INSTALLATION INSTRUCTIONS South Highway 11 Westminster, SC Toll Free (888) (864) FAX (864)

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Moses Washington
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1 These instructions apply to the servicing of the Lift Technologies MaxiMizer Integral Sideshifters Cylinder Head. WARNING! Unless the steps in the following Installation Instructions are properly followed the repair may not be successful, thus requiring repeat repairs. Seal installation and gland nut re-installation procedures have changed as of August Please review carefully pages 3-5 for proper installation instructions. Also, review definitions for documentation on page 2. NOTE: Under normal conditions the cylinder head should not have to be removed to repair the ISS. However, the following specific steps are critical to a proper repair if the cylinder head is removed (Ref. ISS Cylinder Head Torque Check Section, page 11, to determine if removal required): 1. Clean dry surfaces for Loctite application 2. Proper amount and type of Loctite & Activator 3. Correct installation torque 4. Minimum cure time of 1 hour must be allowed Rev-6 Page 1 of 37

2 In order to more clearly report field problems and assist with proper evaluation of the issues the following definition of terms should be followed: Rod Seal Leak: Leak that occurs between the gland nut and rod through the wiper and seal connections. O-Ring Leak: Leak that occurs between the gland nut and cylinder block through the o-ring connection. Backing Off: Condition that occurs when there is a visible gap between the gland nut and cylinder block. The general term of Gland Nut Leak should be avoided. Instead use one of the above terms to better define the problem. Rev-6 Page 2 of 37

3 Proper Installation of New ISS Rod Seal Lubricate the seal with hydraulic oil and install it into the second slot from the unthreaded side of the Cylinder Head with the groove in the seal facing the inside of the cylinder. Start one side of the seal into the groove as shown. U-cup Seal with o-ring facing towards cylinder Rev-6 Page 3 of 37

4 Use one thumb to guide the seal into the groove and other to apply force. Roll the seal around the groove using both thumbs until the seal snaps into the groove. Be sure that the o-ring in the seal does not come out of the seal groove during installation. The seal should be seated properly in the groove as shown below. Properly seated U Cup seal Rev-6 Page 4 of 37

5 Procedure for Use of Activator on Gland Nut Threads Spray loctite 7649 Primer on 360º of the threads on the cylinder block. Allow primer to sit approximately 1 minute before applying red loctite. Rev-6 Page 5 of 37

6 These instructions apply to the servicing of the Lift Technologies MaxiMizer Integral Sideshifters Cylinder Head. Tool Requirements: 1. Cylinder repair kit. This kit includes two O rings, two seals, two wipers and one protective sleeve. Part number Cylinder Head removal / installation socket and 3/16 dowel pin (Part number ) or Cylinder Head removal / installation tool (Part Number ). 3. Loctite Threadlock 277 and Loctite Activator 7649 for cylinder head / cylinder block and Loctite Threadlock 243 for lower carriage claw bolts. 4. ½ inch drive ratchet. 5. 3/4 inch socket. 6. Torque wrench with minimum torque value of 170 ft/lbs for ½ inch socket. 7. 8mm Allen socket head wrench. 8. Oil drain pan. 9. Floor dry. 10. Clean white rags. 11. Brake cleaner or isopropyl alcohol. 12. High temperature grease degree pick tool. Rev-6 Page 6 of 37

An untreated Cylinder Head is used to better show the steps of the assembly. One Protective Sleeve.

7 ISS Cylinder Head Seal and O Ring Assembly Parts The following picture illustrates the required parts for U Cup Seal, Cylinder Rod Wiper and O Ring replacement for the Cylinder Head. An untreated Cylinder Head is used to better show the steps of the assembly. One Protective Sleeve. Two seal sets - One U Cup Seal, One O Ring and one Cylinder Rod Wiper per set. Cylinder Rod Wiper O Ring BD U-Cup Seal Rev-6 Page 7 of 37

ISS Front Frame Removal 1. Remove the backrest from the carriage per manufacturer s instructions. 2. Remove forks from the carriage per manufacturer s instructions. 3.

8 ISS Front Frame Removal 1. Remove the backrest from the carriage per manufacturer s instructions. 2. Remove forks from the carriage per manufacturer s instructions. 3. Raise carriage on the mast to eye level. WARNING: YOU MUST PUSH THE TWO CYLINDER RODS INTO THE CYLINDER BLOCK PER THE FOLLOWING STEPS TO AVOID INJURY. PRIOR TO PUSHING THE RODS INTO THE CYLINDER BLOCK THEY ARE UNDER HIGH PRESSURE! 4. Push the cylinder rods into the cylinder block through the cylinder heads as shown in the following photo. In order to relieve the pressure in the hydraulic circuit, sit in the seat of the truck and with the key turned on (but with the engine not running) cycle the sideshift lever from full forward to full back. Next, remove one sideshifter hose from its lower fitting and manually push front frame towards opposite side till the rod is fully retracted. Reattach hose to fitting and retighten. Repeat the operation on the other sideshifter hose to collapse second rod into cylinder block. Rev-6 Page 8 of 37

9 5. Remove the six lower carriage claw bolts from the front frame lower bar and claws with 8mm Allen wrench. Rev-6 Page 9 of 37

10 6. Lower carriage to ground level until it stops. 7. Remove the front frame by lifting it out and upwards away from the front of the mast channels. 8. Place the front frame flat down on pallet or blocks to prevent damage to the paint. 9. Remove key from truck and lock-out truck for the rework procedure. Rev-6 Page 10 of 37

11 ISS Cylinder Head Torque Check 1. Check for presence of the wear pads to ensure none were removed during disassembly. Three upper wear pads are to be on top of the cylinder block, two small face wear pads or one long face wear pad on the face of the cylinder block and 3 lower wear pads on the face of the lower spine bar. If any are missing, review front frame to see if they are attached to the front frame inner surface. 2. Place oil drain pan under the lower spine bar directly below one of the cylinder heads. 3. Place a white rag on top of the lower spine bar to reduce oil spill during removal of the cylinder head. Rev-6 Page 11 of 37

12 4. Place the cylinder head removal / installation socket onto the cylinder head and align the holes of the socket and the cylinder head. 5. Insert a dowel pin into a hole and ensure it is seated completely. Rev-6 Page 12 of 37

13 6. Use the 3/4 inch socket and cylinder head socket tool to check tightness of the Cylinder Head. Slowly increase the counterclockwise torque applied to the cylinder head and if once 170ft*lbs is applied, the Cylinder Head does not move, stop and skip to installation instruction section titled ISS Fixed Cylinder Head Rebuild (page 27). If the Cylinder Head breaks loose with less than 170ft*lbs of torque proceed to the installation instruction section titled ISS Rebuild with Cylinder Head Removal (page 14). Rev-6 Page 13 of 37

14 ISS Rebuild with Cylinder Head Removal 1. If the Cylinder Head broke loose with less than 170ft*lbs, thread Cylinder Head fully off and let oil drain into the oil pan and remove the cylinder head assembly from the cylinder block. Be sure not to scratch the cylinder rod on the cylinder block threads during removal of the cylinder head assembly. 2. Rest the cylinder rod on a piece of wood and push the cylinder head all the way down the cylinder rod towards the rounded end and remove the cylinder head from the rod. 3. Use the 90 degree pick tool to remove the O ring, wiper and seal from the cylinder head. Discard O ring, wiper and seal after removal. 4. Clean the cylinder head threads with brake fluid or isopropyl alcohol and a white rag to completely remove oil film from the cylinder head threads. Rev-6 Page 14 of 37

15 5. Place the blank cylinder head on a flat surface and slide the protective sleeve over the threads of the cylinder head completely to protect the O ring during installation. Rev-6 Page 15 of 37

Inspect the seating of the O ring after the removal of protective

16 6. Lubricate the O ring with hydraulic oil and slide the O ring over the protective sleeve. O ring Direction 7. Inspect the seating of the O ring after the removal of protective sleeve to ensure the O ring is completely seated in the O ring groove. Rev-6 Page 16 of 37

17 8. Lubricate the seal with hydraulic oil and install it into the second slot from the unthreaded side of the Cylinder Head with the o-ring in the seal facing the inside of the cylinder. Start one side of the seal into the groove as shown. U-cup Seal with o-ring facing downward Rev-6 Page 17 of 37

Be sure that the o-ring in the seal does not come out of the seal groove during

18 Use one thumb to guide the seal into the groove and other to apply force. Roll the seal around the groove using both thumbs until the seal snaps into the groove. Be sure that the o-ring in the seal does not come out of the seal groove during installation. The seal should be seated properly in the groove as shown below. Properly seated U Cup seal Rev-6 Page 18 of 37

facing down, install the cylinder rod wiper with the lip facing upwards

19 9. Lubricate the cylinder rod wiper with hydraulic oil. With the cylinder head seated on a flat surface and with the threads facing down, install the cylinder rod wiper with the lip facing upwards into the first slot on the cylinder head. Ensure it is completely seated. Rev-6 Page 19 of 37

Lubricate the installed U Cup and wiper seal with hydraulic oil and install the completely assembled cylinders head on

20 Completely assembled cylinder head with seals and O ring. Fully assembled cylinder heads 10. Repeat the above steps for the second cylinder head. 11. Lubricate the installed U Cup and wiper seal with hydraulic oil and install the completely assembled cylinders head on the cylinder rods. Install the cylinders head on the rods by sliding them over the rounded end of the rods. DO NOT INSTALL THE CYLINDER HEAD OVER THE TAPERED END OF THE ROD. Push direction Rev-6 Page 20 of 37

21 12. The mating surfaces between the cylinder head and cylinder block must be free from paint build up. Remove any paint if necessary ensuring no metal is removed in the process. Rev-6 Page 21 of 37

22 13. Blow out the cylinder block bore with an air gun and clean the cylinder block threads and bore with brake cleaner or isopropyl alcohol and white rags. All threads must be free from oil. Rev-6 Page 22 of 37

23 14. Inspect the threads and O ring seating surface. The chamfer machined surface on the cylinder block must be free from any burrs or filings. Remove filings or burrs if necessary. 15. Spray loctite 7649 Primer on 360º of the threads on the cylinder block. Allow primer to sit approximately 1 minute before applying red loctite. Rev-6 Page 23 of 37

Do not apply Loctite onto the cylinder head threads. 17.

24 16. Place a ¾ diameter circle of Loctite 277 onto the lower area of the cylinder block threads. Ensure no Loctite is in the first thread. Do not apply Loctite onto the cylinder head threads. 17. Insert the cylinder rod / cylinder head assembly into the cylinder block. Be sure the alignment of the threads is correct to avoid cross threading. Rev-6 Page 24 of 37

25 18. Tighten the cylinder head / cylinder rod assembly until the cylinder head is completely seated on the cylinder block. 19. Push the cylinder rod completely into the cylinder block. Rev-6 Page 25 of 37

26 20. Use the removal / installation socket tool and dowel pin to torque the cylinder head. Be sure you align the holes of the socket tool with the cylinder head and that the dowel pin is completely seated in the holes. TORQUE THE CYLINDER HEAD TO 170 FT/LBS +/- 10 FT/LBS FOR PROPER REPAIR. Rev-6 Page 26 of 37

27 21. Inspect the gap between the cylinder head and cylinder block mating surface. Maximum gap allowed is 0.1mm (0.003 ). 22. Repeat the above steps for the other side. 23. Clean all external surfaces of the rear spine frame of any hydraulic oil. 24. Proceed to Reinstallation of Front Frame (page 30). Rev-6 Page 27 of 37

28 ISS Fixed Cylinder Head Rebuild 1. Remove rods from assembled spine cylinder. Direction Rev-6 Page 28 of 37

29 2. Remove wiper and seal with 90 degree pick. Wiper Seal Rev-6 Page 29 of 37

Lubricate the seal with hydraulic oil and install it into the inner slot of the Cylinder Head with the o-ring in the seal facing the inside of the cylinder.

30 Lubricate the seal with hydraulic oil and install it into the inner slot of the Cylinder Head with the o-ring in the seal facing the inside of the cylinder. Start one side of the seal into the groove as shown. O-ring faces cylinder block Use one thumb to guide the seal into the groove and other to apply force. Roll the seal around the groove using both thumbs until the seal snaps into the groove. Be sure that the o-ring in the seal does not come out of the seal groove during installation. Rev-6 Page 30 of 37

Lubricate the cylinder rod wiper with hydraulic oil and install it

31 The seal should be seated properly in the groove as shown below. Properly seated U Cup seal 3. Lubricate the cylinder rod wiper with hydraulic oil and install it with the lip facing outwards into the first slot on the cylinder head. Ensure it is completely seated. Rev-6 Page 31 of 37

32 4. Ensure wiper and seal are both seated properly. Properly seated wiper and seal Rev-6 Page 32 of 37

Rod must be installed gently with rotating motion to ensure no damage is done to wiper or seal during installation.

33 5. Lubricate inside of seal and wiper and tapered end of the cylinder push rod. Reinstall rod into Cylinder Head with taper end of rod going into Cylinder Head and rounded end being exposed. Rod must be installed gently with rotating motion to ensure no damage is done to wiper or seal during installation. After rod is installed check wiper to ensure it is not damaged or rolled inward. Direction Tapered end in first Check wiper for damage 6. Repeat for other side. 7. Proceed to Reinstallation of Front Frame (page 35). Rev-6 Page 33 of 37

34 Reinstallation of Front Frame 1. Grease the inner surface of the front frame upper and lower carriage bars with high temperature grease. Rev-6 Page 34 of 37

If any pads are loose, apply a small amount of grease onto

35 2. Inspect the presence of all wear pads before re-installing the front frame onto the rear spine. If any pads are loose, apply a small amount of grease onto the back side of the pads to hold the pads in place during assembly. Rev-6 Page 35 of 37

Re-install the lower carriage claws onto the front frame lower bar.

36 3. Install the front frame onto the rear spine frame using the steps of removal in reverse. Ensure the front frame is seated properly onto the rear spine frame. 4. Re-install the lower carriage claws onto the front frame lower bar. Apply Loctite 243 to the carriage claw bolts before installation. The bolts installed should be tightened to approximately 44 ft/lbs. Rev-6 Page 36 of 37

37 5. Re-install the carriage backrest per manufacturer s instructions. 6. Re-install the two forks onto the carriage per manufacturer s instructions. 7. If the cylinder head was removed and reinstalled wait for a minimum of one hour to allow the Loctite to completely cure before using the unit. Do not use the side shifter for one (1) hour. If the seals were replaced without removing the cylinder head, the cure time is not required. 8. After 1 hour, (or immediately if cylinder head not removed) unlock-out truck and slowly push the third function lever to allow cylinder block to fill with oil and push the rod out of the cylinder block. Stop shifting before pressure builds as soon as the cylinder rod makes contact to the front frame. 9. Repeat this process for the other side. THE INTEGRAL SIDESHIFTER IS NOW FULLY OPERATIONAL AND READY FOR USE. Rev-6 Page 37 of 37

INSTALLATION INSTRUCTIONS South Highway 11 Westminster, SC Toll Free (888) (864) FAX (864)

INSTALLATION INSTRUCTIONS South Highway 11 Westminster, SC Toll Free (888) (864) FAX (864) 1.0 Purpose: To identify requirements for the replacement of ISS seals, o-ring and installation of gland nut to rod. 2.0 Scope: This instruction applies to the ISS units manufactured at Lift Technologies