Lift Tek 80D-MS User manual

Service
Manual
80D/100D/110D - MS
Limited Free Lift 2-Stage Mast
Manual Part Number 253274 R3
Lift Technologies, Inc. 2013

Contents
Cover Page...................................................................................................................................... 1
Section 1Introduction ...................................................................................................................... 4
Section 2 Installation Instructions .................................................................................................... 5
Section 3 Periodic Maintenance .................................................................................................... 10
Section 4 Troubleshooting ............................................................................................................. 11
Section 5 Service .......................................................................................................................... 12

Page 4 253273 R3
Section 1Introduction
This manual provides the installation instruction, periodic
maintenance, troubleshooting and service procedures for
the Lift Tek Series masts.
In any communication about the mast, refer to the mast
serial number stamped in the nameplate. If the nameplate
is missing, these numbers are also stamped on the
left-hand upper cheekplate. See Figure 1.
WARNING: Do not install a Lift Tek Mast
on a truck with a capacity greater than the
truck rated capacities shown below
Modifications and additions which affect capacity or safe
operation shall not be performed without prior written
approval from Lift Technologies per ANSI B56. 1.
1.1
Special Definitions
WARNING
WARNING
1.2
Introduction
A statement preceded by is information
that should be acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION
A statement preceded by CAUTION is information that
should be acted upon to prevent machine damage.
IMPORTANT
A statement preceded by IMPORTANT that
possesses special significance.
NOTE
A statement preceded by NOTE is information that is handy
XXXXXX
XXXXXX
XXXX
XXXXXX
XXXX
OR
Example:
80D–MT–001–00025–M
Stamped
Serial
Numbers
MA2780.eps
Figure 1. Serial Mast Number Location
80D 100D 110D
8000 lbs. 10000 lbs. 11000 lbs.
(3629 kg) (4536 kg) (4989 kg)

253273 R3 Page 5
2.1 Truck System
Requirements
To achieve maximum lifting capacity of the mast, the
truck relief valve should be set to relieve at the pressure
indicated in the chart below. This chart also indicates the
hose fitting size to use between the truck control valve
and masts valve.
Section 2 Installation Instructions
Lift Tek Relief Hose Fitting*
Mast Pressure Size Size
80D/100D/110D 2600 psi No. 10 min. No. 10 min.
* Valve inlet port is 3/4 in. SAE O-ring. See Figure 2.
WARNING: For proper truck stability or to
prevent interference, tilt restriction may be
required. Contact the truck manufacturer.
IMPORTANT: Lift Tek Masts are compatible with SAE 10W
petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104
B only. Use of synthetic or aqueous base hydraulic oil is not
recommended. If fire resistant hydraulic oil must be used,
contact Lift Tek.
Mounting Bracket
Installation
2.2
1If it is necessary to install mounting brackets and cross-
members to fit your lift truck, consult with the nearest
Lift Tek Service Department listed on the back cover.
You must supply dimensions A through Fshown in
Figure 3. Failure to install the correct brackets and cross-
members can result in mast structural failure, bodily injury
and loss of warranty.
FigFigure 2. Valve inlet Port.
Figure 3. Determining Mounting Bracket Location.
WARNING: Failure to install the correct
brackets and crossmembers can result in
mast structural failure, bodily injury and
loss of warranty.
MA0022.eps
Valve Inlet Port
3/4 in. SAE O-ring
E
F
A
B
C
D
Truck Cowl
Tilt Cylinders
Front View
Side View
MA0031.eps

Page 6 253273 R3
Section 2 Installation Instructions
Mast Installation
1. Raise and block the front end of the truck 1ft. (30 cm) per
ANSI B56.1 or drive the truck over a service pit.
2. Install the bearings to lower the axle mounts.
3. Lubricate the bearing surfaces of the lower axle and tilt
cylinder mounting brackets with chassis grease.
4. Lift the mast using an overhead hoist with a lifting strap
routed under all the upper crossmembers. Position the mast
onto the lower the axle mounts on the truck axle. Install
the mount caps and capscrews. Tighten the capscrews
to the truck manufacturer’s torque specifications.
IMPORTANT: Prior to connecting the tilt cylinders to the
mast, make sure the cylinders “bottom” evenly. Adjust the tilt
cylinders to prevent the mast from “racking” during tilting.
Refer to your truck service manual for procedures.
5. Connect the lift truck hose to the mast valve.
6. Connect the tilt cylinders to the mast anchor brackets.
NOTE: Use as few fittings as possible and always use 45o
fittings instead of 90o fittings. Keep the hose lengths to a
minimum. Avoid sharp bends or pinch points when routing
the hose.
Tighten the pin capscrews to the truck manufacturer’s
torque specifications.
1
FiFigure 4. Mast Installation.
Contact Lift Tek if
additional fittings are
required. See back cover.
2.3
6
23
4
5
MA2702.eps
4

253273 R3 Page 7
Chain Inspection and
Tension
The hoist Chains have been factory lubricated using heat and
pressure to force the lubricant thoroughly into the chain links.
Avoid removal or contamination of this factory applied
lubricant. Do not wash, sand blast, etch, steam clean, or
paint the chains for internal mast installation.
If the mast has been cleaned using a pressure washer or
heavy detergents that may rinse the chain lubrication
out from within the links, then the recommended method
for reestablishing chain lubrication is to soak the chains
in SAE 40wt oil for at least 8 hours, preferably with the
oil heated to 100o F to 120oF to facilitate complete
lubricant penetration. Excess oil may be wiped off prior
to installation.
The chains must be adjusted with equal tension to ensure
proper load distribution and mast operation.To determine
equal tension, extend the unloaded mast to put the chains
under tension. Press the center of a strand of chain with your
thumb, then press at the same place on the other chain of the
pair. Each chain in a pair should have equal “give”. If they
do not have equal tension, preform the hoist chain adjust-
ments described below.
Hoist Chain adjustment
SEE SECTION 5.6-3.
Section 2 Installation Instructions
Inspection and
Adjustments
2.4
2.4-1
2.4-2
MA2778.eps
Carriage 2 in.
Below Outer
Upright
Outer Upright
and Carriage
Flush Outer
Upright
*3 in.
Underclearance
*5 in.
Underclearance
*NOTE: Underclearance is based on mast
production series, actual mast
underclearance may vary by truck model.
Figure 5. Upright and Carriage Position.
Upright Rail Lubrication
Lubricate the full length of each upright rail with chassis lube
or Kendall SR-12X as shown in Figure 6.
MA606.eps
Load
Rollers Upright
Channels
Lubricate only where indicated
by the heavy line for the full
length of each upright.
Figure 6. Channel lubrication.
2.4-3

Page 8 253273 R3
Mast Skewing
Cylinder Bleeding
2.4-4
Section 2 Installation Instructions
2.4-5
SEE SECTION 5.2-11.
SEE SECTION 5.5-6.

253273 R3 Page 9
Section 2 Installation Instructions
Internal Reeving Installation
2.5
Install carriage hose bracket.
Install the 90ofittings to the carriage bracket. Install the
hoses to the carriage fittings. Leave the fittings loose.
Install the hoses and sheaves to the hoist chain shaft.
Tighten the capscrew to a torque of 65 ft.-lbs. (88 Nm).
Washer (part no. 683794) may be required to add
clearance between the sheave and casting.
Pull hoses down to the middle crossmember. Attach the
hoses to the bracket fittings. Leave the fittings loose on
the bracket.
Pull down on the hoses to remove slack. Attach the
bracket to the front side of the crossmember. See the
bracket and fitting assembly options below. Tighten the
capscrew to a torque of 38 ft.-lbs. (51 Nm).
Raise and lower the mast several times to make sure the
hoses are tracking correctly. Use the white lines on the
hoses to detect twisting. Adjust the hose ends if re-
quired. Tighten fittings making sure they do not twist.
1.
2.
3.
4.
5.
6.
MA2704.eps
OR
IHR with #8 Hoses
IHR with #6 Hoses
and #8 Fittings
Figure 7.Internal Reeving Installation

Page 10 253273 R3
Section 3 Periodic Maintenance
Periodic Maintenance
For proper operation and an extended service life, your
Lift Tek Mast should be inspected and serviced regularly
as part of your normal lift truck maintenance schedule accord-
ing to the following outlines and ANSI B56.1 procedures.
The recommended intervals are for masts operating under
normal conditions. If the mast is operating in severe conditions
or corrosive atmospheres, the inspections should be per-
formed more frequently.
WARNING: Never work on the mast with a load
on the forks or attachment, in the raised position
without supports or while anyone is near the lift
truck control handles per ANSI B56.1
Daily Inspection
Perform the following at the beginning of each work shift:
1. Extend the carriage a few inches off the ground and make
sure the chains are under equal tension. Refer to Section
5.6-3 for chain adjustment.
2. Extend the mast to its fullest height to make sure the mast rails
and carriage extend freely without binding.
3. While the mast is extended, inspect the upright rails for
proper lubrication. Refer to Section 2.4-3 for rail
lubrication.
4. Make sure the internal reeving hoses (if equipped) travel
evenly in the hose guides. Adjust the hose ends if re-
quired. Tighten the fittings making sure they do not twist.
5.In applications with high humidity or condensation, chain
lubrication as described under Item 1 of the 100 hour
inspection may be needed more frequently to reduce the
risk of corrosion.
100 Hour Inspection
After each 100 hours of lift truck operation, and in addition to
the daily inspection:
1. Inspect and lubricate the full length of the chains with SAE
40 wt. oil or equivalent.
CAUTION: The chains must be coated with a film of lubricant
at all times.
500 Hour Inspection
After each 500 hours of lift truck operation, and in addition to
the Daily and 100 Hour Inspection:
1. Each pair of load rollers on the uprights and carriage
should be shimmed so that a total side to side clearance
no greater than 1/16 in. (1.5 mm) occurs at the tightest
point throughout the travel of the member. Pry between
the upright and load roller so that the opposite load roller
is tight against the upright. Measure the clearance for the
pair of rollers at XXX shown. See Figure 8.
2. Check the chains for wear and stretch. Refer to Section
5.6-1 for complete chain inspection.
3.1
3.1-1
MA2705.eps
Pry Here Load Rollers
.06 in.
(1.5 mm)
MAX.
Figure 8. Load Roller Clearances.

253273 R3 Page 11
Section 4 Troubleshooting
The following table lists problems that may be encountered on your Lift Tek Mast, the probable causes and rec-
ommended corrective action that should be taken to restore the mast to normal operating condition.
PROBLEM PROBABLE CAUSE SOLUTION
Empty a
)
Plu
gg
ed inlet hose a
)
Unplu
g
hose or replace.
b
)
Insufficient oil. b
)
Check the truck hydraulic system fo
r
correct oil level in tank, defective pump or
pump drive, leaks in the lines or
disconnect control valve linkage. Repair
or replace as necessary.
c
)
Bent or jammed plun
g
er. c
)
Repair or replace as necessary.
Loaded a
)
Plu
gg
ed piston check valve. a
)
Unplu
g
check valve or replace.
b
)
Truck relief valve settin
g
low. b
)
Raise truck relief settin
g
to specified level
c
)
Over capacity. c
)
Reduce load to specified capacity.
d
)
Mechanical bind due to bent plun
g
er d
)
Remove mechanical bind by
or bad rollers. replacing/freeing plunger and rollers.
Cylinders drift a
)
External leak in pressure line. a
)
Ti
g
hten or replace as necessary.
b
)
Truck valve defective-cycle to full b
)
Repair or replace truck valve.
lift height to verify.
c
)
External leaks at retainer. c
)
Replace all cylinder seals.
d) Piston check valve leaking. d) Replace check valve.
Spongy or jerky action a
)
Sticky or defective truck relief valve. a
)
remove and check the truck relief valve. If
contaminated oil caused the malfunction,
drain and flush the system, change the
filter and refill with fresh oil.
b
)
Bent or dama
g
ed cylinder plun
g
er. b
)
Disassemble, check and repair cylinde
r
assembly.
c
)
Load rollers not properly adjusted c
)
Adjust or replace as necessary.
or defective.
d
)
Mast channels improperly lubricated. d
)
Lubricate mast.
e
)
Low Battery char
g
e. e
)
Char
g
e battery.
f
)
Low pump volume. f
)
Install accumulator.
g)
Low oil level.
g)
Fill oil reservoir.
h
)
Insufficient hydraulic tank capacity h
)
Install lar
g
er tank baffles
or baffles.
Weldments banging
durin
g
lowerin
g
a
)
Insufficient cushion oil exists belo
w
a
)
Replace Main Lift cylinder seals.
the Main Lift cylinder to properly
dampen the Weldment transition.
Cylinders don’t lift load
or won't move
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a
load) is in the raised position.

Page 12 253273 R3
6
23
4
5
MA2706.eps
4
Section 5 Service
Mast Removal
1. Raise and block the front end of the truck 1ft. (30cm) or
drive the truck over a service pit.
2. Disconnect the lift truck supply hose from the mast
valve. Plug the hose end and cap the valve fitting.
WARNING: Do not stand on or near the mast
while suspended by the hoist.
3. Attach overhead hoist with lifting strap routed under all upper
crossmembers. Take up slack in the chain.
4. Disconnect the tilt cylinders from the mast anchor
brackets. For reassembly, tighten the pin capscrews to
the truck manufacturer’s torque specifications.
5. Disconnect the mast lower mounts. For reassembly,
tighten the capscrews to the truck manufacturer’s torque
specifications.
6. Lift away the mast.
7. For mast installation, refer to Section 2.3.
WARNING: Do not stand the mast upright
unless it is chained to a support.
5.1
Figure 9. Mast Removal

253273 R3 Page 13
Figure 10. Main Lift Cylinder
Cylinders
2600 PSI Main Lift Cylinder
Description
The main lift cylinders are a single stage displacement type
cylinders. They consist of a shell and a telescoping
rod/piston assembly. During extension the oil pressure
is acting against the rod outer diameter due to the
internal porting through the piston. The piston seals do not
affect cylinder extension. The truck hoist control valve
holds the cylinders in place once extension has stopped.
The shell is internally threaded at the top end to hold the
retainer. The retainer seals provide a high-pressure hy-
draulic seal against the rod. The retainer also limits the
upward stroke of the rod.
A piston is attached to the bottom end of the rod. The
piston seal provides a high-pressure hydraulic seal against
the shell that engages the cushion valve when the cylinder
is fully lowered.
A external hydraulic fuse/cushion is installed in the cylinder
port. In case of a hose failure between the lowering control
valve and cylinders, the fuse limits the lowering speed of
the cylinder. The valve also cushions the piston when the
cylinder nears the fully lowered position.
5.2-2
MA2707.eps
FREE FLOW <<<-----
External Hydraulic Fuse
( RIGHT HAND SIDE ONLY )
Retainer
Shell
Piston / Rod
Assembly
Section 5 Service
For PID Numbers only:
80D-MS-001 Through 80D-MS-177
100D-MS-001 Through 100D-MS-162
110D-MS-001 Through 110D-MS-008

Page 14 253273 R3
Cylinders
2600 PSI Main Lift Cylinder
Description
The main lift cylinders are a single stage displacement type
cylinders. They consist of a shell and a telescoping
rod/piston assembly. During extension the oil pressure
is acting against the rod outer diameter due to the
internal porting through the piston. The piston seals do not
affect cylinder extension. The truck hoist control valve
holds the cylinders in place once extension has stopped.
The shell is internally threaded at the top end to hold the
retainer. The retainer seals provide a high-pressure hy-
draulic seal against the rod. The retainer also limits the
upward stroke of the rod.
A piston is attached to the bottom end of the rod. The
piston seal provides a high-pressure hydraulic seal against
the shell that engages the cushion valve when the cylinder
is fully lowered.
A external hydraulic fuse/cushion is installed in the cylinder
port. In case of a hose failure between the lowering control
valve and cylinders, the fuse limits the lowering speed of
the cylinder. The valve also cushions the piston when the
cylinder nears the fully lowered position.
5.2-2
MA2708.eps
275 PSI
Retainer
Shell
Piston / Rod
Assembly
External Hydraulic Fuse
( RIGHT HAND SIDE ONLY )
Figure 11. Main Lift Cylinder
For PID Numbers only:
80D-MS-178 Through Present
100D-MS-163 Through Present
110D-MS-009 Through Present
Section 5 Service

253273 R3 Page 15
Section 5 Service
Cylinder Operation
Cylinders Raising
1. When the truck hoist control valve is actuated, oil enters
the lowering control valve through the inlet port and
flows unrestricted through the lowering control car-
tridge.
2. Oil flows to the cylinder inlet ports. Due to the larger
bore diameter of the free lift cylinder compared to both
main lift cylinders, the free lift cylinder will raise com-
pletely before the main lift cylinders raise.
3. 2600 PSI Displacement Type Main Lift Cylinders- Oil
flows through the hydraulic fuse/cushion valve to the
piston. The piston is internally ported to allow oil flow to
the area between the rod and shell. Lifting force is
created that acts on the diameter of the rod
causing the rod to raise.
4. When oil flow from the truck hoist control valve is
discontinued, the cylinders are held in position by the
closed center spool of the truck valve.
Cylinders Lowering
1. When the truck hoist control valve is actuated, the main
lift then free lift cylinder rods lower, forcing oil out
through the hydraulic fuse/cushion valves.
NOTE: The restriction setting of each hydraulic fuse is
lower (allows more oil flow) than the setting of the
lowering control valve. The hydraulic fuses restrict flow
only in the instance of a lowering control valve or hose
failure.
2. Oil flows to the lowering control valve where it is re-
stricted at a controlled speed determined by the load
being handled.
3. As the main lift cylinder pistons lower over the spear in
the bottom of the shell, a high pressure area is devel-
oped between the piston and shell which engages the
cushion valve to restrict flow. This slows the piston/
rod just prior to bottoming providing a smooth
transition to the free lift cylinder lowering.
5.2-4
Shell
Inlet Port
To Truck Valve
Rod
Check Valve
Not used in Main Lift
2000 psi cylinders
Piston
Hydraulic Fuse/
Cushion Valve
Lowering
Control Valve
Main Lift Cylinder Main Lift Cylinder
Figure 12. Cylinder Operation

Page 16 253273 R3
Section 5 Service
Main Lift Cylinder Removal-
Mast on Floor
3. Remove the mast from the truck as described in
Section 5.1
2. Lay the mast down on wooden blocks as shown. Block
under the outer upright so the inner upright will be free
to move. The carriage must be positioned between the
blocks and free to move.
3. Disconnect the cylinder supply hoses from the cylinder
inlet ports. Remove the special long fittings from the
cylinder ports and install plug fittings. NOTE: Each
fitting holds a compressed spring in place.
4. Remove the snap rings fastening the cylinder rods to
the inner upright.
5. Pull the inner upright outward 2 ft. (60 cm).
6. Lift the cylinder from the base mount and angle inward
to remove through the gap at the top of the uprights.
7. Note the number of shims (if equipped) on each
cylinder rod.
8. For reassembly, reverse the above procedures except
as follows:
WARNING: Main lift cylinders must be bled to
remove trapped air prior to returning the mast
to operation. Refer to Section 5.2-4.
5.2-4
6
Figure 13. Cylinder Removal.
3
6
7
6
5
2
6
MA2709.eps

253273 R3 Page 17
Main Lift Cylinder Service
1. Remove the cylinder from the mast as described in
section 5.2-4.
2. Use a claw type spanner wrench to remove the
retainer. See Figure 14.
3. Remove the plunger/piston assembly from the shell.
4. Remove the Hydraulic Fuse/Lowering Cushion
components.
5. Inspect all components for nicks or burrs. Minor nicks
or burrs can be removed with 400 grit emery cloth.
NOTE: Minor nicks are those that will not bypass oil
when under pressure. If they cannot be removed with
emery cloth, replace the part. If the piston requires
replacing, refer to Section 5.2-10.
6. Replace the retainer and piston seals, back-up rings
O-rings and bearing. Lubricate the new seals with
petroleum jelly prior to installation. Note the correct
seal directions. The cylinder will not operate
correctly if the seals are installed backwards.
7. When replacing the piston check valve O-ring, make
sure the check valve is reinstalled with the arrow
pointed in the correct direction.
8. Install the plunger retainer on the plunger. Install the
plunger/piston assembly into the cylinder shell.
Tighten the retainer to the torque value listed below
using the claw spanner wrench and a strap wrench.
Section 5 Service
5.2-6
Figure 15. Cylinder Service.
MA2710.eps
Retainer
Piston / Rod
Assembly
External Hydraulic Fuse
2
3
7
4
Check Valve
MA0071.eps
Figure 14. Claw Type Spanner Wrench.

Page 18 253273 R3
Section 5 Service
Piston Removal
1. Remove the rod/piston assembly from the cylinder shell as
described in Section 5.2-6.
2. Use a strap wrench and 400 grit emery cloth to secure the
rod while turning the piston with a pin type spanner wrench
3. Turn the piston until the snap wire end is visible through the
hole. Use a screwdriver to start the wire end out the hole.
Turn the piston to feed the wire out.
4. Pull the piston from the rod.
5. For reassembly, reverse the above procedures except as
follows:
*Install a new snap wire when installing the piston.
Cylinder Bleeding
WARNING: The cylinders must be bled to
remove air. Air in the cylinders will compress
on the first extension which could rupture the
cylinders causing serious bodily injury and
property damage.
After repair, the cylinders may have air trapped in them that
must removed. To bleed air do the following:
1. Without a load extend the free lift cylinder and con-
tinue to extend the main lift cylinders to 90% of full
stroke. Retract all cylinders completely. Repeat
three times.
2. Extend the cylinders without a load at 50% full engine
speed then build to full system pressure at the end of
the main lift cylinder stroke. Electric trucks - limit the
control valve movement to achieve 50% speed.
Retract all cylinders. Repeat four times.
3. Cycle the mast with a half load (50% mast rated
capacity) through full cylinder extension several times.
The cylinders should extend smoothly. Repeat the
steps if cylinder extension is not smooth.
Valve
Valve Cartridge Service
1. Completely lower the mast.
2. Remove the truck supply hose from the valve car-
tridge. See Figure 17. Plug the hose.
3. Remove the valve cartridge from the valve. Note the
stamped part no. on the cartridge for ordering a
replacement.
WARNING: Replacing the valve cartridge with
a different part no. cartridge may cause the
mast to malfunction.
4. For reassembly, reverse the above procedures.
5.2-10
5.2-11
5.3
5.3-1
Figure 16. Piston Removal.
MA0677.eps
Figure 17. Valve Cartridge Service.
2
MA0937.eps
3

253273 R3 Page 19
Section 5 Service
Carriage
Description
The carriage shown below is the structure that hook-type
forks or attachments are attached. The carriage travels
within the rails of the mast inner upright on six (or eight
optional) rollers. On a six roller carriage only the bottom
four rollers are shim adjustable whereas the top rollers are
not shim adjustable and are held in place by a retainer plate.
On an eight roller carriage only the middle four rollers are
shim adjustable, whereas the top and bottom rollers are not
shim adjustable and are held in place by a retainer plate.
The rollers are held in the uprights. All load rollers are
interchangeable. There are four side thrust rollers to transfer
carriage side loading to the inner rails.These rollers are
eccentrically adjustable. A pair of chain anchors are used
to connect the carriage chains to the carriage.
5.4
5.4-1
Figure 18. Carriage Service.
MA2711.eps
Side
Thrust
Roller
Snap Ring
Shim
Carriage Weldment
Load Roller
Chain
Pin
Cotter
Pin
Chain
Anchor
Retainer

Page 20 253273 R3
Section 5 Service
Carriage Removal- Mast on Truck
1. Raise the mast high enough to 6 in. (15 cm) long 2 X 2
(5 X 5 cm) angle iron between the top of the main lift
cylinder and the crossmember. See Figure 24. Avoid
contacting the cylinder rod seal. Lower the crossmember
onto the angle iron.
2. Attach an overhead hoist to the carriage. Raise the
carriage to slacken the carriage chains.
3. Remove the chain anchors.
4. Disconnect the internal reeving hoses from the
carriage fittings (if equipped). Plug the hose ends.
5. Using the overhead hoist, lower the carriage to the
bottom of the mast to remove.
6. Note the number of shims behind each load roller for
reassembly.
7. For reassembly, Refer to Section 5.4-5.
5.4-2
MA2712.eps
2
4
2
2
1
5
Snap
Ring
3
MA2713.eps
7
7
Snap Ring
Shim
3
MA2714.eps
Angle Iron
2
Figure 19. Carriage Service.
Figure 20. Carriage Service.
Figure 21. Carriage Service.
WARNING: The inner upright must be sup-
ported by angle iron to avoid possible injury.
WARNING: The carriage must be supported by
a block to avoid possible injury.