MAST INSTALLATION INSTRUCTIONS

Truck
How the Truck is Shipped ........................................................................... 1-1
Uprighting a Cradled Truck ......................................................................... 1-1
Option 1: Uprighting with Two Chain Hoist.................................................. 1-2
Option 2: Uprighting with One Chain Hoist and a Lift Truck ........................ 1-3
Mast Installation Instructions
Truck System Requirements ....................................................................... 1-3
Mast Inspection........................................................................................... 1-3
Chain Lubrication........................................................................................ 1-3
Upright and Carriage Position, Chain Tension ............................................ 1-3
Channel Lubrication.................................................................................... 1-4
Mast Mounting Bolts and Torque Specifications.......................................... 1-5
Overhead Guard Mounting Bolts and Torque Specifications ....................... 1-6
Hydraulic Fluid Level................................................................................... 1-7
Hydraulic Functions .................................................................................... 1-7
Pump Intake Coupling (Bleed Points) ......................................................... 1-7
 MAST INSTALLATION INSTRUCTIONS

Truck Uprighting a Cradled Truck

This section includes instructions for uprighting a cra-
How the Truck is Shipped dled truck. Generally, when the OAL (Overall
Before doing the inspection, take note of how the Lowered Height) of a truck is 107 in. (2717.8 mm) or
truck was prepared for shipping from the factory: higher, it will be secured to a cradle and shipped lying
• The Mast/Tractor Assembly is laid down on a down (with the mast horizontal).
skid (this is known as cradling). Usually if the
Overall Lowered Height (OAL) is 107 in.
(2717.8 mm) or more, the truck will be secured
to a cradle and shipped lying down (with its mast
horizontal). Instructions for uncradling a truck
are detailed in “Uprighting a Cradled Truck” on ! CAUTION
this page.
Two technicians are required for erecting
• The carriage is strapped to the truck’s baselegs and assembling the unit.
(for cradled trucks).
In the battery compartment.
• A glass mast guard is installed (if used).
! CAUTION
Remove all jewelry from hands and wrists
• Two battery doors are strapped in place. before doing the installation.

! WARNING
To prevent possible injury or damage to the
unit, use extreme caution when handling a
cradled lift truck. Place the mast, truck, and
pallets in an open area where it will be safe
to work. The truck components are heavy,
unstable, and difficult to handle. Use
extreme care when lifting and assembling
this truck. Proceed with extreme caution.

Warnings and Cautions

Be sure to follow these important warnings and cau-
tions before uprighting a cradled truck:
• Anyone involved in setting up this unit should
wear gloves, safety glasses, steel-toed boots, and
a safety helmet.
• There should be no distractions during setup of
this truck.
• Do not allow observers to stand nearby.

Items Needed
To upright the truck, you will need:
• A hoist with a minimum working capacity of 5
tons (4536 kg).

1-1
MAST INSTALLATION INSTRUCTIONS

• An assembly area with a ceiling clearance in 12. Lift the cradle up and away from the truck and
excess of the truck’s collapsed height. slowly lower it to the floor.
• A hoist sling for the mast.

Option 1: Uprighting with Two Chain

Hoists
Use this procedure when two chain hoists of suitable
weight capacities are available.
1. Before lifting the truck into the upright position,
remove the forks from the cradle. Use a lifting
device to prevent personal injury because the forks
weigh more than 50 lbs. (23 kg) each.
2. Position the cradled truck so it is lying directly
beneath and parallel to the chain hoist rail.

! WARNING
While performing the next step, be sure
that the chain on the baselegs does not lift
the cradle off the floor. Also, be sure not to
let it become slack as this will allow the
truck to lower too quickly.
! WARNING
Once the forks are positioned under the
cradle, attach a safety chain between the
fork carriage of the lifting truck and the
upper cross piece of the cradle. This pre-
vents the cradle from slipping off the
forks during the uprighting procedure.

3. Attach the first chain hoist to the upper cross piece

of the cradled truck’s mast.
4. Attach the second chain hoist to the baselegs of
the cradled truck.
5. Slowly raise each chain until all slack is gone.
6. Begin lifting the chain attached to the upper cross
! WARNING
While performing the next step, be sure
piece of the cradled truck’s mast.
that the chain on the baselegs does not
7. Once the lifting chain reaches a certain point, the lift the cradle off the floor. Also, be sure
center of gravity will shift, causing the weight of not to let it become slack as this will allow
the cradled truck to shift to the chain hoist the truck to lower too quickly.
attached to the baselegs.
8. Once the weight has shifted, continue to lower the
truck with the baseleg chain hoist until it is stand-
ing on the floor in the upright position.
9. Remove the chains from the base legs.
10. Remove the chain from the upper cross piece of
the truck’s mast and attach it to the upper cross
piece of the cradle.
11. Remove the bolts from the bottom cradle cross
piece that secures the cradle to the truck’s front
bumper.

1-2

Option 2: Uprighting with One Chain
Hoist and a Lift Truck
Use this procedure when one chain hoist is available.
This procedure uses a lift truck and a chain hoist, both
of suitable weight capacity.
1. Before lifting the truck into the upright position,
remove the forks from the cradle. Use a lifting
device to prevent personal injury because the forks
weigh more than 50 lbs. (23 kg) each.
2. Position the cradled truck so it is lying directly
beneath and parallel to the chain hoist rail.
3. Position the forks of the lift truck you’re using to
upright the truck under the upper cross piece of
the cradle.
4. Attach the chain hoist to the baselegs of the cra-
dled truck.
5. Slowly raise the chain hoist until all slack is gone.
6. Begin to raise the upper end of the cradle with the
forks of the lifting truck.
7. Once the forks have lifted the cradle to a certain
point, the center of gravity will shift. This causes
the weight of the cradled truck to shift to the chain
hoist.
8. Once the weight has shifted, continue to lower the
truck with the chain hoist until the truck is stand-
ing on the floor in the upright position.
9. Remove the chain between the lifting truck car-
riage and the upper cross piece of the cradle. Back
the lifting truck away.
10. Remove the chain from the baselegs and attach it
to the upper cross piece of the cradle.
11. Loosen and remove the nuts holding the wooden
cradle cross piece to the mast, then remove the
wooden cross piece.
12. With the chain still attached to the cradle, lift the
cradle up and away from the truck and slowly
lower it to the floor.
1-3
MAST INSTALLATION INSTRUCTIONS
Mast Installation Instructions
Truck System Requirements
IMPORTANT: The mast is compatible with SAE
10W petroleum base oil per Mil. Spec. MIL-0-5606 or
MIL-0-2104B only. Use of synthetic or aqueous base
hydraulic oil is not recommended. The recommended
hydraulic oil is Caterpillar HYDO. See service data
chart in section 12 of the Planned Maintenance
Section for oils required for non-standard applica-
tions.
Mast Inspection
Check each of the following before using the Mast for
the first time.
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 chan-
nels.
6. Check for Mast skewing.
Chain Lubrication
The main and free lift chains have been factory lubri-
cated using heat and pressure to force the lubrication
thoroughly into the chain links. Avoid removal or con-
tamination 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 Page 6-16 Chain Lubrication.
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. The free lift chains should be
adjusted so that when the unloaded mast is fully low-
ered, the carriage is properly positioned depending on
the truck type.
MAST INSTALLATION INSTRUCTIONS

All chains should also be adjusted for equal tension of Mast Skewing
the pairs to ensure proper load distribution and mast To adjust the Mast to eliminate skewing, perform the
operation. Mast Skewing Adjustment as described below.
Chains are adjusted at the chain anchors (see Section
• Extend the mast to full lift height and inspect for
6, page 6-14). To determine equal tension, extend the
mast skewing.
unloaded mast to put the chains under tension. Then
press the center of the strand with your thumb. Then • If the mast bends to the right at full extension, a
press at the same place on the other chain of the pair. shim(s) needs to be removed from the left main
Each chain in a pair should have equal “give.” lift cylinder rod.
If the uprights or carriage are not in correct adjust- • If the mast bends to the left at full extension, a
ment, or if the chain pairs do not have equal tension, shim(s)needs to be installed on the left main lift
perform the Main Lift and Free Lift Chain cylinder rod.
Adjustments.
Snap Ring
Washer
Channel Lubrication
Inspect the upright channels for lubrication. If neces-
sary, lubricate the full length of each upright channel
with chassis lube or Kendall SR-12X. Intermediate
Shim
Upright

Cylinder
Alignment
Pin Tab

MA0980.eps

Alignment
Pin

Figure 1.1
Shimming ML Cylinders

1-4
 MAST INSTALLATION INSTRUCTIONS

Mast Mounting Bolts and Torque Specifications

Figure 1.2

Mast is mounted with M16 bolts from top and with M20 bolts from below. The M16 bolts are assembled from
the mast side and the M20 bolts are assembled from the chassis side.

Bolt type Torque [Nm] Quantity [pcs]

M16 x 45 DIN 912 8.8 200(147.5122ft lbs.) 4 Mast from the top
Washer 16 DIN 127 - 4 Mast from the top
M20 x 40 DIN 933 8.8 400(295.02 ft. lbs.) 4 Mast from below
Washer 20 DIN 127 - 4 Mast from below

1-5
MAST INSTALLATION INSTRUCTIONS

Overhead Guard Mounting Bolts and Torque Specifications

Figure 1.3

Bolt type Torque [Nm] Quantity [pcs]

M20 x 40 DIN 933 10.9 400 (292.0244 ft. lbs.) 4
Washer, Lock 20 - 4

1-6

Hydraulic Fluid Level
Refer to Service Data—Planned Maintenance for rec-
ommended oils and fluid capacities.
NOTE
The mast must be in the fully lowered position
before filling the hydraulic tank or bleeding the
hydraulic system.
Oil Tank, filling hole
Oil Level
1. Start by filling the hydraulic tank with 33 liters
(8.7 U.S. gallons) of hydraulic oil.
2. Fill the mast hydraulic system and bleed it.
3. Finally fill the hydraulic tank to the level shown in
the picture above.
1-7
MAST INSTALLATION INSTRUCTIONS
Hydraulic Functions
Trucks that are transported laying down have the
hydraulic oil removed.
New oil must be added and air will be trapped in the
system, resulting in no hydraulic function.
Bleed out the air from the hydraulic system before
putting into service. The bleed points can be found in
the battery compartment as shown in the following
picture.
The battery will have to be pushed aside to get to this
area.
Pump Intake Coupling (Bleed
Points)
The picture below shows the pumps intake couplings,
labeled bleed point A (standard and high performance
model) and bleed point B (high performance model
only), which are located in the battery compartment.
To make sure the pump receives oil immediately and
doesn’t run dry the first time it is turned on—loosen
nut A and wait until you see oil dripping out of it.
Then retighten the nut.
On the high performance models, both A and B need
to be loosened until oil is dripping out of them. Then
both nuts should be retightened.