Repair manual: Installation Model(s): R112, R114, R116

Publication Number: 7575392-040 Date: 2016-10-24 Applies from serial number: 6308581

Step 1

Step 2 Step 3

Step 4a Step 4b

Cesab 6 10 T Code(s): 1006

Repair manual: Installation Model(s): R112, R114, R116
Publication Number: 7575392-040 Date: 2016-10-24 Applies from serial number: 6308581

Step 5 Step 7
Step 6

Step 8 Step 9 Step 10a

Cesab 6 11 T Code(s): 1006

Repair manual: Installation Model(s): R112, R114, R116
Publication Number: 7575392-040 Date: 2016-10-24 Applies from serial number: 6308581

Step 10b

Step 11 Step 12

C
Step 13 Step 14

Cesab 6 12 T Code(s): 1006

Repair manual: Installation Model(s): R112, R114, R116
Publication Number: 7575392-040 Date: 2016-10-24 Applies from serial number: 6308581

189 Nm

124 Nm

Step 15

Step 16 Step 17

Method
1. The precondition of installing the mast in the truck is that the correct mast
is mounted on the correct truck. The matching is done by using the label
and the identification plate behind the operators seat.
2. Park the truck in an area that permits good access and room to mount
the mast on the truck. Place the mast a bit from the truck so that there is
no interference when the mast is lifted from the pallet. Remove the
strapping.
3: Fix the lifting yoke to the top part of the mast when it is still lying on the
pallet.
4: When installing the mast in the reach carriage, it is important to ensure
that the hoses are correctly installed, see figures 4a and 4b
5: For reach carriage with additional sheet metal (applies to 2.0 and 2.5 ton
mast), the hoses must be traced as per the figure 5.

Cesab 6 13 T Code(s): 1006

Repair manual: Installation Model(s): R112, R114, R116
Publication Number: 7575392-040 Date: 2016-10-24 Applies from serial number: 6308581

6: Check that the hoses are not pinched by rear of the reach carriage when
placing the mast.
7: Lubricate the eccentric insert of the mast with MoS2 grease. Place the
mast in the reach carriage.
8: Turn the eccentric inserts so that the flat part is facing forward (towards
the forks) according to figure 8.
Note: The eccentric inserts must not be turned so that the large flat surfaces
face inwards in the cups on the mast attachment in the reach carriage.

9: Fit the locking ring, but do not tighten it.

10: Install the adjusting screws (Figure 10a) and adjust the mast so that
spacing between the mast and the eccentric cams is the same (Figure
10b). There should be no more than 5 mm difference on each side.
11: Fit the lock screws with the washers, but do not tighten.
12: Place the mast against the bottom part of the reach carriage, and fit the
bolts and washers into the lower bracket (do not tighten).
13: Check how many shims are needed on each side after marking. Left and
right side are decided by the operator's position. Check that the
inclination backward is 90 10. They are supplied in the bag (A). If there
are different amount of shims on either side, these are marked as per the
figure, R (right) and L (left). If they are not marked, both sides must
have the same amount of shims.
The shims B are for 1.6 and 2.0 ton masts. The shims C are for 2.5 ton
masts.
14: Adjust the lateral inclination so as to be within 90 6. Check that the
screws to the eccentric lock ring are not too tight. Turn the eccentric
inserts so that the factory markings are in line with the bracket in the
reach carriage, see Figure 14.
Note: This is to ensure that the correct mast setting made at the factory is
maintained.

. Tighten the bolts at the bottom of the mast to 519Nm for 1.6-2.0 ton masts
and
266Nm per bolt (2ea per side) for 2.5 ton masts.
15: Apply Loctite 29320 (Loctite 242 blue) to the threads of the adjusting
screws and tighten to 189Nm. Then tighten the lock ring screws to
124Nm.
16: Refit the hoses at the correct places. Observe the markings on the hoses
that must have been made when the mast was removed from the truck.
17: Connect the electrics connectors needed to start the truck.

Cesab 6 14 T Code(s): 1006