50D MD Dual Mast Unlimited Freelift 2-Stage

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1 P ARTS MANUAL This manual contains standard production Product Identification Numbers. Special Engineered Options not included. 50D MD Dual Mast Unlimited Freelift 2-Stage For PIDs FOR PARTS AND SERVICE: TELEPHONE: (888) Manual Number: R 7040 South Highway Westminster, SC Toll Free (888) (864) FAX (864)

2 About This Manual Introduction This manual shows the parts breakdown for the mast product ID numbers. Locate the product ID (PID) number stamped on the upper left hand side of the outer upright channel. This number must be used when ordering replacement parts for this product. PRODUCT I.D. NUMBER XXX-XX-XXXX 50D MD XYZ XXX-XX-XXX EXAMPLE MA2380.eps Ordering Parts Customers - Parts and service literature is available through authorized lift truck dealers. To place an order, contact the lift truck dealer of your choice. Lift Truck Dealers - To order parts and service literature contact: LIFT-TEK / ELECAR CUSTOMER SERVICE 7040 S. HWY. WESTMINSTER, S.C TELEPHONE: (888) FAX: (864)

3 WARNING Contents Cover... Introduction... 2 Safety Decals PSI Main LH Lift Cylinder PSI Main RH Lift Cylinder PSI Main LH Lift Cylinder PSI Main RH Lift Cylinder PSI Free Lift Cylinder PSI Free Lift Cylinder... 4 Outer Upright... 6 Inner Upright... 8 Hydraulic Group Freelift Chain Lowering Control Valve Load Backrest Roller Carriages Internal Hose Reeving Recommended Spare Parts List Safety Decals 3 Front side of Crossmember Front side of Cylinder 4 4 Both Sides MA2604.eps R 05/7/04 Page 3

4 2000 PSI Main LH Lift Cylinder External Hydraulic Fuse ( LEFT HAND SIDE ONLY ) MA2587.eps Page 4

5 2000 PSI Main LH Lift Cylinder LPML-3 LOW LOW OCL (IN) PRESSURE PRESSURE OCL (IN) LH MAINLIFT LH MAINLIFT QTY QTY OCL - Outer Channel Length LPML-4 Item QTY Part # Description Item QTY Part # Description N/A Spacer 0 Back-Up Ring 2 N/A Rod Piston Seal Snap Ring Sleeve 4 Pull-In Wire Retaining Ring 5 N/A Shell 4 Rod Seal External Fuse Retainer 7 Wiper 6 Back-Up Ring Piston 7 O-Ring 9 Wear Ring - Included in Seal Kit P/N Page 5

6 2000 PSI Main RH Lift Cylinder MA2588.eps Page 6

7 2000 PSI Main RH Lift Cylinder LPML-5 LOW LOW OCL (IN) PRESSURE PRESSURE OCL (IN) RH MAINLIFT RH MAINLIFT QTY QTY OCL - Outer Channel Length LPML-6 Item QTY Part # Description Item QTY Part # Description N/A Spacer Rod Seal Fitting Piston Washer Seal 3 Wear Ring 4 Pull-In Wire 4 Back-Up Ring Bleed Screw 5 Piston Seal 6 N/A Shell Sleeve Fitting Retaining Ring 8 N/A Wiper 8 O-Ring 9 N/A Rod Retainer Snap Ring 20 Back-Up Ring - Included in Seal Kit P/N Page 7

8 2600 PSI Main LH Lift Cylinder External Hydraulic Fuse ( LEFT HAND SIDE ONLY ) 0 9 MA2589.eps Page 8

9 2600 PSI Main LH Lift Cylinder HPML-3 HIGH HIGH OCL (IN) PRESSURE PRESSURE OCL (IN) LH MAINLIFT LH MAINLIFT QTY QTY OCL - Outer Channel Length HPML-4 Item QTY Part # Description Item QTY Part # Description N/A Shell Assembly 0 Back-Up Ring Piston Piston Seal 3 Pull-In Wire 2 Back-Up Ring Sleeve 3 O-Ring Retaining Ring 4 Rod Seal 6 N/A Plunger 5 Wiper 7 N/A Spacer External Fuse Retainer Snap Ring 9 Wear Ring - Included in Seal Kit P/N Page 9

10 2600 PSI Main RH Lift Cylinder MA2890.eps Page 0

11 2600 PSI Main RH Lift Cylinder HPML-5 HIGH HIGH OCL (IN) PRESSURE PRESSURE OCL (IN) RH MAINLIFT RH MAINLIFT QTY QTY OCL - Outer Channel Length HPML-6 Item QTY Part # Description Item QTY Part # Description N/A Shell Assembly Back-Up Ring Piston 2 Piston Seal 3 Pull-In Wire 3 Back-Up Ring Sleeve 4 O-Ring 5 39 Retaining Ring 5 Rod Seal 6 Washer Seal 6 Wiper Bleed Screw Fitting 8 N/A Spacer 8 N/A Plunger Retainer Fitting 0 Wear Ring Snap Ring - Included in Seal Kit P/N Page

12 2000 PSI Free Lift Cylinder MA259.eps Page 2

13 2000 PSI Free Lift Cylinder LPFL-5 LOW LOW OCL (IN) PRESSURE PRESSURE OCL (IN) FREELIFT FREELIFT QTY QTY OCL - Outer Channel Length LPFL-6 Item QTY Part # Description Item QTY Part # Description N/A Plunger 3 Nylon Ring Fitting 4 Piston Seal Roll Pin Check Valve 4 Pull-In Wire 6 O-Ring Fuse Piston Washer Spring Guide 8 Retaining Ring Spring 9 N/A Stand Tube 8 N/A Shell Assembly 20 Rod Seal 9 O-Ring Retainer 0 Wiper 22 Back-Up Ring Piston Snap Ring 2, Wear Ring - Included in Seal Kit P/N Page 3

14 2600 PSI Free Lift Cylinder MA2592.eps 7 Page 4

15 2600 PSI Free Lift Cylinder HPFL-5 HIGH HIGH OCL (IN) PRESSURE PRESSURE OCL (IN) FREELIFT FREELIFT QTY QTY OCL - Outer Channel Length HPFL-6 Item QTY Part # Description Item QTY Part # Description N/A Shell Assembly Nylon Ring 2 N/A Plunger 2 Rod Seal Piston 3 Wiper 4 Pull-In Wire External Fuse Retainer 5 Back-Up Ring Check Valve 6 O-Ring Washer Roll Pin 8 Circlip 8 O-Ring 9 Wear Ring Snap Ring 0 Piston Seal - Included in Seal Kit P/N Page 5

16 Outer Upright 4 OLD STYLE WEAR PLUG & SHIM NEW STYLE WEAR PLUG & SHIM MA0360.eps Page 6

17 Outer Upright WLD-3 OCL Part OCL Part (in) Number (in) Number Ref. Ref OCL - Outer Channel Length. WLD-4 Item Qty Part No. Description Outer Upright Load Roller Load Roller Shim Wear Plug Cylinder Shim Snap Ring Cylinder Shim Bumper Bumper Clamp Cylinder Shim Cylinder Shim - See WLD-3 for part numbers. 2 - Quantity will vary. 3 - Included in Wear Plug Kit P/N One kit per mast. 4 - Included in Cylinder Shim Kit P/N One kit per mast. Page 7

18 Inner Upright MA0374.eps Page 8

19 Inner Upright WLD-5 OCL Part OCL Part (in) Number (in) Number Ref. Ref OCL - Outer Channel Length. WLD-2 Item Qty Part No. Description Item Qty Part No. Description Outer Upright Chain Pin Snap Ring Chain Anchor Capscrew Cotter Pin Crosshead Nut Chain Sheave Cyl Spacer - HP Only Snap Ring Jam Nut Load Roller Load Roller Shim Nut Capscrew Cotter Pin M6 Lockwasher FL Cyl. Band Chain Guard - See WLD-5 for part numbers. 2 - Quantity will vary. Page 9

20 Hydraulic Group These items vary from truck to truck. See the Mast Installation Accessories on pages for the correct part number. 2 MA2565.eps Page 20

21 Hydraulic Group HP Hose 2 FREELIFT HOSE 2 FREE LIFT HOSE OCL OCL REF REF (in) QTY (in) QTY OCL - Outer Channel Length. - For older masts with a /2" O.D. Freelift Tube, Tube Kit p/n must be ordered to install newer 5/8" O.D. tube. 2 - If installing newer cylinders on an older mast with the crossover hose, Kit p/n must be odered to install new 5/8" tube. Common Parts HYD-2 REF QTY PART # DESCRIPTION REF QTY PART # DESCRIPTION Hose Fitting Capscrew Fitting Capscrew Capscrew Lockwasher Clamp 5 2 Lower Control Valve Fitting Bar Fitting * - Quantity will vary. - See HP HOSE. 2 - See LCV-. Page 2

22 Freelift Chain CHN- OCL FL CHAIN OCL FL CHAIN (in) QTY(2) (in) QTY(2) OCL - Outer Channel Length. Page 22

23 Lowering Control Valve 2 3 See LCV Chart REF QTY PART# DESCRIPTION Lowering Control Valve Valve Assembly * PSI Lowering Control Valve, 8 GPM * PSI Lowering Control Valve, 24 GPM * PSI Lowering Control Valve, 7 GPM Valve Body Valve Body Valve Cartridge PSI Valve Cartridge, 8 GPM PSI Valve Cartridge, 24 GPM PSI Valve Cartridge, 7 GPM * - Valve Assembly consists of - Valve Body and - Valve Cartridge. Page 23

24 Load Backrest Backrest-2.eps 3 2 See LBR Chart LBR- ALL Class II Load Backrests REF QTY PART # DESCRIPTION *Backrest, 3" x 36" *Backrest, 3" x 48" *Backrest, 3" x 60" *Backrest, 37" x 36" *Backrest, 37" x 40" *Backrest, 37" x 42" *Backrest, 37" x 48" *Backrest, 37" x 52" *Backrest, 37" x 60" 2455 *Backrest, 37" x 65" *Backrest, 37" x 72" *Backrest, 4" x 36" *Backrest, 4" x 48" *Backrest, 4" x 60" *Backrest, 46" x 48" *Backrest, 49" x 36" *Backrest, 49" x 48" *Backrest, 49" x 60" *Backrest, 52" x 48" *Backrest, 6" x 36" *Backrest, 6" x 48" *Backrest, 6" x 60" Capscrew, M6x2,0x Lockwasher, M6 * - Item inlcudes items 2 and 3. Page 24

25 6 Roller Carriages A MA2607.eps 2 See Chart Below CARR- Carriage drawing is for reference only, specific carriage may look different. REF QTY Part # Description REF QTY Part # Description A 50D MD 6 Roller Carriages Common Parts " Cushion Carriage Weldment Capscrew " Cushion Carriage Weldment Lockwasher " Cushion Carriage Weldment Thrust Roller Assembly Cotter Pin Pin Cotter Pin Chain Anchor 8 * Shim Load Roller Retainer Plate Capscrew Nut, Hex full Nut, Hex Jam Load Roller Fork Stop Kit * - Quantity will vary. Contact Lift Technologies, Inc. Customer Service if your carriage does not match any of those listed (Mast PID number needed). Page 25

26 Internal Hose Reeving 3 2 See Chart on Next Page in. Retracted Channel Length and Lower Left Hand Internal Reeving Use when installing left hand reeving only MA2608.eps Page 26

27 Internal Hose Reeving IHR- IHR COMMON PARTS COMMON PARTS GROUP: PART # REF QTY QTY PART # DESCRIPTION REF Single Double Single Double PART # DESCRIPTION 359 Layout Drawing Lockwasher, M Fitting Clamp Fitting, Spacer Fitting, Capscrew, M0x Capscrew, M2x Bar Lockwasher, M Capscrew, M0x25, Guard Cap Sheave Cap Capscrew, M0x25, 8.8 Right Hand Side Left Hand Side Pneumatic Cushion Hose R.H. R.H. R.H. Truck L.H. L.H. L.H. Truck Outer Outer Part No. Internal Upper Lower Fitting Internal Upper Lower Fitting Channel Channel Reeving Guide Guide Kit Reeving Guide Guide Kit Length (in) Length (in) Group No. Part No. Part No. Group No. Part No. Part No. QTY 2 QTY QTY QTY QTY " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " Page 27

28 Recommended Spare Parts List Replacement Parts PART # DESCRIPTION MASTS SERVICED MAIN LIFT CYLINDERS n Main Lift Cylinder Assembly Snap Ring Shim Shim Valve Kit FREE LIFT CYLINDER n Free Lift Cylinder Assembly Seal Kit INTERNAL REEVING n Hose R.H. and L. H Fitting, Hose Sheave, Single IHR Hose Sheave, Double IHR UPRIGHTS n Chain Pin Cotter Pin n Chain Anchor Jam Nut Nut Cotter Pin Shim,.03 in Roller Wear Plug Service Kit CROSSHEAD Chain Sheave Snap Ring CARRIAGE AND CHAINS n Free Lift Chains Carriage Side Thrust Roller n Main Lift Chains Carriage Roller n Chain Anchor Cotter Pin Chain Pin Cotter Pin Jam Nut Nut n - See specific pages for part numbers. Page 28

29 DATE PURCHASE ORDER PARTS ORDERING LOG SERIAL NUMBER LIFT-TEC PAGE REF# QTY PART # CUSTOMER PART # DESCRIPTION PRICE Page 29

30 Manual Change Summary R0 - Release. R - 05/7/04 Add historical data.

31 Do you have any questions that need to be answered right now? Lift Technologies, Inc South Highway Westminster, SC USA Tel: +(864) Fax: +(864) Customer Service (North America Toll Free) Other Lift Technologies Locations Lift Technologies Inc. Corporate Head Office 25 Woodlawn Road W., Unit 27 Guelph, ON NH 8J Canada Tel: Lift -Tek Elecar Srl 2905 Castel. San. Giovanni (PC) Via G. Galilei Italy Lift Technoloies Inc

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