Assemble
1.
Assemble the integral sideshift cylinder. See
the Cylinder Repair manual listed in the
General section of this manual for procedures.
2.
If lube fittings were removed, install new lube
fittings into outer frame. See Figure 12.
NOTE: Use a wood block or a plastic hammer to
fully seat upper bearings onto inner frame. Proper
lower hook clearance requires the upper bearings
be fully seated.
3.
Apply a 1 mm (0.040 in.) layer of multipurpose
grease to upper and lower bearing surfaces. In-
stall upper and lower bearings into the inner
frame. Bearings snap into place. See Figure 15.
Install
1.
Install integral sideshift cylinder onto carriage.
See Cylinder Repair manual listed in the
General section of this manual for procedures.
2.
Insert a M12 x 1.75 lifting eye in hole on top of
outer frame. Use a crane with a capacity of at
least 78 kg (172 lb) and install outer frame onto
inner frame. See Figure 12.
3.
Install lower mounting hooks using four cap-
screws. Tighten to 150 to 180 N•m (108 to
132 lbf ft). For proper sideshift operation, make
sure there is 0.76 to 1.52 mm (0.03 to 0.06 in.)
clearance between the bottom of the hooks and
the outer frame. See B in Figure 14.
4.
Connect hydraulic hoses, as noted during re-
moval, to sideshift cylinder. See Figure 11.
5.
Install load backrest to sideshift carriage.
Tighten capscrews to 195 N•m (144 lbf ft). See
Figure 9.
6.
Install forks. See Fork Replacement section for
procedures.
FORK POSITIONER CARRIAGE
Remove
NOTE: The fork positioner can be removed from
the integral sideshift carriage with integral side-
shift carriage on or off the mast. In the steps below,
the fork positioner is removed with integral side-
shift carriage on the mast. If integral sideshift car-
riage must be removed from mast first, go to Inte-
gral Sideshift Carriage in this section for proce-
dures.
1.
Remove forks. See Fork Replacement section
for procedures.
2.
Remove four capscrews and load backrest from
carriage. See Figure 9.
WARNING
Before disconnecting the hydraulic hoses, relieve
the pressure in the hydraulic system. Serious in-
jury can occur if pressure is not relieved from hy-
draulic system prior to disconnecting hydraulic
hoses.
WARNING
Always wear the proper protective equipment in-
cluding eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
WARNING
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.
Carriages Repair, Two-Stage LFL Mast 4000 SRM 1999
18
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