polyurethane Shore HAN

1.0 Shimming

1.1 Two stage mast Shimming mast on truck.

1.1.1 Shimming the lift platform.

1) Disconnect the battery and remove battery from truck.

2) The truck will have to hoisted and blocked a foot off floor (see Hoisting Instructions in this manual) before work can begin.

IWARNING! Always make sure unit is on level surface before work can begin.

3) Attach a hoist to top of lift platform and hoist to loosen lift chains. This will allow removal of lift chain anchor pins, steering wheel chain, and elec- trical cable.

4) Determining the amount of shims required by prying the rear of lift frame to one side and slipping shims between the bearings and web on column. Add shims by hand until no more may be added.

5) Divide shims as equally as possible between the two (2) bearings and install under bearings.

6) . Hoist lift platform up inner column to expose the two (2) top bearings. Remove bearings to install shims behind bearings.

7) Lower lift platform down inner column to expose the two (2) lower bearings. Remove bearings to install shims behind bearings.

Raise lift platform up inner column as far as it will go under normal operation. Check bearing shimming as lift platform is raised. Remove shims as required if tight spots are encountered.where assembler cannot roll platform smoothly. Check for excessive bearing clearance with platform in lowered position by prying platform to one side and checking with a .030n shim. Maximum clearance must not exceed .030".

Lower lift platform to install lift chain anchor pins, steering wheel chain, and electrical cable. When installing lift chains, chains are to be free of twists and adjusted for equal tension with adjusting nuts and locknuts torqued to 200 ft./lbs. Chains are to be centered on sheave within l/32".

8)

9)

1.1.2 Shimming of the mast

In order to shim the mast rails the lift platform will have to be removed.

1)

2)

3)

4)

5) Disconnect battery and remove from unit.

!WARNING! Always make sure unit is on level surface before work can begin.

Attach a hoist to top of lift platform (see Hoisting Instructions in this manual) and raise platform to loosen lift chains.

Remove chain anchor electrical cable. pins, steering wheel chain, and

Raise lift platform to floor. up and out of inner column. Lower

l 6)

7)

8)

9) Set platform away from truck.

Attach a hoist to top of inner column and hoist to loosen lift chains. This will allow removal of lift chain anchor pins.

Remove cap screw on top of inner column which secures lift cylinder. Once column is lifted with hoist the lift cylinder is free to move or fall. Secure lift cylinder in place.

Determine the amount of shims required by prying inner column to one &de and slipping shims between bearing and'web on column. Add shims by hand until no more may be added.

Divide shims as equally as possible between the two (2) bearings on both top and bottom of column and install under bearings.

Lower inner column down and out the outer column to expose the two (2) bottom bearings and install shims under bearings.

Raise inner column up outer column as far as it will go under normal operation. Check bearing shimming as inner column is raised. Remove shims as required if tight spots are encountered where assembler can- not roll mast smoothly. Check for excessive bearing clearance with columns in closed position by prying column to one side and check with a 0.030" shim. Maximum clearance must not exceed 0.030".

Check for excessive bearing clearance with inner column in the raised position by prying column to one side and checking with a 0.030" shim. Maximum clearance must not exceed 0.030".

Attach a hoist to top of lift platform frame and place platform in inner column.

Hoist lift platform up inner column to attach lift chain anchor pins. When installing lift chains, chains are to be free of twists and adjusted for equal tension with adjusting nuts and locknuts torqued to 200 ft./lbs. Chains are to be centered on sheave within l/32".

Connect steering wheel chain, and electrical cable.

Remove hoist from mast and lower unit floor.

Install and connect battery to unit.

Loosen locking nuts on chain anchors. Adjust nuts until both chains are free of twist and of equal tension. Tension is correct if you can force lift chains sideways approximately SW to 1" before lift platform raises slightly.

Retighten locknuts on chain anchors.

Test operation of mast and check for tight or loose spots and reshim if found.

1.2 Three Stage Mast

Shimming mast on truck. . .

1.2.1 Shimming the lift platform.

10)

11)

12)

13)

14)

15)

16)

1)

2)

3) Disconnect battery and remove battery from truck:

The truck will have to be hoisted and blocked a foot off floor (see Hoisting Instructions in this manual) before work can begin.

IWARNING! Always make sure unit is on level suface before work tian begin.

Attach a hoist to top of lift platform and hoist to loosen lift chains. This will allow removal of lift chain anchor pins, steering wheel cable, and electrical cable.

Thoroughly clean off all outside dirt around mast roller bearings and steering cables.

Determining the amount of shims required by'prying the rear of lift platform to one side and slipping shims between the bearings and web on the COlUmn. Add shims by hand until no more can be added.

4)

5)

7)

8)

9) Divide shims as equally as possible between the two bearings and install under bearings.

Hoist lift platform up inner column to expose the two (2) top bearings. Remove bearings to install shims behind bearings.

Lower lift platform down inner column to expose the two (2) lower bearings. Remove bearings to install shims behind bearings.

Raise lift platform up inner column as far as it will go under normal operation. Check bearing shimming as the lift platform is raised. Remove shims as required. If tight spots are encountered where assembler cannot roll lift platform smoothly, check for execssive bearing clearance with platform in fully lowered position by prying platform to one side and checking with a 0.030" shim. Maximum clearance must not exceed 0.030". Check for excessive bearing clearance with lift platform in the fully raised position by prying platform to one side.and checking-with a 0.030" shim. Maximum clearance must not exceed 0.030".

Lower lift platform to install lift chain anchor pins, steering wheel chain, and electrical cable. When installing lift chains, chains are to be free of twists and adjusted for equal tension with adjusting nuts (wheel nuts) and locknuts (jam nuts) torqued to 200 ft./lbs. Chains are to be centered on sheave within l/32".

Remove hoist from liiZ$__platform and test operation of unit.

1.2.2 Shimming of the mast rails.

In order to shim the mast rails the lift platform will have to be removed.

10)

11)

1)

2)

3)

4) Disconnect battery and remove from unit.

!WARNING! Always make sure unit is on level surface before work can begin.

Attach a hoist to top of lift platform and raise platform to loosen lift chains.

Remove chain anchor electrical cable. pins, steering wheel chain, and

Raise lift platform up and out inner column. Lower to floor. Place it away from truck.

Attach hoist to top loosen lift chain. chain anchor pins. -91- of inner column and hoist to This will allow removal of lift

5) Before disconnecting hoses and fittings from inner column, thoroughly clean off all outside dirt around fittings. After disconnecting hoses immediately cap ports on tubes and hoses to prevent contaminates from entering the hydraulic system.

NOTE: Take note as to which port the hoses are from for easier installation.

6) Remove cap screw on top of inner column which secures lift cylinder. Once column is lifted with hoist the lift cylinder is free to move or fall. Secure lift cylinder in place.

7) Determine the amount of shims required by prying inner column to one side and slipping shims between bearings and web on column. Add shims by hand until no more may be added.

8) Divide shims as equally as possible between the two bearings on both top or bottom of column and install under bearings.

9) Lower inner column down and out the intermediate column to expose two (2) bottom bearings and install shims under bearings.

10) Divide shims as equally as possible between the two (2) bearings on top of intermediate column and install under bearings.

11)

Raise inner column up intermediate column as far as it will go under normal operation. Check bearing shimming as inner column is,.r+sed. Remove shims as required, if tight spots are encountered where assembler cannot roll mast smoothly. Check for excessive bearing clearance with columns-in lowered position by prying column to one side and check with 0.030" shim. Maximum clearance must not exceed 0.030". 12) Attach a hoist to top of both inner and intermediate column (see Hoisting Instructions in this manual). 13) Remove cap screw on top of intermediate column which secures lift staging cylinder. Once columns are lifted with hoist the lift cylinder is free to move or fall. Secure lift cylinder in place. 14). Determine the amount of shims required by prying intermediate column to one side and slipping shims between bearing and web on column. Add shims by hand until no more may be added.