3 Mast

Technical manual Publ. no. 6193.008 1225

CONTENTS
GENERAL, MAST ................................................................ 3-3
Duplex mast, standard ............................................................ 3-4
Duplex mast, free lift .............................................................. 3-4
Triplex mast, free lift .............................................................. 3-4
MAST .................................................................................... 3-5
Removing forks ...................................................................... 3-5
Removing standard mast ........................................................ 3-5
Removing inner mast .............................................................. 3-6
Removing complete mast ........................................................ 3-7
Installing standard mast ........................................................ 3-10
Removing the ECB attachment ............................................ 3-11
Installing the ECB attachment .............................................. 3-12
Removing the ECB mast ...................................................... 3-14
Installing ECB mast .............................................................. 3-17
MAST WHEEL ................................................................... 3-18
Removal, machine sizes SMV10-16 ...................................... 3-18
Installation, machine sizes SMV10-16 .................................. 3-18
Removal, machine sizes SMV18-60 ...................................... 3-18
Installation, machine sizes SMV18-60 .................................. 3-18
Rewelding the axle journal to the mast wheel ........................ 3-19
SIDE SUPPORT REEL ....................................................... 3-20
Removing ............................................................................. 3-20
Installing .............................................................................. 3-20
Shimming and measuring mast ............................................. 3-21
TOP SUPPORT REEL ........................................................ 3-22
Removing ............................................................................. 3-22
Installing .............................................................................. 3-22
AXLE JOURNAL TO MAST .............................................. 3-22
Removing ............................................................................. 3-22
Installing .............................................................................. 3-22
LIFT CHAINS ..................................................................... 3-23
Chain wheel ......................................................................... 3-23
Removing ...................................................................... 3-23
Installing ........................................................................ 3-23
Chain adjustment ................................................................. 3-24
Chain inspection - Wear ....................................................... 3-25
Maintenance, cleaning and lubrication .......................... 3-25
LIFT TRUCK ...................................................................... 3-26
Removing lift truck .............................................................. 3-26
Installing lift truck ................................................................ 3-26
Removing and installing mast wheel and support reel ........... 3-26
FORKS ................................................................................ 3-27
Marking, forks ...................................................................... 3-27
Wear, forks ........................................................................... 3-27
Deformation, forks ............................................................... 3-27
Crack formation, forks ......................................................... 3-28

Technical manual Publ. no. 6193.008 1225 Mast 3-1

3-2 Mast Technical manual Publ. no. 6193.008 1225
 General, mast

GENERAL, MAST

WARNING
In addition to the checks and safety regulations
found in this description, always refer to the
country’s own applicable laws regarding safety
regulations.

The mast is on two shafts in the chassis and consists of the

following components.
• Outer mast
• Inner mast
• Lift truck with forks
• Lift cylinders
• Tilt cylinders
• Spreading-/side shift cylinders
• Lift chains(standard mast)

The lift truck has fork spreading and fork side shifting as standard.
In addition, tucks are also available with fork banking, fixed forks
and central banking as an option.

There are different types of mast available depending on the

requirement and area of use. The mast is available in the following
versions.
• Duplex, standard mast
• Duplex, free lift mast
1. Outer mast • Triplex, free lift mast
2. Inner mast
3. Lift chains Removal of mast and truck can be carried out in different ways:
4. Lift truck with forks • Only forks, see “Removing forks” on page 5.
5. Spreading-/side shift cylinders • Only truck and forks, see “Lift truck” on page 26.
6. Tilt cylinder • Inner mast, see “Removing inner mast” on page 6.
7. Lifting cylinder • Complete mast, see “Removing complete mast” on page 7.

Table 1: Consumables
Material Part number

Welding rod 2.5 mm2 for welding the 50550150

axle journal
Basic electrode 48-type 1)
Welding rod 3.25 mm2 for welding the 50550142
axle journal
Basic electrode 48-type 1)

1) Classification:
AWS/SFA A5.1: E 7018
DIN 1913: E 51 53 B 10
ISO 2560: E 51 5B 120 20H
Swedish standard: 3211 H10
AS 1553.1: E 4818

Table 2: Special tool

Tool Part number
Slide hammer 6130.109

Technical manual Publ. no. 6193.008 1225 Mast 3-3

 General, mast

DUPLEX MAST, STANDARD

The duplex mast consists of an outer mast, inner mast and lift
Duplex mast standard, main image truck with forks. The inner mast is vertically adjustable via lift
cylinders. The lift truck is vertically guided in the inner mast. The
Advantages: Simple design, good visibility. lift truck is suspended by chains and is vertically adjustable. The
Disadvantage: The mast’s overall height increases when lift truck’s chains are secured in the inner mast and the chains run
the forks are raised. above the inner mast’s chain wheel. When the inner mast is raised,
the lift truck is pulled upwards by the chain.

DUPLEX MAST, FREE LIFT

Duplex mast free lift, main image The difference between duplex standard and duplex free lift is that the
Advantages: The total height of the mast is affected lift truck is raised by hydraulic cylinders. In this way, the lift truck can
when the forklift truck reaches a certain height. be lifted individually without the inner mast having to be raised.
Disadvantages: Complicated design, poorer visibility.
TRIPLEX MAST, FREE LIFT

Triplex mast free lift, main image The triplex mast has a further inner mast and this is raised and
Advantages: Low construction height in relation to lowered by the chain. The lift truck is raised by hydraulics. The
maximum lifting height. The total height of the mast is advantage is that, at the same time as achieving a high lifting
affected when the forklift truck reaches a certain height. height, goods can also be raised in areas with low roof heights. The
Disadvantages: Complicated design, poorer visibility, inner mast does not need to be raised for the lift truck to be raised.
more moving parts, heavier.

3-4 Mast Technical manual Publ. no. 6193.008 1225

 Mast

MAST

REMOVING FORKS
1. Relieve the forks and operate them laterally.
2. Secure the spreading cylinders. Slacken off the screws holding
the cylinders in the forks.
3. Place straps on the forks.

WARNING
There is a high centre of gravity on the forks.
Risk of personal injury. The forks can easily tip
over when lifted out.

4. Lift out the forks from the lift truck.

REMOVING STANDARD MAST

WARNING
The hydraulic system is pressurized.
Risk of personal injury.
Always depressurise the hydraulic system before
starting work on the hydraulic system.

The mast is fitted with lift chains for lifting the lifting truck.

1. Lower the inner mast so that the lift chains and hydraulic
hoses slacken.
2. Mark up the hydraulic hoses for the lift truck and remove the
connections at the lift truck. Plug the hoses and connections.
3. Secure the hoses so that they do not roll around the block for
the hose tension.

Technical manual Publ. no. 6193.008 1225 Mast 3-5

 Mast

4. Open and remove the cotter pin (1). Remove the pin (2) at the
chain tensioner.
5. Secure the lift chain so that it does not roll around the chain
wheel.
6. Remove the lift truck as follows:
• Tilt the mast to take the load off the rollers.
• Carefully lift the inner mast. Check that the lift chains and
hydraulic hoses are not trapped.
• Reverse the machine when the lowest part of the inner mast
has passed the upper rollers.
• Lower the inner mast.

1. Cotter pin
2. Pin

REMOVING INNER MAST

1. Remove the inner mast as follows:
• Secure the lifting link on the inner mast’s top yoke.
• Secure the lift cylinders.
• Detach the lift cylinders at the inner mast.
• Tilt the mast vertically to relieve the load from the mast
wheels.
• Lift out the inner mast using an overhead hoist or crane.
2. Tilt the mast forward.

3-6 Mast Technical manual Publ. no. 6193.008 1225

 Mast

REMOVING COMPLETE MAST

1. Remove the hose mountings (2) Mark up and remove the
hydraulic hoses (1) on the outer mast. Plug the connections.

1. Hydraulic hoses
2. Hose mountings

2. Mark up and remove the hydraulic hoses (1) from the lift
cylinders (2). Plug the connections.

1. Hydraulic hose
2. Lifting cylinder

Technical manual Publ. no. 6193.008 1225 Mast 3-7

 Mast

3. Mark up and remove the hydraulic hoses (1) for the return
connection (2). Plug the connections.
4. Mark up and remove the electrical connections between the
machine and mast.

1. Return hoses
2. Return connection

5. Install lift chains in the outer mast’s lifting eyelets and secure
the outer mast using an overhead hoist.

3-8 Mast Technical manual Publ. no. 6193.008 1225

 Mast

6. Place a wooden block (1) under the tilt cylinders (2) so that
they are secure.
7. Remove the screws (3) that lock the axle (4) to the upper
mounting for the tilt cylinders.
8. Tilt the mast forward to relieve the load from the tilt axles.
9. Screw a slide hammer (5) into place in the threads to the axle
and pull out the axle.
10. Carry out the corresponding action on the other tilt cylinder.
11. Tilt both the cylinders backwards. Fold down the tilt cylinders
towards the wing.

1. Wooden block
2. Tilt cylinder
3. Screw for axle locking
4. Axle
5. Slide hammer

12. Remove the screw (1) for the axle lock

13. Relieve the mast axles using an overhead hoist.

WARNING
The mast may rock when the axles release. Risk
of compression injuries.

14. Install the long screws (3) in the threaded holes (2) in the axle
lock and press out the axle. Remove both the axles.
15. Lift out the outer mast.

1. Screw for axle locking

2. Threaded holes for removing the axle
3. Screw

Technical manual Publ. no. 6193.008 1225 Mast 3-9

 Mast

INSTALLING STANDARD MAST

NOTE!
The condition for installing the standard mast is that the machine has
the status that applies after the mast is removed according to the
instructions in section “Removing standard mast”.

NOTE!
For extra instructions and images, also see section “Removing standard
mast”.

1. Raise the outer mast in position using an overhead hoist.

Ensure that the mast’s lower mounting is in position with the
machine’s mounting eyelets.
2. Install the axles to the mast’s lower mountings. Tighten the
screw for the axle lock.
3. Install the tilt cylinders in the mast’s mounting for tilt cylinder.
Tighten the screw for the axle lock. Check that the tilt
cylinders are securely attached to the machine.
4. Remove the lifting link from the outer mast.
5. Secure a lifting link on the inner mast’s top yoke. Raise the
inner mast in position using an overhead hoist. Guide in the
lift cylinders to the correct position in the inner mast’s top
plate.
6. Connect the switches between the machine and mast.
7. Connect the return hoses from the lift cylinders to the return
connection.
8. Connect the hydraulic hoses to the lift cylinders.
9. Connect the hydraulic hoses from the machine to the mast.
Secure the hydraulic hoses with the hose mountings (2).
10. Raise the inner mast and operate the machine forward to the
lift truck. Lower the inner mast above the lift truck.
11. Pull the hydraulic hoses to the lift truck around the block for
hose tension. Connect the hydraulic hoses.
12. Pull the lift chains over the chain wheel. Install the lift chains
in the lift truck’s chain tensioner. Lock the axle to the chain
tensioner using cotter pins.
13. Adjust the length of the lift chain using the chain tensioner
according to section “Chain adjustment”.
14. Install the forks in the lift truck.
15. Screw the plates for the side shifting cylinders into the forks.

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 Mast

REMOVING THE ECB ATTACHMENT

1. Position the mast in vertical position.
2. Attach the shackles and lifting slings to the attachment.
3. Lift up the attachment until the lift chains slacken.

V0851

4. Remove cotter pin (1) and pull out the pin (2) for the lift
chains.
5. Secure the chains to prevent them from falling over the chain
wheel.

1. Cotter pin
2. Pin

6. Mark up and remove the hydraulic hoses (1) on the

attachment and plug the ends.

V0852

Technical manual Publ. no. 6193.008 1225 Mast 3-11

 Mast

7. Disconnect and remove the electrical cable (1) on the

attachment.
8. Secure the hoses and the electrical cable to prevent them from
falling over the hose wheels.
9. Carefully raise the inner mast whilst watching the chains and
hoses.
10. When lowest part of the inner mast has passed the attachment,
reverse the truck and then lower the inner mast.

V0853

INSTALLING THE ECB ATTACHMENT

1. Position the mast in vertical position.
2. Attach shackles and lifting slings to the attachment.
3. Lift the attachment and raise the inner mast.
4. When the lowest part of the inner mast has passed the
attachment, carefully position the attachment in the mast.
5. Carefully lower the inner mast.

V0851

6. Assemble the pin (2) and fit the cotter pin (1) for the lift
chains.

1. Cotter pin
2. Pin

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 Mast

7. Connect the hydraulic hoses (1) on the attachment.

V0852

8. Connect all the electrical cable on the attachment.

9. Carefully lower the inner mast to its lowest position.

V0853

Technical manual Publ. no. 6193.008 1225 Mast 3-13

 Mast

REMOVING THE ECB MAST

1. Position the mast in vertical position.
2. Mark up and remove the hydraulic hoses(1) on the mast and
plug the connections.

V0852

3. Mark up and remove the hydraulic hoses (1) from the lift
cylinders (2). Plug the connections.

V0854

1. Hydraulic hose
2. Lifting cylinder

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 Mast

4. Mark up and remove the hydraulic hoses (1) for the return
connection (2). Plug the connections.
5. Mark up and remove the electrical connections between the
machine and mast.

1. Return hoses
2. Return connection

6. Install lift chains in the mast's lifting eyelets and secure the
mast using an overhead hoist.

V0855

Technical manual Publ. no. 6193.008 1225 Mast 3-15

 Mast

7. Place the support(1) under the tilt cylinders(2) so that they are
secure.

V0856

8. Remove the screws(3) that lock the axle(4) to the upper

mounting for the tilt cylinders.
9. Tilt the mast forward to relieve the load from the tilt axle.
10. Screw a slide hammer(5) into place in the threads to the axle
and pull out the axle.
11. Carry out the corresponding action on the other tilt cylinder.
12. Tilt both the cylinders backwards

V0857

1. Support.
2. Tilt cylinder.
3. Screw for axle locking
4. Axle
13. Remove the screw (1) for the axle lock
5. Slide hammer
14. Relieve the mast axles using an overhead hoist.

WARNING
The mast may rock when the axles release. Risk
of compression injuries.

15. Install the long screws (3) in the threaded holes (2) in the axle
lock and press out the axle. Remove both the axles.
16. Lift out the outer mast.

1. Screw for axle locking

2. Threaded holes for removing the axle
3. Screw

3-16 Mast Technical manual Publ. no. 6193.008 1225

 Mast

INSTALLING ECB MAST

NOTE!
The condition for installing the ECB mast is that the machine has the
status that applies after the mast is removed according to the
instructions in section “Removing the ECB mast”.

NOTE!
For extra instructions and images, also see section “Removing the ECB
mast”.

1. Raise the mast in position using an overhead hoist. Ensure that

the mast’s lower mounting is in position with the machine’s
mounting eyelets.
2. Install the axles to the mast’s lower mountings. Tighten the
screw for the axle lock.
3. Install the tilt cylinders in the mast’s mounting for tilt cylinder.
Tighten the screw for the axle lock. Check that the tilt
cylinders are securely attached to the machine.
4. Remove the lifting link from the outer mast.
5. Connect the return hoses from the lift cylinders to the return
connection.
6. Connect the hydraulic hoses to the lift cylinders.
7. Connect the hydraulic hoses from the machine to the mast.
Secure the hydraulic hoses with the hose mountings.
8. Connect the electrical cable between the machine and mast.
9. Pull the hydraulic hoses around the block for hose tension.
Connect the hydraulic hoses.
10. Pull the lift chains over the chain wheel. Install the lift chains
in the chain tensioner.
11. Adjust the length of the lift chain using the chain tensioner
according to section “Chain adjustment”.

Technical manual Publ. no. 6193.008 1225 Mast 3-17

 Mast wheel

MAST WHEEL

The mast wheels guide the inner mast against the outer mast and
are available in two versions. Machine sizes SMV10-16 have
spherical twin row roller bearings and machine sizes SMV18-60
have twin conical roller bearings.

REMOVAL, MACHINE SIZES SMV10-16

1. Remove the inner snap ring (1).
2. Remove the inner spacer ring (2).
3. Pull out the mast wheel (6) from the axle journal (7).
4. Remove the outer snap ring (3).
5. Remove the outer spacer (4).
6. Press out the roller bearing (5) from the mast wheel (6).
7. Check that the bearings are complete and that the axle journal
is not damaged or worn.

INSTALLATION, MACHINE SIZES SMV10-16

1. Installing is in reverse order to removal.

Mast wheel, machine sizes SMV10-16

1. Snap ring, inner
2. Spacer ring, inner
3. Snap ring, outer
4. Spacer ring, outer
5. Roller bearings
6. Mast wheel
7. Axle journal

REMOVAL, MACHINE SIZES SMV18-60

1. Knock out the cylindrical lock pin (1) from the inside of the mast.
2. Remove the nut (2).
3. Remove the seal ring (3).
4. Remove both roller bearings (5) and spacer rings and snap
rings (4).
5. Check that the bearings are complete and that the axle journal
is not damaged or worn

INSTALLATION, MACHINE SIZES SMV18-60

1. Grease both roller bearings.
2. Installation of bearings and rings is carried out in reverse order
to removal.
Mast wheel, machine sizes SMV18-60 3. Install the nut (2). Ensure that the thread is clean and
1. Cylindrical lock pin lubricated.
2. Nut 4. Tension the bearings by tightening the nut to a torque of
3. Seal ring 250 Nm.
4. Snap ring and spacer ring 5. Turn the mast wheel around and at the same time knock using
5. Roller bearings a copper mallet. Post tighten to a torque of 250 Nm and repeat
6. Mast wheel until post-tightening can no longer be carried out.
7. Axle journal 6. Tighten the nut further so that one of the holes in the nut is
opposite the locking hole in the axle journal.
7. Lock the nut with the cylindrical lock pin.

3-18 Mast Technical manual Publ. no. 6193.008 1225

 Mast wheel

REWELDING THE AXLE JOURNAL TO THE MAST WHEEL

The axle journal must be replaced if it has become worn due to
seizure for example.
1. Cut, chisel or grind off the welds (2) and (3) for the axle
journal. Do not cut material from the member’s guide hole (1).
Grind clean so that the mating surfaces become even and all
burrs are removed.
2. Install a new axle journal (4). Check that the contact to the
mast is good and that the axle journal is at the correct angle.
3. Preheat the axle journal to approximately 150 °C.
4. Weld the axle journal with metal arc weld. Use basic electrodes
according to Table 1 on page 3.
- Begin with internal welds (3).
- Continue with external welds (2).
- Carry out welding without long gaps in order to prevent
shrinkage cracks.
- Allow the material to cool slowly.
5. Grind the inside smooth.
1)
Check the a-dimension before grinding off the axle
journal. The a-dimension varies with mast size.

1. Guide hole, member

2. External weld
3. Internal weld
4. Axle journal
Comparison steel standard:
Sweden, SS 2142-01
EU, SS-EN 10 025-3-S355N
USA, ASTM A 572

Technical manual Publ. no. 6193.008 1225 Mast 3-19

 Side support reel

SIDE SUPPORT REEL

REMOVING
1. Unscrew the four screws (5).
2. Pull off the axle supports (4) from the axle.
3. Remove the bushings and axle.
4. Check that the axle, side support reel (3) and bushings are
undamaged.
5. Clean the side support reel’s contact surface.

1. Shim T1 (1.0 mm)

2. Shim T2 (2.0 mm)
3. Side support reel
4. Axle support
5. Screw

INSTALLING
1. Check the dimensions of the outer mast and shim the support
reels according to section“Shimming and measuring mast”
2. Install the side support reel in reverse order to removal.

1. Shim T1 (1.0 mm)

2. Shim T2 (2.0 mm)
3. Axle support
4. Bushing
5. Axle
6. Support reel

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 Side support reel

SHIMMING AND MEASURING MAST

1. Carefully measure the distance between the outer mast’s inner
walls (a). Measure along the entire inner walls and note the
shortest distance.
2. Transfer the distance to the side support reels.
3. The gap between the side support reels and outer mast’s inner
walls must be 0.0–0.5 mm.
4. Align the shims in pairs between the holders for the side
support reels and the mast to achieve the correct clearance.

NOTE!
Two different thicknesses of shims are available, 1.0 and 2.0 mm.

Technical manual Publ. no. 6193.008 1225 Mast 3-21

 Top support reel

TOP SUPPORT REEL

REMOVING
1. Remove the four screws (5) holding the top support reel.
1. Remove the cotter pin (9) and pull out the axle (1). Remove
the bushings (3). Check axle and bushings.
2. Clean and check the top support reel (2).
3. Check outer contact surfaces and clearance between axle (1)
and the bushings (3).

INSTALLING
1. Carefully measure the distance between the inner mast’s outer
walls. Measure along the entire outer walls and note the
greatest distance.
1. Transfer the distance to the top support reels.
2. The total clearance between the top support reels and the
inner mast’s outer walls must be 0,0–1,0 mm.
3. Align the shims in pairs between the holders for the top
support reels and the mast to achieve the correct tolerance.
4. Installing is in reverse order to removal.

1. Axle
2. Reel AXLE JOURNAL TO MAST
3. Bushing
4 Washer
The lower mounting of the mast is secured in the frame by two axle
5. Screw
journals. The mast is also secured in the frame by two tilt cylinders
6. Holder
that hold the mast in the correct position. The mounting between
7. Shims 2.0 mm
the tilt cylinders and mast is secured by two axle journals.
8. Shims 1.0 mm
9. Cotter pin REMOVING
1. Remove the locking screw (1), washer (2) and spacer (3) that
hold the lock for the axle (5).
2. Screw in the two screws in the holes for removing the axle (4)
so that the axle (5) is pressed out.
3. Check that the axle and bushing are not damaged.

INSTALLING
Installing is in reverse order to removal.

1. Locking screw
2. Washer
3. Spacer
4. Holes for removing axle
5. Axle with locking lug

3-22 Mast Technical manual Publ. no. 6193.008 1225

 Lift chains

LIFT CHAINS

CHAIN WHEEL
There are two versions of chain wheel. Machine sizes SMV10-16
are equipped with bushings and SMV18-60 have double roller
bearings.

Removing
1. Remove the lift chains according to the instructions in section
“Removing standard mast”.
2. Remove the locking screw (1) for the lock for the axle (3).
3. Screw a screw into the threaded hole (2) so that the axle is
pressed out.
4. Remove the chain wheel (4) and bushing/roller bearing that
are inside the chain wheel.
5. Clean the chain wheel, bushing and axle. Check components
for wear.

Installing
Installing is in reverse order to removal.

1. Locking screw
2. Holes for removing axle
3. Axle with locking lug
4. Chain wheel

Chain wheel with double roller bearings, machine sizes

SMV18-60
1. Locking screw
2. Axle with locking lug
3. Lateral support
4. Roller bearings
5. Chain wheel

Technical manual Publ. no. 6193.008 1225 Mast 3-23

 Lift chains

CHAIN ADJUSTMENT
1. Adjust the lift chains using the adjusting nuts (1) so that the
distance between the base plate and the lift truck is 10 mm
when the stand is in the lowest position. Both lift chains must
be adjusted the same.

To adjust:
- Raise the lift truck 50 mm.
- Place a spacer 10 mm on both sides (1).
- Lower the lift truck so that it rests on the spacer.
- Tension (or slacken) so that both lift chains have the same
tension using the nuts (2).

2. Lock the lower adjusting nut (5) for the lift chain.
3. Raise the truck, preferably with load.
4. Tighten the nut (3) and lock with the nut (2).

1. 10 mm between the base plate and lift truck

Adjuster nuts

3-24 Mast Technical manual Publ. no. 6193.008 1225

 Lift chains

CHAIN INSPECTION - WEAR

WARNING
If the chain breaks, the load can fall
uncontrollably and cause damage.
Risk of serious injury or fatality.
It is of the utmost importance that the chain is
inspected regularly.
Always replace the chain if in doubt.
Always replace the entire length of the lift chains. Do not cut or
rivet lift chains.

1. Raise the truck without load.

2. Measure the chain over the 25 links that first (and most often )
break above the idler pulley. Extension is greatest there.
3. Compare with the value for relevant truck size according to
Table 3 on page 25. The chain must not have stretched more
than 3 %, calculated from its original length.
4. Replace the chain if extension is greater than 3 %.
NOTE!
Local legislations, or if security is is based on one chain, can demand
that the chain is changed when prolonged by 2%.
Table 3: Chain length

New chain, Maximum permitted Maximum permitted

Division (P)
measured measurement of measurement of
over 25 links at 2 % 25 links at 3 %
25 links extension extension
inch mm mm mm mm
1 1/2 38,1 952,5 971 981
2 50,8 1270,0 1295 1308
2 1/2 63,5 1587,5 1619 1635
3 76,2 1905,0 1943 1962
3 1/2 88,9 2222,5 2266 2289

5. Check that:
- No pins in the outer washers are loose or turned.
- No cracks are visible in any of the washers (link section).
- There is no mechanical damage.
- The lift chain is not rusty.
- The lift chain bends easily over the idler pulley (it does not
stick when bent).
If the chain has any of the faults above, replace the chain.

Maintenance, cleaning and lubrication

NOTE!
Service life/extension is completely dependant on how the chain is
maintained. Maintenance intervals are completely dependant on the
environment. In normal conditions the interval is approximately 2000 h.

1. Lower the lift truck to the bottom position.

2. Remove the lift chains from the mast, see section “Removing
standard mast”.
3. Clean the entire length of the lift chains properly.
4. Lubricate the lift chains with light oil or chain spray.
5. Install the chain upside down, inside out.

Technical manual Publ. no. 6193.008 1225 Mast 3-25

 Lift truck

LIFT TRUCK

REMOVING LIFT TRUCK

NOTE!
It is easiest to remove the lift truck with the forks installed.

1. Place the forks in the fork compartments or in some form of

load to secure them.
2. Lower the inner mast until the lift chains slacken.
3. Pull out the pins for the lift chains.
4. Secure the chains to prevent them from falling over the idler
pulley.
5. Remove the hydraulic hoses by the lift truck and plug the ends.
6. Secure the hoses to prevent them from falling over the idler
pulley.
7. Tilt the mast to take the load off the rollers.

8. Carefully raise the inner mast whilst carefully watching the

chains and hoses.

9. When lowest part of the inner mast has passed the reels, the
truck reverses and the inner mast is lowered.

INSTALLING LIFT TRUCK

Installing is in reverse order to removal.

REMOVING AND INSTALLING MAST WHEEL AND

SUPPORT REEL
To remove and install the mast wheel and support reel, see section
“Mast wheel” and section “Side support reel”.

Shim the support reel for the lift truck according to corresponding
instructions for “Shimming and measuring mast”. Measure the
a-dimension against the inner mast.

3-26 Mast Technical manual Publ. no. 6193.008 1225

 Forks

FORKS

MARKING, FORKS
Each fork is stamped (marked) (1) with information about
thickness and the capacity of the fork. The marking is on the side
of the shaft.

Example:
6000/6350x600x60

6000 = The fork’s capacity with a safety factor of 3 with the

indicated centre of gravity distance.
6350 = The fork’s capacity with a safety factor of 2.834 with the
indicated centre of gravity distance.
600 = Centre of gravity distance (Tp).
60 = Original thickness of the fork blade.

WEAR, FORKS
Check that the thickness of the blade (3) is not less than 90 % of
the stamped thickness (1).

1. Stamp, fork thickness

2. Shaft
3. The thickness of the blade must not be less than
90 % of the stamped thickness
4. Fork taper

DEFORMATION, FORKS
Check that the angle between blade and shaft is 90°.
Check the fork blade’s out-of-true.

Technical manual Publ. no. 6193.008 1225 Mast 3-27

 Forks

CRACK FORMATION, FORKS

Check for crack formation at the points exposed to the most stress.
Check welds (1) and fork base (2).
Carry out checks regularly according to local regulations, or every
2000 hours.

1. Welds
2. Fork base

3-28 Mast Technical manual Publ. no. 6193.008 1225