Two-Stage Mast 4000 SRM 764
Two-Stage Mast
REMOVE
WARNING
Fully lower all the mast weldments. Weld-
ments, operator platform, and forks can move
suddenly and cause an injury as hydraulic
lines are disconnected.
NOTE: I
f the mast assembly will be disassembled,re-
move the operator platform before the mast assembly
is removed. See Operator Platform, Remove in this
section.
1. Disconnect and remove the battery. Refer to the
correct procedure in the Operating Manual or
the section Periodic Maintenance 8000 SRM
924 or Periodic Maintenance 8000 SRM 1472.
2. Install blocks under the main frame near the
mast to support the main frame without chang-
ing the height. Make sure the mast, base arms,
and load wheels do not support any weight so the
mast capscrews can be removed. Use chains to
fasten the mast channels together at the top of
the mast.
3. Open the door and remove the access cover over
the electrical compartment. Remove the hy-
draulic tube at the cylinder port of the solenoid
valve. Put caps on the port, the mast hose, and
both ends of the tube to prevent dirt from enter-
ing the system. Use wire to fasten the hose in
a position to prevent damage during removal of
the mast.
4. Disconnect the electrical cable for the operator
platform. Push the cable and connectors through
theholesinthelifttruckframetopreventdam-
agetothecableduringremovalofthemast.Use
wire to fasten the hoses and cable in a position to
prevent damage.
5. Use chains to connect a crane to the top of the
mast. Make sure the chains will not damage
the sheaves or other parts of the mast assembly.
Make sure the chains and crane have the capac-
ity to lift approximately 2000 kg (4500 lb). Use
other chains to fasten all the mast weldments to-
gether so they cannot move. Operate the crane
until it gives support to the weight of the mast.
Move the crane to a position so the mast assem-
bly will be lifted vertically.
6. Remove the four large capscrews and washers
that fasten the bottom of the mast to the lift truck
frame. Hold the spacers and remove the four
large capscrews and washers that fasten the top
of the mast. Remove all the spacers.
WARNING
Lift chains
and cables can roll over the sheaves
to fall and p
ossibly cause an injury if the ends
are not fast
ened. Keep control of the ends of
the lift cha
ins and cables as they are discon-
nected.
7. Use a ladder
to disconnect the lift chains at the
top of the ou
ter mast weldment. Remove the pins
in the chai
n anchors to remove the chains with-
out changi
ng the adjustment. Carefully lower
the lift ch
ains. Disconnect the electrical wires
from the l
imit switches and remove the cables.
8. Remove th
e cross tube (horizontal) at the battery
side of th
ebottomofthemast.
9. Operate t
he crane and carefully move the mast
assembly
away from the lift truck. Do not dam-
age any hy
draulic lines or the electrical cable.
10. Put the ma
st assembly on the floor so the back
(battery
side)ofthemastistowardthefloor.
DISASSEM
BLE
NOTE: Th
is procedure does NOT include the removal
of the op
erator platform. R
emove the operator plat-
form bef
ore starting this procedure. See Operator
Platfor
m, Remove in this section to remove the op-
erator p
latform. See Figure 3 and Figure 4.
WARNING
Make sure the battery side of the mast is to-
ward the floor so the front of the mast is up for
easier disassembly. Make sure the mast weld-
ments are fastened together so the weldments
will only slide when being moved during disas-
sembly.
1. If necessary, remove the lift chains by removing
the pin in the chain anchor. Removing the pin
will allow chain removal without changing the
adjustment.
6
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