Subject Area

U23014 R2
Subject Area: Issue #

New Parts Manual Correction
Part Chart Service Information Level: A
Look-Up Tip
Issue Date: 05/10/2023
Expiration Date: 01/01/2099
Model Category: SLS or TSB# MLA

IC Electric Narrow Aisle
Model(s) PF80 – PF110
Serial Number(s) Run the Dealer Service Campaign Report in TRACS for complete list.
Subject:
Middle mast channel crossmember welds.
Cause:
Weld fusion deficiency.
Completing the campaign is very important, and the failure to do so could result
in a serious incident. This is not an inspection; welds must be replaced.
Solution:
Rework middle mast channel upper crossmember welds.
Tools Required:
• Mast Fixture - Part Number 9040118331 (4 Ton & 5 Ton Models)
• Mast Fixture Adapter - Part Number 9040118421 (5 Ton Model Only)
• 1 - BSPP Hydraulic Cap size 12 – Part Number 0553040400
• 1 - BSPP Hydraulic Plug size 12 – Part Number 0553020400
• 2 - Chain (grade 70)
• 1 - Strap (min. working load limit of 3,333 lbs.)
• 1 - Weld splatter protection blanket
Warranty:
All normal warranty guidelines and claim submission procedures must be
followed.
Service Campaign Technician Labor Time: 10 hrs

• 5 hours to disassemble & 5 hours to reassemble and adjust
Certified Welder: 5 hrs/Labor (3rd party invoice)

• The 3rd party invoice for a mobile certified welder should not
exceed the maximum of $1000.
Note: After repairs are complete, photos of the final welds MUST be attached to
the warranty claim.
Travel or transportation should be entered manually in the claim and is limited to

one customer visit per day.
 Do not operate a lift truck unless you are qualified and authorized and
have read and understand the Operation and Maintenance Manual (OMM)
or Operating Instructions (BL). Do not perform service or repair on lift
trucks unless you are qualified and authorized and have read and
understand the Service Manual or Service Handbook (SH) and for safety
guidelines prior to working on equipment.
 Improper lift truck operation could result in injury or death.
 Make all repairs with the lift truck parked on a level, hard surface. Block
the lift truck so it does not roll while working on or under the lift truck.
 Use a tire cage if the tire/wheel is going to be replaced or worked on.
 Ensure enforcement of company policy for proper lockout/tag out

procedure.
 Disconnect battery prior to working on any electrical components or

welding.
 Obey all safety guidelines when welding near flammable fluid. Always
have an approved fire extinguisher on hand.
Steps for Completion:
1. Remove the forks or attachment from the carriage. Cap and plug hydraulic
lines as needed.
2. Park the truck on a flat surface, apply the parking brake and chock the drive
wheels in both directions.
3. Operate and set the mast to the vertical position and perpendicular to the
floor.
Note:
Location of the welds on the middle channel crossmember that will be reworked
(Four welds per each side)
Photo 1 of 3
Photo 2 of 3
Middle Channel
Photo 3 of 3
4. Raise the mast channels as shown below, tilt back slightly, and place a solid
block of wood (4X4) under the mast channels. Lower the mast channels
down.
5. Tilt forward until the inner channel is pushed up slightly and all three channels
are resting even on the block off wood. Ensure the block of wood covers all
channels evenly as shown below.
6. Lower the free lift cylinder until the bottom of the carriage is right above the tilt
cylinder mounts. Secure the carriage assembly to the crossmember on the
inner channel using a chain, as shown below (Chain A). Turn off engine.
Chain A
Chain A
Note:
Make sure the chain is not wedging between the inner and middle channel, as
the middle channel will need to be raised later in the procedure.
7. With the engine off, ignition in the ON position and seat switch activated,
begin to operate the mast lower function. This will place the load on the chain
securing the carriage and will bleed off the hydraulic pressure.
8. Pull on the chains a bit to assist in collapsing the free lift cylinder down as this
will allow the chains (for free lift cylinder) sag along with the free lift hydraulic
hoses.
9. Secure the free lift cylinder by using either a small chain or strap and routing it
through the cylinder’s head unit and onto the to the crossmember for the inner
channel, as shown below (Chain B). This is to prevent the cylinder from
descending and abruptly releasing hydraulic fluid when the hydraulic line is
removed from it.
Chain B
Photo 1 of 2
[9. Cont’d]
Chain B
Photo 2 of 2
Note:
Make sure the chains are not wedging between the inner and middle channel, as
the middle channel will need to be raised later in the procedure.
10. Unbolt the hose pulley bracket on each side of the middle channel and secure
each assembly away from the mast.
11. Remove the chain and pulley on each side of the middle channel and secure
each assembly away from the mast.
Photo 1 of 2
[11. Cont’d]
Photo 2 of 2
12. Remove the hydraulic line for the free lift cylinder and cap as needed.
Tighten cap fittings snug. Secure the hydraulic line upwards and away from
the mast, as the middle channel will have to be raised slightly. (This will
prevent interference contact)
• BSPP Hydraulic Cap – size 12

• BSPP Hydraulic Plug – size 12
13. Remove the 4 hold down bolts for the hydraulic line brackets, located on each
side of the inner channel. Then secure the hydraulic lines upward and away
from the mast, as the middle channel will have to be raised slightly. (This will
prevent interference contact)
14. Remove the hold down bolt for the hydraulic lines and secure the hydraulic
lines away from the mast pinch point areas. (This will prevent interference
contact)
15. Turn engine on, activate the seat switch and SLOWY begin to activate the
LIFT UP hydraulic function. The secondary lift cylinders will begin to lift the
middle channel.
Important Note:
The stopping point should be right below the chain mount on the inner
channel. DO NOT GO PAST THIS POINT.
[15. Cont’d]
Important Note:
The middle channel should be the ONLY channel lifting. As the middle channel
begins to protrude upwards and away from the other channels, the top roller will
be exposed and because of this, the entire inner channel will begin to shift (pivot)
forward.
16. Secure the inner channel from shifting forward by routing a strap from the
crossmember to the overhead guard, as shown below.
Important Note:
The sliding pads/shims may fall out from the middle channel. Gather the sliding
pads/shims as they will be re-installed during reassembly.
17. Place a cribbing block at bottom of the middle channel (on both sides) to
prevent mast drifting.
18. At this point, the unit is now ready for the certified welder.
• Please cover and protect the dash area and the back of the mast
as shown below.
• Close LPG tank valve and run engine out of fuel.
• Remove LPG tank and store away from the truck.
• Disconnect battery.
Parts required:
Mast Fixture - Part Number 9040118331 (4 Ton & 5 Ton Models)
Mast Fixture Adapter - Part Number 9040118421 (5 Ton Model Only)

Note:
Only the 5 Ton model requires using spacer adapter 9040118421 (on one side)
in conjunction with the mast fixture 9040118331.
Important Note:
Ensure certified welder cleans mast channel surface in preparation to installing
the mast fixture (part number 9040118331). The mast fixture MUST be tack
welded in 3 spots on each side of the fixture, as shown below. The tack welds
must NOT be placed near the edge of the mast channel as this can cause a
stress riser on the metal properties.
Note:
The eight welds on the crossmember for the middle mast channel are to be
completely reworked by the certified welder. Four welds per each side.
Welding Specifications:
• 3-pass weld
• L-56 wire .045” (1.1mm) or equivalent welding rod
10mm Fillet Weld

3 pass Weld
Middle Channel Specifications:
4 Ton Model
5 Ton Model
19. After welding process is completed, remove the tack welds securing the
fixture to the mast channel. Ensure to grind off the tack weld completely and
buff/polish to blend into the mast channel. This is important as it will prevent
stress risers in the mast channel.
• Touch-up spray paint part number: 23300-629A
20. At this point, the unit is now ready for the technician to reassemble the mast
using the disassembly procedure in the reverse order. (Steps 17 to 1)
21. After the reassembly procedure is complete, check chain and mast for proper
adjustment. (Refer to the service manual as needed)
22. Test truck for proper operation.
23. Return truck back to service.
24. The service campaign has now been completed.
Questions? If you have any questions regarding this Service Campaign, please
submit a Service Support Ticket.

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U23014 R2

Subject Area: Issue #

Expiration Date: 01/01/2099

Model Category: SLS or TSB# MLA

Model(s) PF80 – PF110

Service Campaign Technician Labor Time: 10 hrs

Certified Welder: 5 hrs/Labor (3rd party invoice)

Travel or transportation should be entered manually in the claim and is limited to

 Improper lift truck operation could result in injury or death.

 Use a tire cage if the tire/wheel is going to be replaced or worked on.

 Ensure enforcement of company policy for proper lockout/tag out

 Disconnect battery prior to working on any electrical components or

• BSPP Hydraulic Cap – size 12

Mast Fixture - Part Number 9040118331 (4 Ton & 5 Ton Models)

Mast Fixture Adapter - Part Number 9040118421 (5 Ton Model Only)

10mm Fillet Weld

• Touch-up spray paint part number: 23300-629A

22. Test truck for proper operation.

23. Return truck back to service.

24. The service campaign has now been completed.

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