Lift Tek 35DV-MQ Manuale utente
SERVICE MANUAL
35DV/45DV/55DV-MQ
Four Stage
Full FreeliŌMast
LTI # 263920 Lift Technologies, Inc.
Parts and Service
Tel : (864) 647 - 6320
Fax : (864) 647 - 7302
Toll Free : (877) 430 - 6302
Lift Technologies, Inc.
7040 South Highway 11
Westminster, SC 29693
USA
Tel : (864) 647 - 1119
Fax : (864) 647 - 5406
Toll Free : (888) 946 - 3330
Website : www.lift-tek.com
LTI # 263920 Lift Technologies, Inc.
263920 R 2
Page 3
Page
4
4
4
5
5
5
6
7
7
7
8
8
Standard IHR 9
13
15
16
16
Cylinders 17
17
Free Lift Cylinder Description 18
19
20
Free Lift Cylinder Removal - Mast on Floor 21
Main Lift Cylinder Service 23
27
28
Valve 28
28
Carriage 29
Description 29
30
31
32
33
33
34
36
38
39
43
Chains 44
44
45
Main Lift Chain Adjustment 45
45
Chain Replacement 46
Free Lift Chain Adjustment
Channel Lubrication
Mast Skewing
Mast Inspection
Cylinder Operation
Free Lift Cylinder Service
Mast Removal
Main Lift Cylinders Description
PERIODIC MAINTENANCE, Section 3
TROUBLESHOOTING, Section 4
INTRODUCTION, Section 1
Introduction
Special Definitions
Mounting Bracket Installation
INSTALLATION INSTRUCTIONS, Section 2
Truck System Requirements
SERVICE, Section 5
Upright and Carriage Position, Chain Tension
Mast Installation
Chain Lubrication
Main Lift Cylinder Removal- Mast on Floor
Carriage Removal- Mast on Floor
Carriage Removal- Mast on Truck
Upright Disassembly
Piston Removal
Valve Cartridge Service
Carriage Inspection
Mast Uprights
Upright Description
Upright Operation
Measuring Chain Stretch
Upright Reassembly
Upright Inspection
Mast Skewing
Inspection and Tension
Contents
Page 4
263920 R 2
This manual provides the installation Instructions, periodic
maintenance requirements, troubleshooting and service
procedures for the Lift Tek Series Quad roller masts.
These masts provide excellent visibility for the lift truck
driver. The mast carriage and upright channels are all
roller-mounted which provides smooth operation and long
service life.
In any communication about the mast, refer to the mast
serial number stamped in the nameplate. If the nameplate
is missing, these numbers are also stamped on the
left-hand upper cheekplate. See Figure 1.
Special Definitions
WARNING
1.2
Introduction
A statement preceded by is information
that should be acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION
A statement preceded by CAUTION is information that
should be acted upon to prevent machine damage.
IMPORTANT
A statement preceded by IMPORTANT that
possesses special significance.
NOTE
A statement preceded by NOTE is information that is handy
Tool Requirements
1.3
Listed below are the minimum tools needed to work on a.
METRIC
17, 19, 24 mm Open End or Socket Wrench
INCH
3/4, 13/16, 7/8, 15/16, 1.0, 1-1/16 in Open End or
Socket Wrench.
1/8 in. Allen Wrench
Snap Ring Pliers
Claw Type Spanner Wrench
Strap Wrench
Torque Wrench
2 lb. Dead Blow Hammer
Figure 1. Serial Mast Number Location
Introduction
1.1
WARNING
Left-Hand
Side of
Outer
Upright
MA3154.eps
45DV-MQ-001-00025-M
OR
Example:
55DV–MQ–001–00025–M
Stamped
Serial
Numbers
45DV-MQ-001-00025-M
263920 R 2
Page 5
Installation
2.1 Truck System
Requirements
To achieve maximum lifting capacity of the mast, the
truck relief valve should be set to relieve at the pressure
indicated in the chart below. This chart also indicates the
hose fitting size to use between the truck control valve
and masts valve.
* Valve inlet port is 3/4 in. SAE O-ring. See Figure 2.
WARNING: For proper truck stability or to
prevent interference, tilt restriction may be
required. Contact the truck manufacturer.
IMPORTANT: Lift Tek Masts are compatible with SAE 10W
petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104
B only. Use of synthetic or aqueous base hydraulic oil is not
recommended. If fire resistant hydraulic oil must be used,
contact Lift Tek.
Relief
Pressure
Hose
Size
Fitting*
Size
2600 psi No. 8 min.
No. 8 min.
13/32 in. Orifice
FigFigure 2. Valve inlet Port.
MA0022.eps
Valve Inlet Port
3/4 in. SAE O-ring
2.2 Mounting Bracket
Installation
If it is necessary to install mounting brackets and cross-
members to fit your lift truck, consult with the nearest
Lift Tek Service Department listed on the back cover.
You must supply dimensions A through F shown in
Figure 3. Failure to install the correct brackets and cross-
members can result in mast structural failure, bodily injury
and loss of warranty.
Figure 3. Determining Mounting Bracket Location.
WARNING: Failure to install the correct
brackets and crossmembers can result in
mast structural failure, bodily injury and
loss of warranty.
E
F
A
B
C
D
Truck Cowl
Tilt Cylinders
Front View
Side View
MA0031.eps
Page 6
263920 R 2
2.3 Mast Installation
Installation
1. Raise and block the front end of the truck 1ft. (30 cm) per
ANSI B56.1 or drive the truck over a service pit.
2. Install the bearings to lower the axle mounts.
3. Lubricate the bearing surfaces of the lower axle and tilt
cylinder mounting brackets with chassis grease.
4. Lift the mast using an overhead hoist with chain hooks
attached to the upper outer crossmember. Position the mast
lower the axle mounts on the truck axle. Install the mount
caps and capscrews. Tighten the capscrews to the truck
manufacturer’s torque specifications.
IMPORTANT: Prior to connecting the tilt cylinders to the
mast, make sure the cylinders “bottom” evenly. Adjust the tilt
cylinders to prevent the mast from “racking” during tilting.
Refer to your truck service manual for procedures.
5. Connect the lift truck supply hose to the mast valve.
6. Connect the tilt cylinders to the mast anchor brackets.
Tighten the pin capscrews to the truck manufacturer’s
torque specifications.
NOTE: Use as few fittings as possible and always use 45o
fittings instead of 90o fittings. Keep the hose lengths to a
minimum. Avoid sharp bends or pinch points when routing
the hose.
7. Check the hydraulic fluid level in the truck hydraulic
tank when the Mast is fully lower. Fill if required.
MA0016.eps
5
6
23
4
4
FiFigure 4. Mast Installation.
Contact Lift Tek if
additional fittings are
required. See back
cover.
263920 R 2
Page 7
Installation
2.4 Mast Inspection
Check each of the following before using the Mast for the
first time.
CAUTION: The factory-set adjustments may not be
correct for your truck.
1. Inspect all chains for lubrication.
2. Inspect all chains for any visible damage.
3. Inspect the main lift chain adjustment for proper
tension and upright position.
4. Inspect the free lift chain adjustment for proper
tension and carriage position.
5. Inspect for lubrication in the Mast upright channels.
6. Check for Mast skewing.
MA2777.eps
Carriage 2 in.
Below Outer
Upright
Outer Upright
and Carriage
Flush Outer
Upright
*3 in.
Underclearance *5 in.
Underclearance
NOTE: Underclearance is based on mast
production series, actual mast
underclearance may vary by truck
model.
Figure 5. Mast side view showing correct position
for uprights and carriage.
2.4-1 Chain Lubrication
The main and free lift chains have been factory lubricated
using heat and pressure to force the lubrication thoroughly
into the chain links. Avoid removal or contamination of
this factory-applied lubrication. Do not wash, sand blast,
etch, steam clean, or paint the chains for initial Mast
installation. If chains need lubrication, refer to
Section 5.6. Chain Service
2.4-2 Upright and Carriage
Position, Chain Tension
The main lift chains should be adjusted so that when the
unloaded Mast is fully lowered, the uprights are flush at
the bottom (see Figure 5). The free lift chains should be
adjusted so that when the unloaded Mast is fully lowered,
the carriage is properly positioned depending on the truck
type (see figure 6).
CONTINUED ON PAGE 8
MA0015.eps
Free Lift Chains
Adjusting Nuts
Outer Main
Lift Chain
Adjusting Nuts
Inner Main
Lift Chain
Adjusting
Nuts
Figure 6. Adjusting Chain Anchor
Location (driver’s view).
Page 8
263920 R 2
2.4-2 Upright and Carriage
Position, Chain Tension
( Continued )
Installation
All chains should also be adjusted for equal tension of the
pairs to ensure proper load distribution and mast opera-
tion. Chains are adjusted at the chain anchors (see
Figure 6 ). To determine equal tension, extend the
unloaded mast to put the chains under tension. Then press
the center of the strand with your thumb. Then press
at the same place on the other chain of the pair. Each
chain in a pair should have equal “give”.
If the uprights or carriage are not in correct adjust-
ment, of if the chain pairs do not have equal tension,
perform the Main Lift and Free Lift Chain Adjustments
as described in Section 5.6-3 and 5.6-4.
2.4-3 Channel Lubrication
MA0028.eps
Upright
Rails
Lubrication
Figure 7. Lubricating upright channels.
Inspect the upright channels for lubrication. If necessary,
lubricate the full length of each upright channel with
chassis lube or Kendall SR-12X (see Figure 7).
2.4-4 Mast Skewing
Extend the mast to full lift height and inspect for mast
skewing (see Figure 8).
* If the mast bends to the right at full extension, a shim(s)
needs to be removed from the left main lift cylinder rod.
* If the mast bends to the left at full extension, a shim(s)
needs to be installed on the left main lift cylinder rod.
To adjust the Mast to eliminate skewing, perform the Mast
Skewing Adjustment as described in Section 5.5-6.
MA0017.eps
Right Hand
Main Lift
Cylinder
Left Hand
Main Lift
Cylinder
Free Lift
Cylinder
Figure 8. Extending Mast to check for
skewing (driver’s view).
MA0020.eps
Snap
Ring
Shim
Outer
Intermediate
Upright
4 X 4 in.
( 10 X 10 cm)
Wood Block
Outer
Upright
Figure 9. Blocking upright to retract LH main lift cylinder rod..
263920 R 2
Page 9
Installation
2.4-2 Internal Reeving
STANDARD
1. Install the shaft, tires and hose guards to the
crosshead center plate (see Figure 10). Leave the
capscrew and nut finger-tight to allow for hose
installation.
2. Install the carriage hose bracket to the center tab
on the lower carriage bar.
3. Install the fittings to the bracket (see Figure 11).
* 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.
4. Install the lower IHR bracket and plastic inserts to
the block at the bottom of the inner upright
weldment. Tighten capscrew to 52 ft-lbs (71Nm).
Do not install cover plate at this time.
5. Install the shaft and hardware to the inner interme-
diate upright chain sheave shaft. Tighten the
capscrew to 52 ft-lbs. (71 Nm). See figure 12.
MA3167.eps
1
Figure 10. Installing shaft, tires and hose guards on
crosshead.
MA3168.eps
3
2
Figure 11. Installing hose bracket and fittings on carriage.
MA0256.eps
3
SINGLE
FUNCTION
OR
DOUBLE
FUNCTION
Page 10
263920 R 2
Installation
MA3188.eps
Upper Hose Guide
16
19
17
19
Outer
Upright
Outer
Intermediate
Upright
Inner
Intermediate
Upright
Inner
Upright
Crosshead
Components
Carriage
Components
Lower Inner
Components
Lower Guides
7
9
5
6
4
Figure 12.Installing internal hose reeving components on uprights.
6. Install the lower hose guide to the outer intermedi-
ate upright. Tighten the capscrew to 30 ft-lbs (41
Nm).
7. Install hose clamps to lower guide. Leave
capscrews finger tight.
8. Completely lower the carriage. Route the short
hoses down behind the carriage bar to the carriage
bracket fittings. Connect the hose ends to the
fittings leaving the hose ends finger tight. 35DV
Double Function: The No. 4 hoses connect to the
two right fittings (viewed from the driver’s seat).
2.4-2 Internal Reeving
STANDARD ( Continued )
9. Route the hoses over the crosshead sheaves.
10. Route the hoses down between the freelift
cylinder and crossmember. Position the hoses in
their natural curve over the crosshead sheaves.
Tighten the hose ends at the carriage bracket.
11. Connect the long hoses to the short hoses behind
the freelift cylinder. The outside hose(s) is
approximately 4” shorter than the inside hose(s).
See figure 13.
12. Pull down on the hoses with approximately 30 lbs.
of force. Clamp the hoses to the lower bracket
attached to the inner upright crossmember.
Tighten the capscrews to a torque of 7-11 ft-lbs
(10-15 Nm).
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