REPLACING A PULLEY
Follow this procedure to replace a pulley without
having to fully disassemble the mast.
Refer to related parts diagrams in Section 5.
NOTE: Fully lower the Fork Carriage.
❑ Unwind one to two feet (about 30 to 61 cm) of
cable from the winch reel.
❑ Using a crane and/or two or more technicians,
the machine is positioned on its back with the
Push Tube Weldment placed in the second
highest position, so that the machine is resting
on the rear of the base (or transport wheels if
equipped) and the wheels on the Push Tube
Weldment. In this case, the Push Tube Wheels
should be placed on a pallet or two stacked
pallets (or other similar firm structure acting as
a spacer) to ensure the mast is parallel to the
ground.
❑ If replacing the upper pulley on a mast, slide
the mast in front of the pulley to be replaced. If
replacing the lower pulley on a mast, slide the
mast containing the pulley to be replaced.
❑ Slide the appropriate mast forward to expose
the Mast Down Stop (M00062).
❑ Remove the flat head screw that attaches the
mast Down Stop (M00062) to the mast.
❑ Remove the Down Stop. Slide out the
appropriate mast backward until the pulley to
be replaced is exposed.
❑ Remove the cap screw that attaches the pulley
to the pulley assembly on the mast being
repaired.
❑ Replace the pulley using the same fastener
hardware (screws and washers) used to mount
the original pulley. Install the cable into the new
pulley during the replacement process and
ensure Pulley Guard index hole is aligned to
the index point on the Pulley Mount. Use Red
Loc-Tite® on the Pulley cap screw and torque
to specification.
Note: The fasteners (screws and washers) used to
mount the pulleys vary by mast and/or position.
Reference parts diagrams in Section 5 for the
appropriate cap screw length and the amount and
type of nuts and washers.
❑ Slide the mast forward (back into the mast
assembly).
❑ Attach the Down Stop and install the flat head
screws.
❑ Repeat this procedure as needed for each
pulley to be replaced.
NOTE: Make sure that each Down Stop mounting
screw is tightened and that Blue Loctite®, or
equivalent, has been applied to the screw’s
threads.
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