Hyster F117 H40 00xm H48 00xm 16ch H50 00xm H52 00xm 16ch Forklift service Manual Download Pdf

ASSEMBLY GUIDE H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

PART NO. 1572882

8000 SRM 1173

Assembly Guide

Table of Contents

TABLE OF CONTENTS List of All Special Tools and Equipment Needed for the Assembly ................................................................

General Considerations Before Starting the Job .............................................................................................

Preparation of the Components Before Assembly............................................................................................

Checking of the Wheels .....................................................................................................................................

Air Pressure ...................................................................................................................................................

Drive Wheels .............................................................................................................................................

Steer Wheels ..............................................................................................................................................

Wheel Nut Torque..........................................................................................................................................

Installation of the Cab .......................................................................................................................................

Preparation Of The Mast...................................................................................................................................

Mast................................................................................................................................................................

Mast Label Placement ...................................................................................................................................

Safety Procedures When Working Near Mast..................................................................................................

Mast Installation................................................................................................................................................

Mast................................................................................................................................................................

Tilt Cylinder Pin Installation........................................................................................................................

Truck Header Hoses and Electrical Cable Connections ..............................................................................

Installation of the Dedicated Carriage/Gantry ................................................................................................

Install .............................................................................................................................................................

Carriage Side Blocks .....................................................................................................................................

Adjust .........................................................................................................................................................

Connection of the Hoses and Cables to the Carriages .....................................................................................

Installation of the Container Attachment on the Dedicated Carriage ...........................................................

Installation of the Container Attachment on the Gantry................................................................................

Lights Installation - Operator Compartment...................................................................................................

General Procedures After Assembly .................................................................................................................

Hydraulic Oil Check ..........................................................................................................................................

Lubrication Points .............................................................................................................................................

Check Points.......................................................................................................................................................

Checkpoint 1 ..................................................................................................................................................

Checkpoint 2 ..................................................................................................................................................

Checkpoint 3 ..................................................................................................................................................

Checkpoint 4 ..................................................................................................................................................

Checkpoint 5 ..................................................................................................................................................

General Truck Install Procedures .....................................................................................................................

1 1 2 2 2 3 8 12 14 17 17 18 19 20 20 22 24 26 26 26 26 27 32 34 36 37 37 38 38 38 38 38 38 38 38

This section is for the following models: H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

Š2005 HYSTER COMPANY

i

ASSEMBLY GUIDE H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

PART NO. 1572882

8000 SRM 1173

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Assembly Guide

Table of Contents

TABLE OF CONTENTS List of All Special Tools and Equipment Needed for the Assembly ................................................................

General Considerations Before Starting the Job .............................................................................................

Preparation of the Components Before Assembly............................................................................................

Checking of the Wheels .....................................................................................................................................

Air Pressure ...................................................................................................................................................

Drive Wheels .............................................................................................................................................

Steer Wheels ..............................................................................................................................................

Wheel Nut Torque..........................................................................................................................................

Installation of the Cab .......................................................................................................................................

Preparation Of The Mast...................................................................................................................................

Mast................................................................................................................................................................

Mast Label Placement ...................................................................................................................................

Safety Procedures When Working Near Mast..................................................................................................

Mast Installation................................................................................................................................................

Mast................................................................................................................................................................

Tilt Cylinder Pin Installation........................................................................................................................

Truck Header Hoses and Electrical Cable Connections ..............................................................................

Installation of the Dedicated Carriage/Gantry ................................................................................................

Install .............................................................................................................................................................

Carriage Side Blocks .....................................................................................................................................

Adjust .........................................................................................................................................................

Connection of the Hoses and Cables to the Carriages .....................................................................................

Installation of the Container Attachment on the Dedicated Carriage ...........................................................

Installation of the Container Attachment on the Gantry................................................................................

Lights Installation - Operator Compartment...................................................................................................

General Procedures After Assembly .................................................................................................................

Hydraulic Oil Check ..........................................................................................................................................

Lubrication Points .............................................................................................................................................

Check Points.......................................................................................................................................................

Checkpoint 1 ..................................................................................................................................................

Checkpoint 2 ..................................................................................................................................................

Checkpoint 3 ..................................................................................................................................................

Checkpoint 4 ..................................................................................................................................................

Checkpoint 5 ..................................................................................................................................................

General Truck Install Procedures .....................................................................................................................

1 1 2 2 2 3 8 12 14 17 17 18 19 20 20 22 24 26 26 26 26 27 32 34 36 37 37 38 38 38 38 38 38 38 38

This section is for the following models: H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

Š2005 HYSTER COMPANY

i

8000 SRM 1173

General Considerations Before Starting the Job

List of All Special Tools and Equipment Needed for the Assembly WARNING Read all the instructions contained in this manual before starting any work on the unit.

Also read all procedures contained in the Operating Manual before operating the truck.

1. LIFT tools: • A crane with a minimum capacity of 20,000 kg (44,000 lb) when the boom is raised at the top of the mast. This means the boom must have a length of the mast’s retracted height +1 m (3 ft) + slings height + hook and cables height, and at that height, it must have the capacity to hoist 20,000 kg (44,000 lb).

• Cables or slings of sufficient capacity (see components weight chart).

• Blocks of hard wood of various lengths, widths, and thickness.

• A small mechanical hoisting winch of 1500 kg (3300 lb) capacity.

• Strips and two solid ropes of approximately 150 kg (330 lb) capacity each.

• A lift truck with sufficient lift height to reach the top of the mast.

• A safety platform fastened on the truck carriage.

2. Tooling: • A complete set of imperial and metric ring and open-end spanners/wrenches.

• A torque wrench with a capacity up to 500 N•m (approximately 370 lbf ft).

• Gloves and protective clothing.

• Safety glasses and helmets.

• A hydraulic jack with a minimum capacity of 12,000 kg (26,500 lb).

• A safety cage for inflating tires.

3. Trained mechanics: • It is recommended that personnel involved in the assembly of the machine have followed a specific training session on those units or have a proven understanding of the product to be able to perform the job professionally.

• The minimum personnel required to do the job is at least two mechanics.

General Considerations Before Starting the Job NOTE: This assembly guide is extensive to cover different situations. Assembly of new trucks depends primarily upon how the truck was transported and which carriage is supplied. If the truck was transported overseas, it will be more disassembled than if only shipped by land. Use the portions of the assembly guide that meet your needs.

CAUTION The following assembly procedures are for assembling the lift truck after shipment from the factory. Be sure to check all fluid levels and tire pressures before removing the truck from the trailer. If in doubt, check the torque of all relevant hardware.

1. Safety is always the most important item!

When lifting parts or assemblies, make sure that all slings, chains, or cables are correctly fastened and balanced before lifting. Make sure that all

lifting devices have enough capacity to lift the weight. If in doubt, do not hesitate to use a device with a higher capacity than required. Always use your common sense and avoid dangerous situations.

2. Plan enough personnel to do the job. Never lift heavy parts by hand. Always use a lifting mechanism.

3. The rental price of the crane, which you will need to lift the major components, is very expensive. Plan the job as well as possible in order to limit the costs to the minimum required.

4. Check that all the items ordered are available upon receipt of the machine and its components.

Unpack the case accompanying the machine and identify all the components contained in it.

Check that all capscrews, nuts, pins, washers, and brackets are all presented.

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Checking of the Wheels

8000 SRM 1173

5. Prepare the job. Do all possible preparation and preassembly of parts, cleaning, or lubrication in advance. Allowing yourself half a day before the arrival of the crane will enable you to mount the drive wheels and prepare the mast for direct assembly, and will reduce the rental charges of the crane.

with the procedures. It is advised to read those procedures when the machine and components have arrived, in order to have a better practical understanding of the instructions.

7. It is recommended to perform all assembly procedures outside. During the carriage assembly, the inner mast will be almost fully retracted.

6. Take enough time to read the instructions contained in this guide and to familiarize yourself

Preparation of the Components Before Assembly 1. As previously mentioned, first check that all the components, which will be needed later during installation, are available. (Check this according to the specific packaging list.)

2. If needed, clean all parts before installation.

3. Grease all fittings that will be less accessible later (chain sheaves, for example).

5. Check that the following hanging points are clean and free of paint and grease: • Mast hanger holes in the frame • Mast hanger holes in the upright • Tilt cylinder bushings in the mast • Tilt cylinder rod ends

4. Fasten the hose sheaves on the right-hand top of the inner mast weldment.

Checking of the Wheels AIR PRESSURE WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 1.

Check air pressure of the wheels. See the nameplate for correct air pressure of the tires. If the air pressure is less than 80% of the pressure indicated on the nameplate, remove the wheel after removing all air from the tire and inflate it in a safety cage.

2

8000 SRM 1173

Checking of the Wheels

Drive Wheels WARNING Verify the jack, needed for the installation of the wheels, has a capacity equal to at least half the weight of the lift truck. Refer to the nameplate for weight. The surface must be solid and even.

Tires and wheels must be changed and repaired by trained personnel only. Always wear safety glasses, safety shoes, and gloves.

STEP 1.

Put blocks on each side (front and back) of the steer tires to prevent movement of the lift truck.

1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES STEP 2.

Put the mast in vertical position. Place a block under the outer mast channel.

STEP 3.

Tilt the mast fully forward until the drive tires are raised from the surface.

STEP 4.

Put additional blocks under the frame behind the drive tires.

STEP 5.

If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near the drive axle.

Verify the jack has a capacity of at least half the weight of the lift truck. See the nameplate.

3

Checking of the Wheels

8000 SRM 1173

WARNING Deflate tires before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.

WARNING Always move wheels during assembly with a lifting device. Verify the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 6.

Completely remove the air pressure from the tires of the driving wheels. Remove the 28 wheel nuts from the hub, including the washers and the rim clamps.

Remove the wedgeband, the temporary spacer, outer wheel, the wheel spacer, and the inner wheel from the hub. The outer and inner wheel must be removed by using a lifting device.

1.

2.

3.

4.

4

WEDGEBAND TEMPORARY SPACER WHEEL SPACER EDGE WITH THE BEVEL

8000 SRM 1173

Checking of the Wheels

WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 7.

Put the tire in a safety cage.

NOTE: Safety cage in use.

STEP 8.

Add air pressure to the tire. Check for correct air pressure, see the nameplate. Check that all wheel parts are correctly installed.

STEP 9.

Reassemble the inner wheel on the hub with a lifting device, verify the edge with the bevel is toward the outside of the truck.

STEP 10.

Install the valve extension for the inner wheel and fasten it. Check for proper working order, by seeing if the pressure indicator reacts on the pressure in the rim. If working properly, reassemble the wheel spacer on the hub.

5

Checking of the Wheels

8000 SRM 1173

STEP 11.

To install the outer drive wheel, verify the edge with the bevel is toward the inner drive wheel. Also verify that the outer notch in the wheel spacer aligns with the edge with the bevel on the wheel rim. Install the outer drive wheel on the hub with a lifting device. Verify the valve stem aligns with the notch in the rim.

1. EDGE WITH THE BEVEL 2. NOTCH

CAUTION Verify all the contact areas between the rim, the axle, and the spacers are clean and have a minimum paint thickness.

STEP 12.

Install the wedgeband on the hub (see picture). Clamp the wedgeband on the hub with the rim clamps including spacers and wheel nuts. Fasten the wheel nuts. Be sure the rim clamps are well positioned on the wedgeband, because the wedgeband locks up the rim on the hub.

1. WEDGEBAND 2. RIM CLAMP

6

3. HUB SIDE 4. WEDGEBAND SIDE

8000 SRM 1173

Checking of the Wheels

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque again. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 250 hours.

CAUTION Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer band, or forcing rims out of round.

NOTE: Do the below STEP 13 a minimum of two times.

STEP 13.

Verify the tires are not touching the ground. Tighten the wheel nuts, in the correct sequence, to 405 and 440 N•m (300 and 325 lbf ft).

NOTE: Correct sequence of torquing the driving wheels.

STEP 14.

Lower the truck, and then remove the hydraulic jack.

STEP 15.

Remove the wooden blocks in front and behind the steer tires.

STEP 16.

Follow the same procedure, STEP 1 through STEP 14, for the drive wheel on the other side, when required.

NOTE: Driving wheel reassembled.

7

Checking of the Wheels

8000 SRM 1173

Steer Wheels STEP 1.

Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck.

1. STEER AXLE/STEER TIRE 2. DRIVE AXLE/DRIVE TIRE

WARNING Verify the jack, needed for the installation of the wheels, has a capacity equal of at least 2/3 of the weight of the lift truck. Refer to the nameplate for weight. The surface must be solid and even.

Tires and wheels must be changed and repaired by trained personnel only. Always wear safety glasses, safety shoes, and gloves.

STEP 2.

Use a hydraulic jack to raise the steer tires.

STEP 3.

Put the hydraulic jack under the mounting pad of the steer axle to raise the lift truck. Raise the lift truck so the steer tire is just above the surface. Put additional blocks of wood under the frame to support the lift truck so the lift truck is stable.

WARNING Deflate tires before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.

8

8000 SRM 1173

Checking of the Wheels

WARNING Always move wheels during assembly with a lifting device. Verify the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 4.

Completely remove the air pressure from the tires of the steer wheels. Remove the 24 wheel nuts from the hub, including the washers and the rim clamps. Remove the wedgeband, the temporary spacer, and the wheel spacer from the hub.

CAUTION Do not damage the threads on the studs when removing the wheels.

STEP 5.

Remove the wheel nuts and remove the wheel from the lift truck. Use caution not to damage the studs when removing the wheels. The lift truck wheels are heavy and must be removed by using a lifting device.

WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 6.

Put the tire in a safety cage.

NOTE: Safety cage in use.

9

Checking of the Wheels

8000 SRM 1173

STEP 7.

Add air pressure to the tire. Verify for correct air pressure, see the nameplate. Check that all wheel parts are correctly installed.

CAUTION Do not damage the threads on the studs when installing the wheels.

STEP 8.

Reassemble the wheel on the hub with a lifting device.

STEP 9.

Reassemble the wheel spacer on the hub.

CAUTION Make sure all the contact areas between the rim, the axle, and the spacers are clean and have a minimum paint thickness.

STEP 10.

Install the steer wheel on the hub with a lifting device. Verify the valve stem aligns with the notch in the rim.

STEP 11.

Install the wedgeband on the hub. Clamp the wedgeband on the hub with the rim clamps including spacers and wheel nuts. Fasten the wheel nuts. Verify the rim clamps are well positioned on the wedgeband and the wedgeband locks up the rim on the hub.

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 250 hours.

CAUTION Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer band, or forcing rims out of round.

NOTE: Complete the below step at least twice.

10

8000 SRM 1173

Checking of the Wheels

STEP 12.

Verify the tires are not touching the ground. Tighten the wheel nuts, in the correct sequence, to 271 to 339 N•m (200 to 250 lbf ft).

NOTE: Correct sequence of torquing the steer wheels.

STEP 13.

Lower the lift truck and remove the hydraulic jack.

STEP 14.

Remove the wooden blocks in front and behind the drive tires.

STEP 15.

Follow the same procedure, STEP 1 through STEP 13, for the steer wheel on the other side, when required.

11

Checking of the Wheels

8000 SRM 1173

WHEEL NUT TORQUE STEP 1.

Check the wheel nut torque of each wheel. When the wheel nut torque for one or more wheels are not correct, the wheel nut torque must be adjusted. Do the torque adjustment at least two times.

WARNING Verify the jack needed for lifting one side of the lift truck has a capacity equal to at least half of the weight of the lift truck. Refer to the nameplate for the correct weight. The surface must be solid and even. Always wear safety glasses, safety shoes, and gloves.

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 250 hours.

STEP 2.

Put blocks in front and behind each tire that will remain on the ground. Put a jack under the mounting pad of the axle and lift one side of the lift truck. (the opposite side). Raise the ReachStacker so the tires are just above the surface. Put additional blocks under the frame to support the lift truck so the lift truck is stable.

WARNING Check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule table. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 500 hours.

STEP 3.

Verify the tires are not touching the ground. Tighten the wheel nuts in the correct sequence until the torque indicated has been reached. The torque for drive wheels is between 405 to 440 N•m (300 to 325 lbf ft). The torque for the steer wheels is between 271 to 339 N•m (200 to 250 lbf ft).

NOTE: Correct sequence of torquing the drive wheels.

12

8000 SRM 1173

Checking of the Wheels

STEP 3. (Cont)

NOTE: Correct sequence of torquing the steer wheels.

STEP 4.

Lower the lift truck, and then remove the hydraulic jack.

STEP 5.

Remove the blocks in front and behind the tires.

13

Installation of the Cab

8000 SRM 1173

Installation of the Cab For transporting, the cab is located on the frame. See Figure 1. For transport purposes, all hydraulic hoses and electrical wire harnesses are connected so it is possible to drive the lift truck.

CAUTION Use caution when lifting the cab so there is no damage to the cab or cab components.

NOTE: Be sure that all hydraulic hoses and electrical wire harnesses are secure and clear of the fan when driving in the transport position.

7. Carefully lift the cab.

1. Place the lift truck on a solid and level surface.

3. Apply parking brake.

Verify that all hydraulic hoses and electrical wire harnesses are free and clear of other components. Hydraulic hoses and electrical wire harnesses can be disconnected or damaged when moving the cab.

4. Operate brake pedal until hydraulic pressure is released.

8. Position the cab on the platform. See Figure 2.

Verify the cab is fully seated.

5. Connect a lifting device to the cab and carefully lift the cab until the straps of the lifting device are tight.

9. Bolt the subframe of the cab on the platform with a capscrew and nut. See Figure 3.

6. Disconnect the cab from the transport brackets.

10. Verify that the hydraulic hoses and electrical wire harnesses are seviceable and not damaged.

2. Shut down the engine.

CAUTION

Figure 1. Cab Position for Transport

14

8000 SRM 1173

Installation of the Cab

Figure 2. Cab Positioning for Assembly Legend for Figure 3 1. CAPSCREW 2. WASHER 3. NUT 11. Connect the quick disconnect air-conditioning coupling.

12. Connect the windshield washer hoses.

13. Install the bracket under the cab which guides the hydraulic hoses.

14. Attach the ground cable to the cab.

15. Remove the brackets from the frame where the cab was bolted on for transport.

16. Attach hose clamps and straps.

17. Install the hood panel above the air cleaner.

Figure 3. Cab Mounting

15

Installation of the Cab

8000 SRM 1173

18. Install the precleaner and pipe to the air cleaner.

19. Install the hood panels and the panel in front of the cab.

1. LOCK NUT 2. EXHAUST TUBE

20. Remove the rain cap at the end of the tube for the exhaust extension pipe.

21. Install the exhaust extension pipe on the exhaust tube. Figure 4.

3. MUFFLER 4. FLEX TUBE Figure 4. Exhaust System

16

8000 SRM 1173

Preparation Of The Mast

Preparation Of The Mast MAST NOTE: To avoid serious damage to the mast parts during transport, the following precautions are made: • The bracket weldment and hose sheave are disconnected from the right outside of the mast and fastened to the rear side of the mast with straps.

• The labels are not attached to the mast, and are delivered separately.

1. Install the bracket weldment (item 1) with the hoses on the right-hand top of the right lift cylinder as shown in Figure 5. Tighten the two capscrews to 88 N•m (63 lbf ft).

A. DRIVE DIRECTION 1. BRACKET WELDMENT

2. HOSE SHEAVE

3. CAPSCREW

Figure 5. Mast Preparation

17

Preparation Of The Mast

8000 SRM 1173

2. Install the hose sheave (item 2) on the right-hand top of the inner mast weldment as shown in Figure 5. Tighten the four capscrews to 88 N•m (63 lbf ft). Lubricate the fittings on the chain sheaves and the upright rollers.

MAST LABEL PLACEMENT NOTE: The mast labels are stored in the card box located inside the operator’s cab. The labels were not installed prior to shipment to prevent damage.

1. Clean the mast in the areas of label replacement prior to affixing the labels. Clean the mast with

a solvent or high pressure washer using a water soluble degreaser with warm water.

2. Attach the truck label (item 1) to the top crossmember before mounting the mast as shown in Figure 6.

3. Attach the truck label (item 1) to the left and right outside of the lift cylinders as shown in Figure 6.

4. Attach the no one under the mast (item 2) and mast pinch point warning labels to the left and right outside of the lift cylinders, align with tilt anchor as shown in Figure 6.

A. DRIVE DIRECTION 1. TRUCK LABEL 2. NO ONE UNDER THE MAST WARNING LABEL 3. MAST PINCH POINT WARNING LABEL Figure 6. Mast Label Placement

18

8000 SRM 1173

Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• DO NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

WHEN WORKING NEAR THE MAST ALWAYS: • Lower the mast and carriage completely.

Push the lift/lower control lever forward and make sure there is no movement in the mast.

Make sure that all parts of the mast that move are fully lowered.

OR • If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: 1. Put the mast in a vertical position.

2. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment.

3. Use a 1/2 inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast.

19

Mast Installation

8000 SRM 1173

Mast Installation MAST WARNING When working on or near the mast, review and follow the Safety Procedures When Working Near Mast.

WARNING

Connect the chains to the anchors with the chain anchor pins. Use new snap rings to lock the chain anchor pins. Check the threads on the chain anchors and repair damaged thread, if necessary.

Mount the chain anchors to the brackets at the back of the mast. Protect the threads during the installation. Use straps to hold the ends of the chains to each of the lift cylinders. Adjust the chain anchors as shown in Figure 7.

Verify that the mast lifting device has a minimum rated capacity of 6,500 kg (14,500 lb).

Required tools: • 30 mm socket wrench • 24 mm socket wrench • Torque wrench 1. Place the truck on a solid and level surface.

2. Apply the parking brake.

3. Turn off the engine.

4. Remove the mast pivot pins including caps, washers, and temporary transporting sleeves from the mast points of suspension (mast hanger points).

Remove all paint, rust, or grease from the pivot pins surfaces, the inside of the caps, and the mast hanger holes.

CAUTION During installation, the mast pivot pins and mast hanger holes must be and must remain absolutely free of grease, to assure proper seating of the end plates and prevent pin rotation during operation.

5. In preparation for the assembly of the mast, lubricate the fittings on the chain sheaves and the upright rollers.

6. Clean the two bearings for the tilt cylinder anchor pins on the outer mast. Also, clean the two holes for the mast pivot pins. Leave these two holes clean and dry. Do not grease the holes!

If required, install the chains partially into the sheaves until they reach the back of the mast.

20

NOTE: ADJUST TO 10.0 mm (0.4 in.) ONLY FOR THE 7010 mm (23 ft) LIFT HEIGHT ASSEMBLY. Figure 7. Chain Anchor Adjustment

WARNING Make sure the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

7. Connect a lifting device with a correct capacity to the lifting eyes. Raise the mast and verify it is stable. Verify the mast is vertical and that the hanger holes are at the same height and parallel to the ground. See Figure 8.

8000 SRM 1173

Mast Installation must be oriented to the surface. Tighten the nut. Install the other pivot pin including caps, capscrew, washers, nut, and support pin. Make sure that everything is seated together, then torque the bolts of the pivot pins (on both sides of the truck) with 285 N•m (210 lbf ft). Lubricate the pins, using the two grease fittings, while the weight of the mast is off the pin, e.g., while mast is still being supported by the crane.

Figure 8. Mast Hanger Holes

WARNING Never check the alignment of the mast and frame holes with your hand or finger.

8. Move the truck to within approximately 30 cm (1 ft) of the mast. Apply the park brake and stop the engine. Move the mast to the mounts in the frame. Align the holes in the frame with the holes in the mast.

CAUTION Verify the frame holes for the mast, the mast hanger holes, and the mast pivot pins are clean and dry before continuing with Step 9! In particular, all the conical surfaces must absolutely be dry and free of grease.

9. On one side, install the pivot pin, the two caps, the capscrew, the two washers, and the nut for the support pin. See Figure 9. Position the outer cap at the wheel side. The lubrication fitting

NOTE: MAST PIVOT PIN CONSTRUCTION. TORQUE THE BOLT TO 285 N•m (210 lbf ft).

1.

2.

3.

4.

CAP PIN CAPSCREW WASHER

5.

6.

7.

8.

CAP LOCK NUT FRAME MAST

Figure 9. Mast Pivot Pin

21

Mast Installation

TILT CYLINDER PIN INSTALLATION 1. Operate the lifting device to move the mast so the tilt cylinders can be connected. Use a small mechanical hoisting winch to lift both tilt cylinders on one side. Place wooden blocks under the cylinders for support. Ensure they are the correct height and at the correct angle to be fastened to the mast. Do the same on the other side of the truck.

2. Clean the two tilt cylinder bearings and anchor pins. Prepare the two lockplates, capscrews, and washers. Check if the rod ends are secured with the two bolts through each of the rod ends.

WARNING Do not put your fingers in the rod end holes or tilt-cylinder anchor holes. Use a piece of wood to push the anchor pins. The tilt cylinder can drop and cause injury.

3. Ask a trained assistant to start the engine and operate the tilt controls smoothly. Operate the tilt cylinders to align the rod end holes with the

22

8000 SRM 1173 mast mounting holes. See Figure 10. Grease the tilt cylinder pins with never-seize and install the two tilt cylinder pins using a hammer starting from the inside to the outside. Install lockplates.

The cylinders must bottom at the same time in backward tilt position.

In case adjustment of tilt cylinder is required: Put the mast in a vertical position.

Loosen the two bolts through the cylinder rod end. Turn the piston counterclockwise to increase the length of the tilt cylinder or clockwise to reduce the length. After adjustment of the tilt cylinder, tighten the cylinder rod end hardware to 156 N•m (115 lbf ft).

When all cylinders are correctly adjusted, be sure lock plate is installed on each cylinder and all tilt cylinder rod end hardware is tightened to 156 N•m (115 lbf ft). Lubricate the two rod end fittings.

4. Disconnect the lifting device and the mechanical winch from the mast and the tilt cylinders.

8000 SRM 1173

1.

2.

3.

4.

TILT CYLINDER ANCHOR PIN RETAINER WASHER

Mast Installation

5. CAPSCREW 6. SCREW 7. MAST Figure 10. Tilt Cylinder Mounting

23

Mast Installation

8000 SRM 1173

TRUCK HEADER HOSES AND ELECTRICAL CABLE CONNECTIONS

NOTE: Place an oil catch pan under the hoses before removing the hose plugs.

1. Shut the engine OFF.

3. Remove the two plugs from the adapters for the lift cylinders on the tilt/lift manifold installed for shipping. See Figure 11. Remove the two plugs from the hydraulic hoses attached to the mast installed for shipping.

2. Remove the accumulated hydraulic oil pressure by turning the ignition key to the ON position and moving the hydraulic control levers back and forth, until all pressure has been removed.

1. DRAIN HOSE CONNECTION 2. AUX B CONNECTION HOSE 3. AUX A CONNECTION HOSE

4. LEFT LIFT CYLINDER HOSE CONNECTION 5. RIGHT LIFT CYLINDER HOSE CONNECTION Figure 11. Hose Connections

24

8000 SRM 1173

Mast Installation

CAUTION

CAUTION

Check hose movement during full-forward and back-tilt operation. Route the hoses away from sharp edges to prevent damage during use.

NOTE: Maintain control of the header hose ends.

Use wire/rope to temporarily control the ends of the header hoses. Do this to avoid having the header hoses struck at the top of the mast during lowering the mast.

4. Route hoses as shown in Figure 12.

5. Clean the hose fittings and O-ring.

6. Apply a light film of oil to the O-ring.

1. LEFT LIFT CYLINDER HOSE

After assembly, check if all the hydraulic fittings, hoses, or tubes have been correctly fastened and well positioned. Verify visually there are no leaks in the system. Make sure the hydraulic hoses or tubes are not in contact with sharp edges, which might damage them.

If this is the case, reroute the hoses in order to avoid damage. Avoid all sharp bends in hoses, especially near fittings.

7. Connect the two hydraulic hoses from the lift cylinder to the tilt/lift manifold, located on the frame. See Figure 12. Connect left lift cylinder hose on the left port HOIST, and right lift cylinder hose on the right port HOIST.

2. RIGHT LIFT CYLINDER HOSE Figure 12. Hose Routing

25

Installation of the Dedicated Carriage/Gantry NOTE: Apply a thin coat of dielectric silicone compound to the connector pins before making the electrical connection.

8000 SRM 1173 8. Connect the electrical connector from the attachment to the electrical connector on the frame, located on the right side of the tilt/lift manifold.

See Figure 12.

Installation of the Dedicated Carriage/Gantry INSTALL 1. Connect a lifting device at each side of the top crossmember of the carriage.

2. Start the engine.

NOTE: To lift the mast, the override system must be used.

3. Operate the lift cylinders to raise the inner weldment of the mast. Raise the inner weldment just past the top load rollers of the carriage.

4. Shut down the engine.

10. Connect header hoses, drain hose, and wiring harness at the carriage. See the section Connection of the Hoses and Cables to the Carriages.

WARNING Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components.

Hydraulic oil can be injected into the body by pressure and cause personal injury.

11. Start the engine and operate the hydraulic system. Check that all functions of the carriage work correctly.

12. Check for leaks.

WARNING When disconnecting the lift chains, maintain control of the ends. Use wire to temporarily connect the ends of the lift chains to the mast.

This procedure will prevent the lift chains from falling and causing injury or damage.

13. Remove the blocks from the front and back of the tires.

CARRIAGE SIDE BLOCKS Adjust

Avoid overlifting to prevent anchors from jamming at the upper sheave.

NOTE: The side blocks must be free of paint or any dirt.

5. Operate the lifting device and move the carriage into position under the inner weldment.

6. Start the engine.

1. Adjust wear plates so maximum clearance at the point of tightest fit is 0.5 to 1.5 mm (0.020 to 0.060 in.).

7. Lower the inner weldment completely to engage the rollers of the carriage.

NOTE: If more than five shims are required, replace the bearing block.

8. Shut down the engine.

2. Insert shims between wear plate and bearing bracket weldment as necessary.

9. Raise the carriage and connect the lift chains at the carriage. Remove the lifting device. Adjust the lift chains as described in the section Mast 4000 SRM 1160.

3. If necessary, grease the side blocks with multipurpose grease with 2-4% molybdenum disulfide.

26

8000 SRM 1173

Connection of the Hoses and Cables to the Carriages

Connection of the Hoses and Cables to the Carriages 1. Carefully lift the carriage with the lifting device.

7. Lower mast completely.

2. Fasten the two hydraulic hoses (supply and return), from the sheave at the top of the right outer weldment to the fittings on the bracket at the right side of the carriage.

8. Connect the two hydraulic hoses from the attachment to the tilt/lift manifold, located on the frame. Connect hose with identification straps green-green on port Aux A, and hose with identification straps green-yellow on port Aux B. See Figure 16.

3. Connect hose (Aux A) with identification straps green-green to the hose with the same identification straps to the top of the right outer weldment.

4. Connect hose (Aux B) with identification straps green-yellow to the hose with the same identification straps to the top of the outer weldment.

5. Fasten the electrical connector to the carriage with screws.

9. Connect the drain hose from the top of the lift cylinder to the tilt/lift manifold, located on the frame. Connect the drain hose on port ROD. 10. Verify wires have been connected properly. See Table 1 and Figure 17.

6. Route the cable(s) on the carriage in the same brackets used for the hoses. See Figure 13, Figure 14, and Figure 15.

27

Connection of the Hoses and Cables to the Carriages

1.

2.

3.

4.

5.

ELECTRICAL SUPPLY TO THE ATTACHMENT HYDRAULIC HOSES TO THE ATTACHMENT HOSES FROM TOP OF THE MAST CONNECTOR BOLTED ON THE CARRIAGE BRACKET ON THE ATTACHMENT

8000 SRM 1173

6.

7.

8.

9.

10.

AUX B AUX A DEDICATED CARRIAGE HOSE AND CABLE BRACKET MAST

Figure 13. Route of Hoses and Cables Over the Dedicated Carriage

28

8000 SRM 1173

General Considerations Before Starting the Job

List of All Special Tools and Equipment Needed for the Assembly WARNING Read all the instructions contained in this manual before starting any work on the unit.

Also read all procedures contained in the Operating Manual before operating the truck.

1. LIFT tools: • A crane with a minimum capacity of 20,000 kg (44,000 lb) when the boom is raised at the top of the mast. This means the boom must have a length of the mast’s retracted height +1 m (3 ft) + slings height + hook and cables height, and at that height, it must have the capacity to hoist 20,000 kg (44,000 lb).

• Cables or slings of sufficient capacity (see components weight chart).

• Blocks of hard wood of various lengths, widths, and thickness.

• A small mechanical hoisting winch of 1500 kg (3300 lb) capacity.

• Strips and two solid ropes of approximately 150 kg (330 lb) capacity each.

• A lift truck with sufficient lift height to reach the top of the mast.

• A safety platform fastened on the truck carriage.

2. Tooling: • A complete set of imperial and metric ring and open-end spanners/wrenches.

• A torque wrench with a capacity up to 500 N•m (approximately 370 lbf ft).

• Gloves and protective clothing.

• Safety glasses and helmets.

• A hydraulic jack with a minimum capacity of 12,000 kg (26,500 lb).

• A safety cage for inflating tires.

3. Trained mechanics: • It is recommended that personnel involved in the assembly of the machine have followed a specific training session on those units or have a proven understanding of the product to be able to perform the job professionally.

• The minimum personnel required to do the job is at least two mechanics.

General Considerations Before Starting the Job NOTE: This assembly guide is extensive to cover different situations. Assembly of new trucks depends primarily upon how the truck was transported and which carriage is supplied. If the truck was transported overseas, it will be more disassembled than if only shipped by land. Use the portions of the assembly guide that meet your needs.

CAUTION The following assembly procedures are for assembling the lift truck after shipment from the factory. Be sure to check all fluid levels and tire pressures before removing the truck from the trailer. If in doubt, check the torque of all relevant hardware.

1. Safety is always the most important item!

When lifting parts or assemblies, make sure that all slings, chains, or cables are correctly fastened and balanced before lifting. Make sure that all

lifting devices have enough capacity to lift the weight. If in doubt, do not hesitate to use a device with a higher capacity than required. Always use your common sense and avoid dangerous situations.

2. Plan enough personnel to do the job. Never lift heavy parts by hand. Always use a lifting mechanism.

3. The rental price of the crane, which you will need to lift the major components, is very expensive. Plan the job as well as possible in order to limit the costs to the minimum required.

4. Check that all the items ordered are available upon receipt of the machine and its components.

Unpack the case accompanying the machine and identify all the components contained in it.

Check that all capscrews, nuts, pins, washers, and brackets are all presented.

1

Checking of the Wheels

8000 SRM 1173

5. Prepare the job. Do all possible preparation and preassembly of parts, cleaning, or lubrication in advance. Allowing yourself half a day before the arrival of the crane will enable you to mount the drive wheels and prepare the mast for direct assembly, and will reduce the rental charges of the crane.

with the procedures. It is advised to read those procedures when the machine and components have arrived, in order to have a better practical understanding of the instructions.

7. It is recommended to perform all assembly procedures outside. During the carriage assembly, the inner mast will be almost fully retracted.

6. Take enough time to read the instructions contained in this guide and to familiarize yourself

Preparation of the Components Before Assembly 1. As previously mentioned, first check that all the components, which will be needed later during installation, are available. (Check this according to the specific packaging list.)

2. If needed, clean all parts before installation.

3. Grease all fittings that will be less accessible later (chain sheaves, for example).

5. Check that the following hanging points are clean and free of paint and grease: • Mast hanger holes in the frame • Mast hanger holes in the upright • Tilt cylinder bushings in the mast • Tilt cylinder rod ends

4. Fasten the hose sheaves on the right-hand top of the inner mast weldment.

Checking of the Wheels AIR PRESSURE WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 1.

Check air pressure of the wheels. See the nameplate for correct air pressure of the tires. If the air pressure is less than 80% of the pressure indicated on the nameplate, remove the wheel after removing all air from the tire and inflate it in a safety cage.

2

8000 SRM 1173

Checking of the Wheels

Drive Wheels WARNING Verify the jack, needed for the installation of the wheels, has a capacity equal to at least half the weight of the lift truck. Refer to the nameplate for weight. The surface must be solid and even.

Tires and wheels must be changed and repaired by trained personnel only. Always wear safety glasses, safety shoes, and gloves.

STEP 1.

Put blocks on each side (front and back) of the steer tires to prevent movement of the lift truck.

1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES STEP 2.

Put the mast in vertical position. Place a block under the outer mast channel.

STEP 3.

Tilt the mast fully forward until the drive tires are raised from the surface.

STEP 4.

Put additional blocks under the frame behind the drive tires.

STEP 5.

If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near the drive axle.

Verify the jack has a capacity of at least half the weight of the lift truck. See the nameplate.

3

Checking of the Wheels

8000 SRM 1173

WARNING Deflate tires before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.

WARNING Always move wheels during assembly with a lifting device. Verify the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 6.

Completely remove the air pressure from the tires of the driving wheels. Remove the 28 wheel nuts from the hub, including the washers and the rim clamps.

Remove the wedgeband, the temporary spacer, outer wheel, the wheel spacer, and the inner wheel from the hub. The outer and inner wheel must be removed by using a lifting device.

1.

2.

3.

4.

4

WEDGEBAND TEMPORARY SPACER WHEEL SPACER EDGE WITH THE BEVEL

8000 SRM 1173

Checking of the Wheels

WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 7.

Put the tire in a safety cage.

NOTE: Safety cage in use.

STEP 8.

Add air pressure to the tire. Check for correct air pressure, see the nameplate. Check that all wheel parts are correctly installed.

STEP 9.

Reassemble the inner wheel on the hub with a lifting device, verify the edge with the bevel is toward the outside of the truck.

STEP 10.

Install the valve extension for the inner wheel and fasten it. Check for proper working order, by seeing if the pressure indicator reacts on the pressure in the rim. If working properly, reassemble the wheel spacer on the hub.

5

Checking of the Wheels

8000 SRM 1173

STEP 11.

To install the outer drive wheel, verify the edge with the bevel is toward the inner drive wheel. Also verify that the outer notch in the wheel spacer aligns with the edge with the bevel on the wheel rim. Install the outer drive wheel on the hub with a lifting device. Verify the valve stem aligns with the notch in the rim.

1. EDGE WITH THE BEVEL 2. NOTCH

CAUTION Verify all the contact areas between the rim, the axle, and the spacers are clean and have a minimum paint thickness.

STEP 12.

Install the wedgeband on the hub (see picture). Clamp the wedgeband on the hub with the rim clamps including spacers and wheel nuts. Fasten the wheel nuts. Be sure the rim clamps are well positioned on the wedgeband, because the wedgeband locks up the rim on the hub.

1. WEDGEBAND 2. RIM CLAMP

6

3. HUB SIDE 4. WEDGEBAND SIDE

8000 SRM 1173

Checking of the Wheels

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque again. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 250 hours.

CAUTION Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer band, or forcing rims out of round.

NOTE: Do the below STEP 13 a minimum of two times.

STEP 13.

Verify the tires are not touching the ground. Tighten the wheel nuts, in the correct sequence, to 405 and 440 N•m (300 and 325 lbf ft).

NOTE: Correct sequence of torquing the driving wheels.

STEP 14.

Lower the truck, and then remove the hydraulic jack.

STEP 15.

Remove the wooden blocks in front and behind the steer tires.

STEP 16.

Follow the same procedure, STEP 1 through STEP 14, for the drive wheel on the other side, when required.

NOTE: Driving wheel reassembled.

7

Checking of the Wheels

8000 SRM 1173

Steer Wheels STEP 1.

Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck.

1. STEER AXLE/STEER TIRE 2. DRIVE AXLE/DRIVE TIRE

WARNING Verify the jack, needed for the installation of the wheels, has a capacity equal of at least 2/3 of the weight of the lift truck. Refer to the nameplate for weight. The surface must be solid and even.

Tires and wheels must be changed and repaired by trained personnel only. Always wear safety glasses, safety shoes, and gloves.

STEP 2.

Use a hydraulic jack to raise the steer tires.

STEP 3.

Put the hydraulic jack under the mounting pad of the steer axle to raise the lift truck. Raise the lift truck so the steer tire is just above the surface. Put additional blocks of wood under the frame to support the lift truck so the lift truck is stable.

WARNING Deflate tires before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.

8

8000 SRM 1173

Checking of the Wheels

WARNING Always move wheels during assembly with a lifting device. Verify the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 4.

Completely remove the air pressure from the tires of the steer wheels. Remove the 24 wheel nuts from the hub, including the washers and the rim clamps. Remove the wedgeband, the temporary spacer, and the wheel spacer from the hub.

CAUTION Do not damage the threads on the studs when removing the wheels.

STEP 5.

Remove the wheel nuts and remove the wheel from the lift truck. Use caution not to damage the studs when removing the wheels. The lift truck wheels are heavy and must be removed by using a lifting device.

WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 6.

Put the tire in a safety cage.

NOTE: Safety cage in use.

9

Checking of the Wheels

8000 SRM 1173

STEP 7.

Add air pressure to the tire. Verify for correct air pressure, see the nameplate. Check that all wheel parts are correctly installed.

CAUTION Do not damage the threads on the studs when installing the wheels.

STEP 8.

Reassemble the wheel on the hub with a lifting device.

STEP 9.

Reassemble the wheel spacer on the hub.

CAUTION Make sure all the contact areas between the rim, the axle, and the spacers are clean and have a minimum paint thickness.

STEP 10.

Install the steer wheel on the hub with a lifting device. Verify the valve stem aligns with the notch in the rim.

STEP 11.

Install the wedgeband on the hub. Clamp the wedgeband on the hub with the rim clamps including spacers and wheel nuts. Fasten the wheel nuts. Verify the rim clamps are well positioned on the wedgeband and the wedgeband locks up the rim on the hub.

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 250 hours.

CAUTION Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer band, or forcing rims out of round.

NOTE: Complete the below step at least twice.

10

8000 SRM 1173

Checking of the Wheels

STEP 12.

Verify the tires are not touching the ground. Tighten the wheel nuts, in the correct sequence, to 271 to 339 N•m (200 to 250 lbf ft).

NOTE: Correct sequence of torquing the steer wheels.

STEP 13.

Lower the lift truck and remove the hydraulic jack.

STEP 14.

Remove the wooden blocks in front and behind the drive tires.

STEP 15.

Follow the same procedure, STEP 1 through STEP 13, for the steer wheel on the other side, when required.

11

Checking of the Wheels

8000 SRM 1173

WHEEL NUT TORQUE STEP 1.

Check the wheel nut torque of each wheel. When the wheel nut torque for one or more wheels are not correct, the wheel nut torque must be adjusted. Do the torque adjustment at least two times.

WARNING Verify the jack needed for lifting one side of the lift truck has a capacity equal to at least half of the weight of the lift truck. Refer to the nameplate for the correct weight. The surface must be solid and even. Always wear safety glasses, safety shoes, and gloves.

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 250 hours.

STEP 2.

Put blocks in front and behind each tire that will remain on the ground. Put a jack under the mounting pad of the axle and lift one side of the lift truck. (the opposite side). Raise the ReachStacker so the tires are just above the surface. Put additional blocks under the frame to support the lift truck so the lift truck is stable.

WARNING Check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule table. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 500 hours.

STEP 3.

Verify the tires are not touching the ground. Tighten the wheel nuts in the correct sequence until the torque indicated has been reached. The torque for drive wheels is between 405 to 440 N•m (300 to 325 lbf ft). The torque for the steer wheels is between 271 to 339 N•m (200 to 250 lbf ft).

NOTE: Correct sequence of torquing the drive wheels.

12

8000 SRM 1173

Checking of the Wheels

STEP 3. (Cont)

NOTE: Correct sequence of torquing the steer wheels.

STEP 4.

Lower the lift truck, and then remove the hydraulic jack.

STEP 5.

Remove the blocks in front and behind the tires.

13

Installation of the Cab

8000 SRM 1173

Installation of the Cab For transporting, the cab is located on the frame. See Figure 1. For transport purposes, all hydraulic hoses and electrical wire harnesses are connected so it is possible to drive the lift truck.

CAUTION Use caution when lifting the cab so there is no damage to the cab or cab components.

NOTE: Be sure that all hydraulic hoses and electrical wire harnesses are secure and clear of the fan when driving in the transport position.

7. Carefully lift the cab.

1. Place the lift truck on a solid and level surface.

3. Apply parking brake.

Verify that all hydraulic hoses and electrical wire harnesses are free and clear of other components. Hydraulic hoses and electrical wire harnesses can be disconnected or damaged when moving the cab.

4. Operate brake pedal until hydraulic pressure is released.

8. Position the cab on the platform. See Figure 2.

Verify the cab is fully seated.

5. Connect a lifting device to the cab and carefully lift the cab until the straps of the lifting device are tight.

9. Bolt the subframe of the cab on the platform with a capscrew and nut. See Figure 3.

6. Disconnect the cab from the transport brackets.

10. Verify that the hydraulic hoses and electrical wire harnesses are seviceable and not damaged.

2. Shut down the engine.

CAUTION

Figure 1. Cab Position for Transport

14

8000 SRM 1173

Installation of the Cab

Figure 2. Cab Positioning for Assembly Legend for Figure 3 1. CAPSCREW 2. WASHER 3. NUT 11. Connect the quick disconnect air-conditioning coupling.

12. Connect the windshield washer hoses.

13. Install the bracket under the cab which guides the hydraulic hoses.

14. Attach the ground cable to the cab.

15. Remove the brackets from the frame where the cab was bolted on for transport.

16. Attach hose clamps and straps.

17. Install the hood panel above the air cleaner.

Figure 3. Cab Mounting

15

Installation of the Cab

8000 SRM 1173

18. Install the precleaner and pipe to the air cleaner.

19. Install the hood panels and the panel in front of the cab.

1. LOCK NUT 2. EXHAUST TUBE

20. Remove the rain cap at the end of the tube for the exhaust extension pipe.

21. Install the exhaust extension pipe on the exhaust tube. Figure 4.

3. MUFFLER 4. FLEX TUBE Figure 4. Exhaust System

16

8000 SRM 1173

Preparation Of The Mast

Preparation Of The Mast MAST NOTE: To avoid serious damage to the mast parts during transport, the following precautions are made: • The bracket weldment and hose sheave are disconnected from the right outside of the mast and fastened to the rear side of the mast with straps.

• The labels are not attached to the mast, and are delivered separately.

1. Install the bracket weldment (item 1) with the hoses on the right-hand top of the right lift cylinder as shown in Figure 5. Tighten the two capscrews to 88 N•m (63 lbf ft).

A. DRIVE DIRECTION 1. BRACKET WELDMENT

2. HOSE SHEAVE

3. CAPSCREW

Figure 5. Mast Preparation

17

Preparation Of The Mast

8000 SRM 1173

2. Install the hose sheave (item 2) on the right-hand top of the inner mast weldment as shown in Figure 5. Tighten the four capscrews to 88 N•m (63 lbf ft). Lubricate the fittings on the chain sheaves and the upright rollers.

MAST LABEL PLACEMENT NOTE: The mast labels are stored in the card box located inside the operator’s cab. The labels were not installed prior to shipment to prevent damage.

1. Clean the mast in the areas of label replacement prior to affixing the labels. Clean the mast with

a solvent or high pressure washer using a water soluble degreaser with warm water.

2. Attach the truck label (item 1) to the top crossmember before mounting the mast as shown in Figure 6.

3. Attach the truck label (item 1) to the left and right outside of the lift cylinders as shown in Figure 6.

4. Attach the no one under the mast (item 2) and mast pinch point warning labels to the left and right outside of the lift cylinders, align with tilt anchor as shown in Figure 6.

A. DRIVE DIRECTION 1. TRUCK LABEL 2. NO ONE UNDER THE MAST WARNING LABEL 3. MAST PINCH POINT WARNING LABEL Figure 6. Mast Label Placement

18

8000 SRM 1173

Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• DO NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

WHEN WORKING NEAR THE MAST ALWAYS: • Lower the mast and carriage completely.

Push the lift/lower control lever forward and make sure there is no movement in the mast.

Make sure that all parts of the mast that move are fully lowered.

OR • If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: 1. Put the mast in a vertical position.

2. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment.

3. Use a 1/2 inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast.

19

Mast Installation

8000 SRM 1173

Mast Installation MAST WARNING When working on or near the mast, review and follow the Safety Procedures When Working Near Mast.

WARNING

Connect the chains to the anchors with the chain anchor pins. Use new snap rings to lock the chain anchor pins. Check the threads on the chain anchors and repair damaged thread, if necessary.

Mount the chain anchors to the brackets at the back of the mast. Protect the threads during the installation. Use straps to hold the ends of the chains to each of the lift cylinders. Adjust the chain anchors as shown in Figure 7.

Verify that the mast lifting device has a minimum rated capacity of 6,500 kg (14,500 lb).

Required tools: • 30 mm socket wrench • 24 mm socket wrench • Torque wrench 1. Place the truck on a solid and level surface.

2. Apply the parking brake.

3. Turn off the engine.

4. Remove the mast pivot pins including caps, washers, and temporary transporting sleeves from the mast points of suspension (mast hanger points).

Remove all paint, rust, or grease from the pivot pins surfaces, the inside of the caps, and the mast hanger holes.

CAUTION During installation, the mast pivot pins and mast hanger holes must be and must remain absolutely free of grease, to assure proper seating of the end plates and prevent pin rotation during operation.

5. In preparation for the assembly of the mast, lubricate the fittings on the chain sheaves and the upright rollers.

6. Clean the two bearings for the tilt cylinder anchor pins on the outer mast. Also, clean the two holes for the mast pivot pins. Leave these two holes clean and dry. Do not grease the holes!

If required, install the chains partially into the sheaves until they reach the back of the mast.

20

NOTE: ADJUST TO 10.0 mm (0.4 in.) ONLY FOR THE 7010 mm (23 ft) LIFT HEIGHT ASSEMBLY. Figure 7. Chain Anchor Adjustment

WARNING Make sure the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

7. Connect a lifting device with a correct capacity to the lifting eyes. Raise the mast and verify it is stable. Verify the mast is vertical and that the hanger holes are at the same height and parallel to the ground. See Figure 8.

8000 SRM 1173

Mast Installation must be oriented to the surface. Tighten the nut. Install the other pivot pin including caps, capscrew, washers, nut, and support pin. Make sure that everything is seated together, then torque the bolts of the pivot pins (on both sides of the truck) with 285 N•m (210 lbf ft). Lubricate the pins, using the two grease fittings, while the weight of the mast is off the pin, e.g., while mast is still being supported by the crane.

Figure 8. Mast Hanger Holes

WARNING Never check the alignment of the mast and frame holes with your hand or finger.

8. Move the truck to within approximately 30 cm (1 ft) of the mast. Apply the park brake and stop the engine. Move the mast to the mounts in the frame. Align the holes in the frame with the holes in the mast.

CAUTION Verify the frame holes for the mast, the mast hanger holes, and the mast pivot pins are clean and dry before continuing with Step 9! In particular, all the conical surfaces must absolutely be dry and free of grease.

9. On one side, install the pivot pin, the two caps, the capscrew, the two washers, and the nut for the support pin. See Figure 9. Position the outer cap at the wheel side. The lubrication fitting

NOTE: MAST PIVOT PIN CONSTRUCTION. TORQUE THE BOLT TO 285 N•m (210 lbf ft).

1.

2.

3.

4.

CAP PIN CAPSCREW WASHER

5.

6.

7.

8.

CAP LOCK NUT FRAME MAST

Figure 9. Mast Pivot Pin

21

Mast Installation

TILT CYLINDER PIN INSTALLATION 1. Operate the lifting device to move the mast so the tilt cylinders can be connected. Use a small mechanical hoisting winch to lift both tilt cylinders on one side. Place wooden blocks under the cylinders for support. Ensure they are the correct height and at the correct angle to be fastened to the mast. Do the same on the other side of the truck.

2. Clean the two tilt cylinder bearings and anchor pins. Prepare the two lockplates, capscrews, and washers. Check if the rod ends are secured with the two bolts through each of the rod ends.

WARNING Do not put your fingers in the rod end holes or tilt-cylinder anchor holes. Use a piece of wood to push the anchor pins. The tilt cylinder can drop and cause injury.

3. Ask a trained assistant to start the engine and operate the tilt controls smoothly. Operate the tilt cylinders to align the rod end holes with the

22

8000 SRM 1173 mast mounting holes. See Figure 10. Grease the tilt cylinder pins with never-seize and install the two tilt cylinder pins using a hammer starting from the inside to the outside. Install lockplates.

The cylinders must bottom at the same time in backward tilt position.

In case adjustment of tilt cylinder is required: Put the mast in a vertical position.

Loosen the two bolts through the cylinder rod end. Turn the piston counterclockwise to increase the length of the tilt cylinder or clockwise to reduce the length. After adjustment of the tilt cylinder, tighten the cylinder rod end hardware to 156 N•m (115 lbf ft).

When all cylinders are correctly adjusted, be sure lock plate is installed on each cylinder and all tilt cylinder rod end hardware is tightened to 156 N•m (115 lbf ft). Lubricate the two rod end fittings.

4. Disconnect the lifting device and the mechanical winch from the mast and the tilt cylinders.

8000 SRM 1173

1.

2.

3.

4.

TILT CYLINDER ANCHOR PIN RETAINER WASHER

Mast Installation

5. CAPSCREW 6. SCREW 7. MAST Figure 10. Tilt Cylinder Mounting

23

Mast Installation

8000 SRM 1173

TRUCK HEADER HOSES AND ELECTRICAL CABLE CONNECTIONS

NOTE: Place an oil catch pan under the hoses before removing the hose plugs.

1. Shut the engine OFF.

3. Remove the two plugs from the adapters for the lift cylinders on the tilt/lift manifold installed for shipping. See Figure 11. Remove the two plugs from the hydraulic hoses attached to the mast installed for shipping.

2. Remove the accumulated hydraulic oil pressure by turning the ignition key to the ON position and moving the hydraulic control levers back and forth, until all pressure has been removed.

1. DRAIN HOSE CONNECTION 2. AUX B CONNECTION HOSE 3. AUX A CONNECTION HOSE

4. LEFT LIFT CYLINDER HOSE CONNECTION 5. RIGHT LIFT CYLINDER HOSE CONNECTION Figure 11. Hose Connections

24

8000 SRM 1173

Mast Installation

CAUTION

CAUTION

Check hose movement during full-forward and back-tilt operation. Route the hoses away from sharp edges to prevent damage during use.

NOTE: Maintain control of the header hose ends.

Use wire/rope to temporarily control the ends of the header hoses. Do this to avoid having the header hoses struck at the top of the mast during lowering the mast.

4. Route hoses as shown in Figure 12.

5. Clean the hose fittings and O-ring.

6. Apply a light film of oil to the O-ring.

1. LEFT LIFT CYLINDER HOSE

After assembly, check if all the hydraulic fittings, hoses, or tubes have been correctly fastened and well positioned. Verify visually there are no leaks in the system. Make sure the hydraulic hoses or tubes are not in contact with sharp edges, which might damage them.

If this is the case, reroute the hoses in order to avoid damage. Avoid all sharp bends in hoses, especially near fittings.

7. Connect the two hydraulic hoses from the lift cylinder to the tilt/lift manifold, located on the frame. See Figure 12. Connect left lift cylinder hose on the left port HOIST, and right lift cylinder hose on the right port HOIST.

2. RIGHT LIFT CYLINDER HOSE Figure 12. Hose Routing

25

Installation of the Dedicated Carriage/Gantry NOTE: Apply a thin coat of dielectric silicone compound to the connector pins before making the electrical connection.

8000 SRM 1173 8. Connect the electrical connector from the attachment to the electrical connector on the frame, located on the right side of the tilt/lift manifold.

See Figure 12.

Installation of the Dedicated Carriage/Gantry INSTALL 1. Connect a lifting device at each side of the top crossmember of the carriage.

2. Start the engine.

NOTE: To lift the mast, the override system must be used.

3. Operate the lift cylinders to raise the inner weldment of the mast. Raise the inner weldment just past the top load rollers of the carriage.

4. Shut down the engine.

10. Connect header hoses, drain hose, and wiring harness at the carriage. See the section Connection of the Hoses and Cables to the Carriages.

WARNING Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components.

Hydraulic oil can be injected into the body by pressure and cause personal injury.

11. Start the engine and operate the hydraulic system. Check that all functions of the carriage work correctly.

12. Check for leaks.

WARNING When disconnecting the lift chains, maintain control of the ends. Use wire to temporarily connect the ends of the lift chains to the mast.

This procedure will prevent the lift chains from falling and causing injury or damage.

13. Remove the blocks from the front and back of the tires.

CARRIAGE SIDE BLOCKS Adjust

Avoid overlifting to prevent anchors from jamming at the upper sheave.

NOTE: The side blocks must be free of paint or any dirt.

5. Operate the lifting device and move the carriage into position under the inner weldment.

6. Start the engine.

1. Adjust wear plates so maximum clearance at the point of tightest fit is 0.5 to 1.5 mm (0.020 to 0.060 in.).

7. Lower the inner weldment completely to engage the rollers of the carriage.

NOTE: If more than five shims are required, replace the bearing block.

8. Shut down the engine.

2. Insert shims between wear plate and bearing bracket weldment as necessary.

9. Raise the carriage and connect the lift chains at the carriage. Remove the lifting device. Adjust the lift chains as described in the section Mast 4000 SRM 1160.

3. If necessary, grease the side blocks with multipurpose grease with 2-4% molybdenum disulfide.

26

8000 SRM 1173

Connection of the Hoses and Cables to the Carriages

Connection of the Hoses and Cables to the Carriages 1. Carefully lift the carriage with the lifting device.

7. Lower mast completely.

2. Fasten the two hydraulic hoses (supply and return), from the sheave at the top of the right outer weldment to the fittings on the bracket at the right side of the carriage.

8. Connect the two hydraulic hoses from the attachment to the tilt/lift manifold, located on the frame. Connect hose with identification straps green-green on port Aux A, and hose with identification straps green-yellow on port Aux B. See Figure 16.

3. Connect hose (Aux A) with identification straps green-green to the hose with the same identification straps to the top of the right outer weldment.

4. Connect hose (Aux B) with identification straps green-yellow to the hose with the same identification straps to the top of the outer weldment.

5. Fasten the electrical connector to the carriage with screws.

9. Connect the drain hose from the top of the lift cylinder to the tilt/lift manifold, located on the frame. Connect the drain hose on port ROD. 10. Verify wires have been connected properly. See Table 1 and Figure 17.

6. Route the cable(s) on the carriage in the same brackets used for the hoses. See Figure 13, Figure 14, and Figure 15.

27

Connection of the Hoses and Cables to the Carriages

1.

2.

3.

4.

5.

ELECTRICAL SUPPLY TO THE ATTACHMENT HYDRAULIC HOSES TO THE ATTACHMENT HOSES FROM TOP OF THE MAST CONNECTOR BOLTED ON THE CARRIAGE BRACKET ON THE ATTACHMENT

8000 SRM 1173

6.

7.

8.

9.

10.

AUX B AUX A DEDICATED CARRIAGE HOSE AND CABLE BRACKET MAST

Figure 13. Route of Hoses and Cables Over the Dedicated Carriage

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