Installation. - TM-10-3930-624-340105

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

(para 6-3).

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.

27. Nut

(8) Start the engine and operate the mast

28. Capscrew

61.

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