-tions are tight.
Connecting Coils
*Plug connectors to each coils. See illustration on page96.
*Tighten all mounting fasteners.
*Install guard.
MA2216.eps
TiltCylinder
Hardwood (Oak)Blocking
Floor
Before working on PantographBe Certain it is Blocked as Shown
TiltSelector
Valve
MA2569.eps
Figure 11-32
11.9-1
Page 101
P antograph Service Section 11
Figure 11-33
MA2202.eps
Capscrew
CapscrewHose Clamp
Carrier AssemblyCarriage Pin
Dowel Pin
Shim
Snap RingShim
Upper Wear PadBushing
Tilt Cylinder Carriage Weldment
Fitting
Tilt Pin
Tilt Pin Bushing
Snap Ring
Grease Fitting
LowerWear Pad
CapscrewLockwasher
Guard
Capscrew
Capscrew
Valve Assembly
Coil
FittingCarriage Claw
RetainerSS Rod
WiperSeal
Fitting
Tilt PivotBushing
Carriage BarAssembly
Cap
Seal
Wear Pad Shim
Shim
Page 102
P antograph Service Section 11
11.10 Servicing a Double Reach PantographThe Double Reach Pantograph is serviced the same as the Single Reach Pantograph with oneexception. The Double Pantograph has two scissor assemblies. Follow service proceduresoutlined in Sections 11-1 through 11-9. Refer to Figures 11-34 through 11-37.
MA2312.eps
Rear FrameScissor Pin
Grease Fitting
Pivot Bushing
Rear Scissor Frame
Scissor Arm
Bearing CupBearing ConeLock Nut
NutO-Ring
HousingSnap Ring
Grease Fitting
CylinderBearing
Washer
Grease FittingScissor Arm
Shield
Bearing Cone
Bearing Cup
Snap Ring
Bushing
Washer
Cotter Pin
Flat Washer
Nut
Grease Fitting
Scissor Arm
Pivot Bushing
Shield
Bearing Cone
Bearing Cup
Snap Ring
Bearing Cup
Bearing ConeLock Nut
Nut
O-Ring
HousingSnap Ring
Grease FittingCarriageScissor Arm
Shims
Bearing
Flat Washer
Capscrew
Figure 11-34Double Reach Assembly
Page 103
P antograph Service Section 11
C2
CONNECT TO PLUG ONMAST WIRE HARNESS
MA2313.eps
Sideshifting Models Only
Sleeve
Clamp
Capscrew
Wire Harnessto Sideshifter
Scissor Pin Roll Pin
Reach Cylinder
Fitting
Tube
O-Ring
Guard
Hose Guard
Clamp
Cylinder Pin
Nut
Tube Assembly
Capscrew
Wire Harness
Fitting
Clamp
Fitting
SolenoidCoil
Fitting
Fitting
SolenoidValve Block
Couter Balance Valve
Figure 11-35Double Reach Assembly
Page 104
P antograph Service Section 11
MA2310.eps
Inner Reach Cylinder Hose
Outer Reach Cylinder Hose
Cover
Cable Tie
Tilt Cylinder Hoses
Double Reach Without Sideshifter
MA2311.eps
Inner Reach Cylinder Hose
Outer Reach Cylinder Hose
Cover
Cable Tie
Tilt Cylinder Hoses and Cable
Double Reach With Sideshifter
Figure 11-36 HoseRouting.
Figure 11-37 Hose Routing.
11.10 Servicing a Double Reach Pantograph (continued)
Page 105
P
Outside Spanner Tool
2"
Inside Spanner Tool
1 1/2" 700
4 1/2"
200
400
3 1/2"
9"
4 1/2"
9"
1 1/2"
MA1046.eps
1"
1"
1"
1"
1/2" Thick Material
1/2" Thick Material
1/4" Fine Thread
Figure 12-1
antogragh Shimming Section 12
Page 106
Shim
HandleShim Set
Side View
Carpenter Square
Top View
Front View
MA1047.eps
Protractor
Sliding T Bevel
450
4 3/4"
7/8"
Figure 12-2
P antogragh Shimming Section 12
Page 107
AllenHeadScrew
Load RollerAdjustmentShims
Carriage
Scissors
MA2190.eps
Lift Fork Carriage
Pantograph Assembly
Figure 12-3
P antogragh Shimming Section 12
Page 108
Truck Side
Hardwood (Oak) Blocking
MA1038.eps
Inner Rail Assembly
IntermediateRail Assembly Outer
Rail Assembly
Outrigger(s)
TopBottom
PANTOGRAPH CARRIAGE ROLLERS
The clearance between the upright inner rails and the pantograph carriage rollers must be checked and adjusted.
Checks and Adjustments
NOTE: Roller clearance and adjustment may accomplished withthe upright mounted to the truck or removed and laying onthe floor as shown above.
1. Span inner rail with inside spanner tool.
Find the smallest distance between rails.
After finding the smallest distance, place a roller shim between the spanner tool and the inner rail. Lock the tool inposition.
Inner Rail
MA1048.eps
**
Step 1Span Railto findnarrowestpoint.
Inside Spanner Tool
Figure 12-4
Figure 12-5
12.0
12.0-1
P antogragh Shimming Section 12
Page 109
Lock
Lock
Lock
Lock
Outside Spanning Tool
Inside Spanning Tool
MA1050.eps
MA1051.eps
UpperCarriageRoller
OuterSpanningTool
AllenHeadScrew
Load RollerAdjustmentShims
Carriage
Scissors
MA1052.eps
2. Set outside spanning tool to match the adjusted insidespanning tool.
3. Lock the outside spanning tool in the adjustedposition.
4. Span the upper carriage rollers at their outer mostcamber point. Add or remove shims at the roller shaftto match tool size.
5. Center carriage rollers by counting the shims andusing equal numbers of shims on both sides. If thereis an odd number of shims, place the odd shim on theright hand side.
IMPORTANTWhen upright is fully extended, the uppercarriage rollers extend beyond the inner railassembly. To allow the rollers to retractsmoothly back into the rail, one shim shouldbe removed from each side.
6. Install upper carriage rollers and securely tighten theAllen head retaining capscrews.
Figure 12-6
Figure 12-7
Figure 12-8
P antogragh Shimming Section 12
Page 110
7. Span center carriage rollers at their outer mostcamber point. Add or remove shims to match toolsize.
8. Center carriage rollers by using equal amounts ofshims on both sides. If an odd number is used, placethe odd shim on the right hand side.
MA1053.eps
CenterCarriageRoller
OuterSpanningTool
9. Place a carpenters square at the outer most camberpoint of the center and lower rollers. Hold the squaretight against rollers and take the following measure-ments.
*Measure the distance between the top of thesquare and the straight edge at point (A).
*Take a measurement at point (B). These mea-surements should be the same. If they are not,add or remove shims from the lower rollersshaft(s) until the distance measured at eachpoint is equal.
Figure 12-9
Figure 12-10
P antogragh Shimming Section 12
Page 111
10. Span lower rollers. Add or remove shims to (the rollerthat has not be squared) match the size of the outsidespanning tool.
MA1055.eps
BottomCarriageRoller
OuterSpanningTool
11. Check and adjust rollers on the opposite side ofcarriage. Place square at the outer most camber ofthe center and lower rollers. Take measurements asbefore. This side will be square within 1/32:, if not ,return to step 9 and repeat procedure. Make surerollers are center as previously described.
Figure 12-11
Figure 12-12
P antogragh Shimming Section 12
Page 112
13. Check opposite roller in use the same procedure,adjusting if necessary.
NOTEUpper Rollers are retained only withthe Allen head capscrews. Center
and lower rollers are always captivewithin the rails.
Carriage
Scissors
MA1057.eps
1/32" Shim
Carriage
Scissors
MA1058.eps
1/32" Shim
12. The top rollers are checked last. Remember that thetop carriage rollers extend out of the inner rails whenthe mast uprights are at full extension. To makereentry of these rollers into the inner rails easier,additional clearance is required for the top rollers.(Refer to steps 4,5 and 6).
*Place the square directly through the center ofthe rollers as shown in the illustration to theright.
*The rollers are shimmed properly when a 1/32”shim can be fit between the outer most camberpoint of top roller and the square. The clearanceshould not exceed 1/32”.
*If adjustments are necessary, remove the Allenhead capscrew and the roller. Add or removeshims to correct the adjustment.
*Install Allen head capscrew and check adjust-ment.
Figure 12-13
Figure 12-13
P antogragh Shimming Section 12
Page 113
Reach and Tilt Selector Valve Service
S ervice
DisassemblyRemove nuts, coils and solenoid valves (S5) and (S6)from the valve body.
Remove both counter balance valves from the valvebody.
NOTEIt will not be necessary to sepa-rate the valve bodies unlessthere was leakage between thetwo bodies. If the valve is leak-ing between the bodies, thenremove four 1/4-20 screws andsperate the bodies. Replace thevalve bodies with new ones.
Wash all parts except the coils in a Stoddard typecleaning solution. Wipe the coils with a clean cloth.
Wipe all parts dry with a clean lint-free cloth. Allowcomponents to air dry before reassembly.
Cleaning
*
*
*
*
Section 13Pantograph Valve Service
MA2580.eps
Typical Solenoid Valves
Typical Counterbalance Valve
CAUTION
Cleanliness is of extreme importance. Before discon-necting hydraulic components, clean exterior ofplumbing and solenoid valve to prevent dirt and otherforeign material from entering hydraulic system.
Figure 13-1
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MA1073.eps
Back-Up Ring(s)
O-Ring(s)
Solenoid Valve
Typical Illustration
Leads
Nut
Coil
Valve Body
Torque to 5 lb.ft.(6.8 Nm) Max.
Typical Cartridge Kit
Lubricate all parts in clean hydraulic fluid prior toinstallation.
If the O-Rings are damaged, replace the valve.
Install the solenoid valves back into their respectiveports on the valve body. Be certain the solenoid valveis torqued correctly to the body. Torque to 8 - 10 lb. ft.(11 - 14 Nm.).
Install the coil over the solenoid valve.
Install the coil retainer nut and torque to 25 lft.lb.(33.9 Nm) maximum. This allows the coil to becorrectly positioned during installation to the truck.
1.
2.
3.
4.
Reassembly - Solenoid Valves
Figure 13-2
Figure 13-3
Pantograph Valve Service Section 13
5.
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Lubricate all parts in clean hydraulic fluid prior toinstallation. Use only new seals.
If the O-Rings are damaged, replace the valve.
Install the counterbalance valves back into theirrespective ports on the valve body. Torque to 35 ft.lb. (47 Nm) maximum.
S ervice
1.
MA2581.eps
Counterbalance Valve(NON-ADJUSTABLE)If the valve has been tampered with,it must be replace with a new one.
O-RINGS
BACK-UP RINGS
BODYCAUTION
Cleanliness is of extreme importance. Before discon-necting hydraulic components, clean exterior ofplumbing and solenoid valve to prevent dirt and otherforeign material from entering hydraulic system.
Reassembly - Counter-balance Valves
InstallationIMPORTANT
Inspect hoses, hydraulic connections and their sealsfor damage. Replace defective parts.
Wipe hose ends and connections clean prior toinstalling them to the solenoid valve.
Remove hose caps just prior to installation.
2.
3.
Figure 13-4
Pantograph Valve Service Section 13
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Valve Body
Solenoid Stem Valve
Check Valve
Solenoid Coil
Figure 13-5
Pantograph Valve Service Section 13
Typical Illustration
Side Shift Selector Valve Service
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S ervice
MA1073.eps
Back-Up Ring(s)
O-Ring(s)
Solenoid Valve
Typical Illustration
Leads
Nut
Coil
Valve Body
Torque to 5 lb.ft.(6.8 Nm) Max.
Typical Cartridge Kit
DisassemblyRemove nut and coil from each solenoid valve.
Remove both solenoid valves from the valve body.
Wash all parts except the coils in a Stoddard typecleaning solution. Wipe the coils with a clean cloth.
Wipe all parts dry with a clean lint-free cloth. Allowcomponents to air dry before reassembly.
If the O-Rings are damaged, replace the valve.
Cleaning*
*
*
*
*
ReassemblyLubricate all parts in clean hydraulic fluid prior toinstallation.
Install the solenoid valves back into their respectiveports on the valve body. Be certain the solenoid valveis torqued correctly to the body. Torque to 8 - 10 ft. lb.(11 - 14 Nm.).
Install the coil over the solenoid valve.
Install the coil retainer nut and torque to 25 lft.lb.(33.9 Nm) maximum. This allows the coil to becorrectly positioned during installation to the truck.
*
Figure 13-7
Pantograph Valve Service
Figure 13-6
Section 13
*
*
*
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M anual Changes Section 14
R3 - Update manual for four valve reach valve and new SS seal kit.Update illustrations for SS kit on pages 56, 68, 78, 82.Update illustrations for new valve on pages 70, 72, 73, 74, 76, 84.Break Manual into sections and reorganize sections.
R4 - 04/08/04Section 6Add page 18, for Tri-Line Cable Service.
Section 11Revise schematic on page 73.Revise note on pages 76 and 80.Revise schematic on page 80.
Section 13Create valve assembly service section.
R5 - 06/28/04Revise Section 11 to show two valve and 4 valve configurations.
R6 - Revise cylinder illusrtations in Cylinder Service Section.
R7 - 11/12/07Revise chain adjustment instructions on page 23.
R8 - 12/15/07Revise hydraulic schematic on pages 74, 82, 91 and 99.
Lift Technologies, Inc.7040 South Highway 11Westminster, SC 29693USATel: +1(864) 647-1119Fax: +1(864) 647-5406
Lift Technologies Inc.Corporate Head Office251 Woodlawn Road W., Unit 217Guelph, ON N1H 8J1 CanadaTel: +1-519-823-4545
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