Document Outline

• INTRODUCTION - operation/safety precautions
• INTRODUCTION - Maintenance safety precautions
  • General
  • Hydraulic System Safety
  • Maintenance Safety
• Effectivity Changes
• TABLE OF CONTENTS
• Section 1. specifications
  • 1.1 Capacities
    • Hydraulic Oil Capacity
  • 1.2 Component Data
    • Hydraulic Pump/Electric Motor Assembly
  • 1.3 Performance data
    • Machine Specifications
  • 1.4 Torque Requirements
  • 1.5 Hydraulic Pressure Adjustment
  • 1.6 Cylinder Specifications
  • 1.7 Serial Number Locations
  • 1.8 Lubrication
    • Hydraulic Oil
    • Lubrication Specifications
• Section 2. SERVICE PROCEDURES
  • 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
    • General
    • Preparation, Inspection, and Maintenance
    • Pre-Start Inspection
    • Pre-Delivery Inspection and Frequent Inspection
    • Annual Machine Inspection
    • Preventative Maintenance
  • 2.2 Preventive Maintenance and Inspection Schedule
  • 2.3 Servicing and Maintenance Guidelines
    • General
    • Safety and Workmanship
    • Cleanliness
    • Components Removal and Installation
    • Component Disassembly and Reassembly
    • Pressure-Fit Parts
    • Bearings
    • Gaskets
    • Bolt Usage and Torque Application
    • Hydraulic Lines and Electrical Wiring
    • Hydraulic System
    • Lubrication and Servicing
    • Mast Chain Inspection Procedure
  • 2.4 Lubrication Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.5 Machine Bolt Down Specification
  • 2.6 AC Junction Box Components
  • 2.7 hydraulic LIFT pump - servicing
    • MONARCH BRAND PUMP - Brush Replacement
    • Motor Assembly - Remove/Install - Reference Marks
    • Motor/Brush Cover - Remove/Install
    • Brush Carrier Assembly - Remove/Install
    • Brush Assembly - Remove/Install
    • TANK AND PUMP REMOVAL - (All Pumps)
    • Tank Installation
    • Filter Screen Installation
    • Pump Installation
    • Pressure Adjust Valve Installation
    • Pressure Check Valve Installation
  • 2.8 Hydraulic Lift Cylinder - Removal, Inspection and rebuild
    • Mast Removal
    • Cylinder Removal From Mast
    • Cylinder Disassembly
    • Lift Cylinder Component Inspection
    • Cylinder Assembly
    • Cylinder Installation
  • 2.9 15BD- MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
    • 15BD - Mast Disassembly Procedure
    • 15BD - Mast Assembly
    • Mast To Base Frame Installation
    • Mast Chains Adjustment - 15BD
  • 2.10 19BD - Mast Assembly and Disassembly Procedure
    • 19BD - Mast Disassembly Procedure
    • 19BD - Mast Assembly
    • Mast To Base Frame Installation
    • Mast Chains Adjustment - 19BD
  • 2.11 Sequencing Cable Adjustment
  • 2.12 Sequence Cable replacement kit
    • Remove Old Cable
    • Replacement Cable Installation
    • Clamp Installation (Drum/Socket Type)
• Section 3. troubleshooting
  • 3.1 General
  • 3.2 Troubleshooting Information
  • 3.3 Hydraulic Circuit Checks
  • 3.4 ELECTRICAL SYSTEM - MULTIMETER BASICS
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 3.5 ELECTRICAL SWITCH TESTING
    • Basic Check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side