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KEY to fig. 6-1:
(4) Inspect chains for worn or damaged links.
34.
Crosshead
1. Cotter pin
Replace as required.
35.
Primary lift cylinder
2. Link
(5) Inspect all other components for damage,
36.
Nut
3. Link
distortion and wear. Repair or replace parts as
W asher
37.
4. Chain
necessary.
38.
Spacer
5. Nut
39.
Capscrew
d. Reassembly. Reassemble the mast in the
6. Bolt
40.
Washer
7. Cotter pin
reverse order of disassembly. Adjust the mast
41.
Nut
8. Link
bearings (subpara g) as required.
42.
Secondary lift cylinder
9. Link
e. Installation.
43.
Capscrew
10. Chain
(1) Hoist the mast assembly into position on
44.
Capscrew
11. Nut
45.
Lockwasher
12. Bolt
the truck.
46.
Spring
13. Nut
(2) Install the pivot pins and capscrews which
47.
Sleeve
14. Lockwasher
secure the mast to the frame.
48.
Stud
15. Clip
(3) Install the carriage and backrest assembly
16. Spacer
49.
Nut
50.
Latch
17. Capscrew
51.
Capscrew
18. Capscrew
(4) Connect the tilt cylinder to the mast
52.
Plate
19. Tube
bracket. Install the lift chains. Adjust the tilt
Inner mast
53.
20. Bracket
cylinder as instructed in TM 10-3930-624-12.
54.
Capscrew
21. Elbow
(5) Connect hydraulic lines to the primary and
55.
Latch
22. Packing
secondary lift cylinders.
56.
Intermediate mast
23. Elbow
57.
Outer mast
24. Packing
(6) Install the forks (TM 10-3930-624-12).
58.
Capscrew
25. Fitting
(7) Lubricate grease fittings as instructed in
59.
Lockwasher
26. Regulator
the current LO 10-3930-624-12.
60.
Pin
27. Nut
(8) Start the engine and operate the mast
28. Capscrew
61.
Pin
29. Lockwasher
62.
Spacer
through several cycles. Remove the bleed screws on
63.
Bearing
30. Chain guard
the cylinders and bleed the system until air-free oil
31. Capscrew
64.
Bearing
flows out the openings.
32. Washer
65.
Shim
(9) Shut down the engine and check for
66.
Bushing
33. Bearing
hydraulic oil leaks.
(2) Remove the primary lift cylinder (35) and
(10) Check the oil level in the hydraulic tank
remove the chain guard (30), bearing (33) and
and add oil as necessary.
crosshead (34). Refer to paragraph 5-9 for primary
(11) Adjust the lift chains (subpara f).
lift cylinder repair.
f. Lift Chain Adjustment.
(3) Remove the spacer (38) and the secondary
(1) Lower the carriage to its lowest point of
lift cylinder (42). Refer to paragraph 5-10 for
travel. The bottom of the carriage lower bar should
secondary lift cylinder repair.
be 3.0 to 3.5 inches from the floor. Adjust the chain
(4) Remove the spring (46), latch (50) and
adjustment bolts (6 and 12, fig. 6-1) as necessary.
plate (52). Slide the inner mast assembly (53) out
(2) Extend the mast until the primary cylinder
the bottom of the intermediate mast (56).
reaches  maxim urn  extension.  M e a s u r e  the
(5) Remove the latch (55) and slide the in-
clearance between the stop on the inner mast and
termediate mast (56) out the top of the outer mast
the carriage stop screws. Clearance should be in.
(57).
to 3/8 in. Adjust bolts as required.
(6) Remove the pin (61), bearing (63),
bearing (64) and bushing (66).
Note. Ensure that chains are adjusted to equal tension.
c. Cleaning. Inspection and Repair.
g. Mast Bearing Adjustment.
(1) Clean structural components with a soap
(1) Using an adjustable spanning tool, locate
solution and rinse with clean water. Soak chains for
the narrowest point on the rear inside of the outer
four hours in a solution of 50% engine oil with 50%
mast channel. Lock the tool in this position. Set an
solvent. Wipe dry. Clean remaining parts with
adjustable outside spanning tool to match the inside
solvent.
spanning tool and lock in position.
(2) Inspect the mast structures for cracks,
(2) Install bearings on studs at the bottom of
fatigue lines, distorted or misaligned channels,
the intermediate mast assembly. Using the outside
broken welds and other damage. Repair cracks and
spanning tool. span bearings at the maximum
minor breaks in the mast by welding. Avoid heat
camber point. Add shims as required to obtain a
distortion. Replace the mast if damage is excessive.
maximum clearance of 0.015 inch between the
(3) Inspect bushings and rollers for wear,
bearings and the outside spanning tool. Divide
scoring, pitting, discoloration, and other damage.
shims as equally as possible between bearings.
Replace if damaged.
6-3

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