Model 4700 Maintenance Manual

Section 7.Component Procedures

Mast Quad Mast Service

16

Note: Bubbled numbers refer to steps in associated procedure.

17.Install the free lift chain anchors (short anchors) and chains to the inner upright center cross member.

18.Install the free lift cylinder supply hose to the free lift cylinder tube. Leave the tubing clamp loose.

19.Install the carriage. See “InstallationMast on Floor”.

20.Install the free lift cylinder. See “Free Lift Cylinder Installation - Mast on Floor” on page7-85. Connect the tube to the cylinder fitting and tighten the tubing clamp.

21.Place a 2 x 4 in. (5 x 10 cm) wood block between the outer and outer intermediate lower cross members to prevent upright movement.

22.Turn the mast over (face down), rotating it on its lower end. Make sure the mast is

Publication re-blocked in a level position. See Figure7-103.

Figure 7-103.Blocking Uprights Before Turning Mast Over

22 21

MA0254.eps

Note: Bubbled numbers refer to steps in associated procedure.

23.Install main lift cylinders. See “Main Lift Cylinder Installation - Mast on Floor” on page7-85.

24.Install the Mast. Refer to “Mast Removal and Installation” on page7-68

7-83

Section 7.Component Procedures

Model 4700 Maintenance Manual

Quad Mast Service Mast

25.Install the internal hose reeving. See “Reeving” on page7-86.

26.Adjust the main and free lift chains.

27.Check the mast for skewing.

Carriage

Removal - Mast on Floor

1.Remove mast from truck. See “Mast Removal and Installation” on page7-68.

2.Remove the pins fastening the free lift chains to the carriage chain anchors.

3.Disconnect the intern al reeving hoses from the carriage fittings (if equipped). Plug the hose ends.

4.Remove the socket head stops on the inner upright lower cross member. For reassembly, tighten to 80 ft. lb. (110 Nm).

5.Roll the carriage to the bottom end of the mast.

6.Attach an overhead hoist to the carriage side bars and remove the carriage through the bottom end of the mast.

7.Remove the load rollers, noting the number of shims behind each roller for reassembly.

Installation - Mast on Floor

Reverse the removal procedure and do the following:

1.Inspect the carriage.

2.Lubricate the inner upright rails. Refer to “Lubrication Specification Chart” on pageA-2

3.Assemble shims and load rollers on the carriage stub shafts. The shims should be installed to provide a total side to side clearance no looser than 0.06 in. (1.5 mm) at the tightest point throughout the travel of the carriage. Use an equal amount of shims on each side.

4.Adjust the carriage side thrust rollers for unrestricted clearance along the travel of the carriage. Turn the eccentric mount base of each roller toward the upright rail

7-84 to decrease clearance. See Figure7-104. Torque the cap screws to 79 to 80 ft. lb. (95 to 110 Nm).

5.Check and adjust the free lift chains.

6.Adjust mast tilt. See “Mast Tilt Adjustment” on page7-90.

Cylinder Removal and Installation

Main Lift Cylinder Removal - Mast on Floor

1.Remove the mast from the truck. See “Mast Removal and Installation” on page7-68.

2.Insert a 2 x 4 in. (5 x10 cm) wood block between the lower cross members of the outer upright and outer intermediate upright to prevent uprights from moving out the bottom of the mast.

3.Lay the mast face-down on wood blocks. Block under each end of the outer upright so the mast is level and the inner uprights and carriage are free to move.

4.Using a 1 in. wrench, disconnect the cylinder supply hoses from the cylinder inlet ports. Using a 1 in. socket, remove

Publication 1160093, Issued: 20 May 2013

Section 7.Component Procedures

Mast Quad Mast Service the special long fittings from the cylinder ports and install plugs.

5.Remove the snap ring from the top of the left hand cylinder rod, the tube, and fitting from the top of the right hand cylinder rod. Plug the cylinder port.

6.Roll the uprights through the top of the mast 1 to 2 ft. (30 to 60 cm) and disengage the cylinder rods from the outer intermediate upright.

7.Lift the cylinder from its base mounting boss in the outer upright and angle inward. Remove the cylinders through the sides of the uprights.

8.Note the number of shims (if equipped) on each cylinder rod.

Main Lift Cylinder Installation - Mast on Floor

For installation, reverse the Removal procedure. Bleed the system. See “Bleeding the Hydraulic System” on page7-60.

Free Lift Cylinder Removal - Mast on Floor

1.Remove the mast from the truck. See “Mast Removal and Installation” on page7-68.

2.Lay the mast face-up, blocking under the lower mounts so the mast is level.

3.Roll the carriage upward to allow slack in the free lift chains and internal reeving.

4.Remove the snap ring fastening the crosshead to the cylinder rod.

5.Pull the crosshead with chains and hoses of the cylinder rod.

6.Roll the carriage above the free lift cylinder.

7.Using a 1 in. wrench, disconnect the tube from the cylinder fitting. Cap the cylinder fitting and plug the tube.

8.Using a 5 mm Allen wrench, remove the cylinder strap.

9.Remove the cylinder from the mast.

Free Lift Cylinder Installation - Mast on Floor

For installation, reverse the Removal procedure. Bleed the system. See “Bleeding the Hydraulic System” on page7-60.

Free Lift Cylinder Supply HoseTracking and Adjustment

1.Make sure the cylinder supply hose is not twisted, and that it travels evenly in the hose sheave.

2.Check the hose to make sure it is not scuffing.

3.Adjust the hose by loosening the hose clamp on the outer upright as shown in Figure7-105 and twisting the hose. Figure 7-105.Free Lift Cylinder Supply Hose Adjustment

4.Tighten the clamp while holding the hose in place.

NOTE : The hose and the clamp must be dry of oil and water before inserting the hose into the clamp.

5.After inserting the hose through the loose clamp and tensioning the hose, snugly tighten the two clamp bolts, then tighten to 5.9 ft. lb. (8 Nm) with a torque wrench.

Section 7.Component Procedures

Model 4700 Maintenance Manual

Reeving

Internal Reeving

1.Install the shaft, sheave, and hose guards to the crosshead center plate. See Figure7-106. Leave the cap screw and nut finger tight to allow for hose installation.

3.Install the fittings on the bracket. See Figure7-108.

• Single Function - Install the fittings to the left or right side location. Tighten the fittings finger tight.

• Double Function - Install the fittings to the left and right side location. Tighten the fittings finger tight.

2.Install the carriage hose bracket to the center tab on the lower carriage bar. See Figure7-107.

Note: Bubbled numbers refer to steps in associated procedure.

4.Make up two hose assemblies by connecting the two hoses to the two long hoses. See Figure7-110.

5.Install the shaft, sheave(s), shim, and hardware to the inner intermediate upright chain sheave shaft. See Figure7-109. Torque the cap screw to 37ft. lb. (50 Nm).

6.Route the hose ends over the inner intermediate upright sheave(s) down to the inner upright bracket.

NOTE : The short hose routes over the cylinder crosshead.

7.Position the hoses with the tabs on the inner upright bracket as shown in Figure7-110

8.Loosen the crosshead cover plate cap screw. Route the hoses up over the crosshead rollers.

Note: Bubbled numbers refer to steps in associated procedure.

Publication 1160093, Issued: 20 May 2013

Quad Mast Service Mast 7-86