Toyota Orderpicker

Mast Section

8. Reinstall the roller bearings. Torque the bolts per Table 7-2.

9. Use a suitable lifting device and reinstall the inner mast into the outer mast. Check for tightness while moving the inner mast to the bottom of the outer mast.

NOTE: If the inner mast hangs up, a pry bar may be used to move the mast.

10. With the inner mast fully nested, use a pry bar to check for bearing tightness. If a thin shim can be inserted between the bearing and the outer mast, remove the inner mast and install the shim between the bearing and the roller boss. Torque the bearing stud retaining bolt (refer to Table 7-2 on page 7-86) . Leave the lifting device connected to the outer mast. Do not apply excessive pressure to the bearings with the pry bar.

11. Assemble the two roller bearings and bosses for the top inner mast without shims.

12. Insert the bearing/boss assemblies and attach with the retaining bolts. Draw the bearing bosses up snug to the outer mast.

NOTE: Failure to snug the assemblies to the main frame will result in the wrong amount of shims, since the studs are canted.

13. Use a pry bar and carefully move the inner mast to the other side. Using spare shims between the bearing and inner mast, determine the number of shims required to remove side play.

14. Remove the bearing/boss assemblies.

15. Install half the total shim thickness to each bearing/boss assembly.

16. Install the bearing/boss assemblies into the outer mast/inner mast. Attach with a mounting bolt and tighten.

17. With the inner mast fully nested, use a pry bar to check for bearing tightness. If more shims can be inserted between the bearing and the inner mast, remove the bearing/boss assembly and install the shim($. Reinstall the bearing/boss assembly. Torque the bearing stud

Mast Disassembly and Shimming

retaining bolt. (See Table 7-2 on page 7-86.)

18. Check for proper shimming by pulling the inner mast out and then pushing it in all the way. The inner mast should not hang up while moving it in and out.

19. Install the outer lift cylinders.

20. Install the chain rollers and lift chains.

2 1. Install the center lift cylinders

Shimming Inner Mast to Carriage

1. Install the mast roller bearings on the carriage roller bosses.

2. Use a suitable lifting device and insert the carriage into the inner mast all the way to the bottom.

NOTE: The carriage may have to be removed several times to obtain the proper fit.

3. Using a pry bar, move the bottom carriage bearings to one side.

4. Use spare shim($ as a gauge to determine the amount required to move the bearings outward to make contact with the inner mast.

5. Move the carriage to the top of the inner mast and repeat the process for the top set of bearings.

6. Remove the carriage from the inner mast.

7. Install half of the total shim thickness required to each roller boss.

8. Reinstall the roller bearings.

9. Use a suitable lifting device and reinstall the carriage into the inner mast. Check for tightness while moving the carriage to the bottom of the inner mast.

10. Use a pry bar to check for bearing tightness. If a thin shim can be inserted between the bearing and the inner mast, remove the carriage and install the shim between the bearing and the roller boss. Do not apply excessive pressure to the bearings with the pry bar.

11. Use a suitable lifting device and reinstall the carriage, checking for tightness. Make