Lift mast – 7000

12.1.2 Maintenance

Mounting

The maintenance schedule states that only a visual inspection of the mast mounting bolts (8) must be carried out and that they must not be tightened when they are checked. If the mast has to be replaced or if the bolts have become loose, new bolts and washers must be used. The tightening torque must be 150+/-15 Nm.

Lubrication

Lubricating the beam

1 The inner sides of the beam flanges must be lubricated with part no. 223690 (Q8 Rembrandt EP2).

2 The inner sides of the beam rib must be lubricated with part no. 29586 (Gleitmo 805).

12.1.3 Cylinder

Disassembly

•Remove the mast cover.

•Lift the fork carriage so that the lift chain slackens.

•Unscrew the chain guide (Fig. 19).

•Remove the chain sprocket (Fig. 19).

•Undo the bolts on the cylinder mounting (Fig. 20).

•Lift the fork carriage up past the cylinder.

•Lift out the cylinder and unscrew the hose (Fig. 20).

NOTE:

If the hose is difficult to reach, remove one of the truck’s batteries and loosen the other end of the hose.

Assembly

Assembly takes place in the reverse order.

12.2 Fork carriage

12.2.1 Maintenance

•Check that the fork carriage’s play is not too great.

•Shim as illustrated (1) if necessary.

12.3 Main lift chain system

12.3.1 Checking the chain setting

The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule.

Any adjustment is made with the chain mounting bolts. Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.

12.3.2 Chain inspection

The chains are exposed to two types of wear, outline wear and stretching. Wear to the bolts and disc holes is caused by stretching. The chains are also affected by the environment they are used in.

Noise

If lubrication has been insufficient there will be metallic friction on the chain and this will result in noise. The chain should be replaced.

Surface rust

Surface rust is easy to recognize as the chain will be reddish brown. Deep-seated rust has generally started and the chain has impaired strength.

The chain should be replaced

Rusty links

Fretting corrosion results in a reddish brown powder being visible by the outer discs. It can also appear as if the chain is bleeding when lubricated.

The chain should be replaced.

Stiff links

If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing.

The chain should be replaced.

Lift mast – 7000

Main lift chain system

T-codeValid

Bolt rotation

Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain.

The chain should be replaced

Loose bolts

If a bolt is loose it will protrude from the side of the chain, which is due to a stiff link or bolt rotation.

The chain should be replaced

Outline wear

P = Pitch

H2 = Nominal disc height.

H3 = Minimum disc height.

A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3