06 - Mast 2013B

Service Manual A-Ergo — D003936, C, GBR, Translated
06 Mast system
06 MAST SYSTEM
2013B
6.1 Design and function 63

6.1.1 Mast system .................................................................................................................... 63
6.1.2 Fork carriage ................................................................................................................... 63
6.1.3 Vertically adjustable straddle legs ................................................................................... 65
6.1.4 Side stabilisers ................................................................................................................ 66
6.2 Repair and maintenance instructions 67

6.2.1 Replacing the mast/straddle legs .................................................................................... 67
6.2.2 Dismantling the mast ....................................................................................................... 72
6.2.3 Lift chains ........................................................................................................................ 77
6.2.4 Forks................................................................................................................................ 78
6.2.5 Fork carriage ................................................................................................................... 84
6.2.6 Fork carriage with telescopic forks (TF) .......................................................................... 85
6.2.7 Vertically adjustable straddle legs ................................................................................... 90
6.2.8 Side stabilisers ................................................................................................................ 91
6.3 Diagnostics and trouble shooting 92

6.3.1 Troubleshooting chart ...................................................................................................... 92
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06 MAST SYSTEM
6.1 Design and function
6.1.1 Mast system
There are four mast systems as standard versions, depending on the application or roof
height, etc.
Table 17. Mast types

Description Descriptions
T Telescopic mast
TV Telescopic Free-view mast
TFV Telescopic Free-lift Free-view mast
DTFV Double Telescopic Free-lift Free-view mast
A telescopic mast consists of an outer and inner mast, fork carriage and lift cylinder. The fork
carriage is lifted up and down in the inner mast, which in turn moves up and down in the
outer mast. The lift cylinder first lifts the fork carriage approx. 15 cm, and then the mast
system follows the lifting movement.
A mast of the double telescopic type also has, in addition to an inner and outer mast, an
intermediate mast. The lifting movement is the same as for a telescopic mast, and all the
masts begin to move up (or down) simultaneously.
A mast type with free-lift function works in a similar way, but with the difference that the fork
carriage moves to its top position in the inner mast before the next mast section starts to lift.
Free-lift frames can be used to advantage in rooms with low ceilings or low door openings.
A mast of the free-view type implies that the distance between the mast profiles is longer,
which gives better visibility.
6.1.2 Fork carriage

Different fork arrangements are mounted on the back of the fork carriage. Everything from
fixed forks to complex units with telescopic forks.
Fixed forks
Forks with a fixed width and length.
Figure 27. Fork carriage with fixed forks

Laterally adjustable forks
The forks can be adjusted to different widths.
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Figure 28. Fork carriage with laterally adjustable forks

Telescopic forks (TF)
The fork blades can be extended.
Figure 29. Fork carriage with extendable/telescopic forks

Overload clutch with telescopic forks (TF)
AThe TF fork carriage has an overload clutch. The overload clutch is a unit that safeguards
against overloading the components that drive the forks in and out.
The torque that the overload clutch can transfer is limited by the force that the pressure
springs (item 1) transfer to the pressure plate (item 2), and the brake linings (item 3) to the
sprocket (item 4) (see Figure 30, page 65). For the adjustment instructions see Section
6.2.6.4, page 89.
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Figure 30. Overload clutch

Fork drive motor with telescopic forks (TF)
The fork drive motor is mounted on the back of the fork carriage and is used to move the
forks out and in so they can reach further forward. Power is transferred from the motor to the
forks via an angle gear and chain. The motor is controlled by a control on the control panel.
Refer to the plate on the motor for motor data.
6.1.3 Vertically adjustable straddle legs

Vertically adjustable straddle legs means that the straddle legs can be raised sufficiently high
to lift a pallet from the floor. Masts with vertically adjustable straddle legs are able to
transport a pallet on the fork carriage, and if the fork carriage is raised high enough, a pallet
directly on the straddle legs. This enables two pallets to be transported at the same time.
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Figure 31. Vertically adjustable straddle legs
6.1.4 Side stabilisers

The truck can be fitted with extendable side stabilisers to guarantee lateral stability and to
eliminate the risk of tipping during high lifts. The system consists of extendable side
stabilisers, which are extended by means of the standard hydraulic unit.
A limit switch, a height position switch, on the mast limits the lifting height when the
stabilisers are withdrawn. When the stabilisers are extended a pressure switch gives a signal
that the forks can be lifted to their maximum position.
NOTE!
It is risky to drive with the side stabilizers extended.
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Figure 32. Stabilizers
6.2 Repair and maintenance instructions

6.2.1 Replacing the mast/straddle legs
6.2.1.1 Detach the mast/straddle legs from the chassis
1) Remove the battery.
2) Support the chassis on pallets.
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Figure 33. Blocking up the chassis

3) Hang up the mast so that the attachments are not loaded.
Figure 34. Suspending the mast

If the mast has vertically adjustable straddle legs:
Figure 35. Vertically adjustable straddle legs

4) Screw a screw into one of the screw holes on the spacer between the guides and
chassis in order to hold up the spacer while dismantling.
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Figure 36. Spacer/guide screw

5) Secure the guides to the mast with a tension band.
Figure 37. Secure the guides together

6) Remove the screws attaching the mast to the chassis.
Figure 38. Upper screw attachment, mast
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7) Remove the hydraulic connections.
NOTE!
Mop up spilled surplus hydraulic oil in a suitable way.
Figure 39. Hydraulic connection
6.2.1.2 Mounting the mast/straddle legs on to the chassis

1) Make sure that the mast is suitably supported so that it cannot move
Figure 40. Example of suspended mast

2) Check that the guides are level with each other in height and secure them to the mast.
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Figure 41. Secure the guides together

3) Be sure to screw tight the spacer between the mast and chassis in the guide in one of
the screw holes that are not used.
Figure 42. Spacer/guide screw

4) Insert a suitable number of shims, 3 is the standard number.
Figure 43. Shims

5) Lower the mast so that the link arms slide in under the chassis when the mast and
chassis are brought together.
6) Connect the hydraulic couplings together.
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7) Bring the mast and chassis together and tighten the screws.
8) Torque
The tightening torque between the mast and the machine housing when
reassembling must be 277 Nm.

9) Remove the tension band and screw that are holding the spacer against the guides.
Figure 44. Removing the spacer/guide screw

10) Check that the distance between the floor and the forks is correct, see Section 6.2.7.1,
page 90.
6.2.2 Dismantling the mast

6.2.2.1 General
The following is generally applicable for all types of masts when dismantling:
• Stand in an area with adequate ceiling height and with approved lifting devices.
The following is generally applicable for all types of masts when assembling:
• The mast is assembled in the reverse order to dismantling.
Inspecting or repairing the mast system:
• Check that the thrust rollers lie against the roller surfaces on the mast. Also check that
they roll easily.
• A function test must be made after each measure/action on the mast system. The mast
must not jam or run too slowly (the mast sections move in the wrong order) when lifting
and lowering.
6.2.2.2 Adjustment of the side lean in the top position

1) Lower the mast and slacken the chains.
2) Adjust the attachment of the outer cylinders with the top nut (item 1). Adjust both
cylinders equally so that the mast does not pull skew.
3) If there is sufficient movement in the cylinder attachment, the rollers will be in contact
with the running surfaces of the mast at all lifting heights.
4) Test the operation of the lifting movement. Lift up to top position and check that the mast
does not swing to the side when the end position is reached.
5) Lock the top nut with the locking screw (item 2).
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6) Tighten the chain and check that the rollers still make contact with the running surface.
7) The cylinder attachment should be flexible.
8) Adjusting the mast, see Section 6.2.2.3, page 73.
6.2.2.3 Adjusting the play in the mast

The lateral play is adjusted with 0.5 or 1 millimetre shims behind the thrust rollers. If there is
excessive play between thrust roller and roller surface on the mast profile, the thrust roller
must be replaced with a new roller with a larger diameter.
Thrust rollers are available in three different diameters (the diameter is specified on each
roller):
160 mast:
• 78.2 mm, 78.6 mm 79.0 and 79.4 mm.
200 mast and TF-mast:
• 107.0 mm, 107.5 mm 108.0 mm, and 108.5 mm.
Mast type Permitted play between thrust rollers and roller surfaces between mast
sections and fork carriage and mast
160 0.5 mm
200 0.6 mm
TF 0.6 mm
6.2.2.4 Changing the DFTV mast

1) Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate
cylinder lift chain slackens.
2) Release the lift chain from the intermediate cylinder by releasing the chain bolt, and
removing the pin between the bolt and chain.
3) Lift the mast until the fork carriage separates from the inner mast.
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4) Place a wooden block on the straddle legs between the outer profiles so that it comes
under the intermediate cylinder. Lower the inner and intermediate masts so that the
inner mast rests on the wooden block and the outer chains slacken.
5) Remove the two outer chains by removing the pins in the upper chain attachment.
6) Release the hoses that run in the mast from the block in the outer mast, and plug them.
7) Remove the pulley wheel for the hoses from the intermediate mast.
8) Remove the pulley wheel for the chains from the intermediate mast.
9) Unscrew the screw for the lifting stop.
Figure 45. Screw, lifting stop

10) Lift the inner mast straight up until the inner mast’s lower support rollers and the
intermediate mast’s upper support rollers meet, and then pull the inner mast forwards to
release it from the intermediate mast. If the ceiling is too low dismantle the mast, see
Section 6.2.1.1, page 67, and lay it down.
Figure 46. Position for dismantling intermediate masts
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11) Remove the upper securing screws for the side cylinders.
12) Lift out the intermediate mast in the same way as the inner mast.
13) Torque
6.2.2.5 Changing the TFV mast

3) Lift the mast until the fork carriage separates from the inner mast.
4) Lower the mast to its bottom position.
5) Release the hose from the outer mast and plug it. Remember to remove the cable ties.
7) Lift the inner mast straight up until the inner mast's lower support roller and the outer
mast's upper support roller meet, and then pull the inner mast forwards to release it from
the outer mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page
67, and lay it down.

8) Torque
6.2.2.6 Replacing a TV mast

1) Lower the fork carriage onto a European pallet, or the like, so that the lift chains slacken.
2) Release the lift chains from the outer mast by removing the upper pins.
3) Lift until the fork carriage separates from the inner mast.
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7) Torque
6.2.2.7 Replacing a T mast

3) Lift until the fork carriage separates from the inner mast.
5) Secure the lift cylinder so that it cannot move sideways.
6) Remove and plug the oil pipes.
7) Release the upper retaining bolts on the lift cylinder from the inner mast.
8) Remove the lower retaining screw.
9) Carefully lift up the inner mast until it can be lifted out from the cylinder.
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11) Torque
6.2.3 Lift chains

6.2.3.1 Replacement
1) Remove any stop screw in the inner mast.
Figure 50. Screw, lifting stop

2) Lower the fork carriage onto a European pool pallet, or equivalent, so that the lifting
chains slacken.
3) Remove the lift chain.
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6.2.3.2 Re-fitting the chains

When chains are re-fitted it is important to align them correctly, and that there is no
deterioration of the clearance.
6.2.3.3 Checking the lift chains

• Check that the chain is clean. Measure when the forks are unloaded.
• Measure the chain elongation. Measure along the 25 links that go over the pulley wheel,
since elongation is normally greatest here. Compare with the measurements below. If
the chain has stretched by more than 2% it must be replaced.
Figure 51. Chain dimensions
Chain P (nominal) Pitch P (true) Actual Measureed over 25 Maximum stretch

dimensions dimension (mm) pitch dimension links New chain over 25 links is
(inches) (mm) (mm) 2% (mm)
1/2”-2*2 12,70 12,59 314,75 321,05
5/8”-4*4 15,88 15,875 396,88 404,81
3/4”-3*4 19,05 19,05 476,25 485,78
3/4”-4*4 19,05 18,91 472,75 482,21
1”-4*4 25,40 25,32 633,00 645,66
1 1/4”-4*4 31,75 31,54 788,50 804,27
1 1/2”-4*4 38,10 38,06 951,50 970,53
• Measure the height of the chain's link plates, i.e. dimension G, Figure 51, page 78.
Max. wear is 5%. Measure the original height where the chain is not worn as a
comparison.
Example: A chain has an original plate height of 23.2 mm. Therefore the plate height should
be at least 23.2 - 5% = 23.2 x 0.95 = 22 mm.
• Make sure than none of the pins in the plates have twisted.
Figure 52. Twisted pin

• Make sure that there are no cracks in the plates.
• Look for traces of mechanical damage or rust.
• Check that the chain runs easily over the pulley wheel and does not jam.
• Lubricate the chain after cleaning and inspection. For the recommended types of oil and
grease, see Section 1.6, page 11.
6.2.4 Forks
6.2.4.1 Adjusting the lowest height on forged forks
1) The inner and outer masts should be lowered.
2) Adjust the two outer lifting chains so that the mast just hangs a little from them.
3) Adjust the middle chain so that the fork head is 5 ± 2 mm from the ground.
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6.2.4.2 Adjusting the lowest height on welded forks

1) The inner and outer masts should be lowered.
2) Adjust the two outer lifting chains so that the mast just hangs a little from them.
3) Adjust the lifting chains so that the fork height is as shown in the table.
Fork height in lowered position:
Table 18. Height of forks over floor in rest position

Mast type Min Max (mm)
A-Ergo 160 controlled by ground clearance 89
A-Ergo 200 controlled by ground clearance 91
A-Ergo Telescopic forks (TF) controlled by ground clearance 73
6.2.4.3 Inspection of forged forks

6.2.4.3.1 General
CAUTION!
Inspection of the forks must be carefully performed by trained personnel.
The purpose of the inspection is to detect damage, faults, deformation, etc. Forks showing
this type of damage may not be used before they have been repaired and tested in
accordance with ISO 2330.
Several test points are included in the fork inspection. A fork inspection in accordance with
ISO/ 5057 must be carried out on at least one (1) occasion per year on forks that are in use;
if deformation, damage or other permanent changes are discovered at any other time, an
inspection must be carried out immediately. If the forks are often used for heavy lifting, the
fork inspection interval may be shorter. If the forks fail to meet any of the inspection points,
the machine must be taken out of service. If the customer is not prepared to do this, it should
be written in the report that: "The forks do not comply with the requirements in ISO/ 5057".
When the customer subsequently signs the service order, they bear the responsibility for the
defective forks.
In case of doubt, comply with the requirements set by the applicable ISO standard or by the
fork manufacturer. See table.
The fork blade is bent ISO/5057
Crack formation ISO/5057
Wear ISO/5057
Fork tip Fork manufacturer
Fork angle Fork manufacturer
Difference in height between the tips of the forks ISO/5057
Locking device ISO/5057
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Worn fork hook ISO/5057

Fork labelling ISO/5057
6.2.4.3.2 The fork blade is bent
A. Ruler B. Deformation location

The fork blade must not be bent downwards by more than a certain proportion of the length
of the fork.
l= fork blade length in mm.
k= measurement in mm between the fork blade tips and a ruler.
Measurement when a blade must be changed: greater than k=l/33. Example: k=1150/33= 34
mm.
6.2.4.3.3 Crack formation
A. Attachment hooks B. Heel

Use a non-destructive method to check if there are cracks in the forks. Take extra care when
checking around the insides of the holes and the securing hooks. If cracks are detected, the
forks must not be used.
6.2.4.3.4 Wear
Figure 53. Wear/markings

A. Fork labelling. C. Wear in the fork heel.
B. Location for measuring the shank thickness.
Check the forks for wear, especially around the heel. If 10% of the original thickness of the
fork has been worn away, the fork must not be used.
Example: original thickness (n) = 40 mm -> limit for the fork not to be used = 36 mm. (n)-10%
= forks must be changed.
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Worn forks must not be welded or repaired in any other way.

The original thickness is found by:
• Read the markings. The markings must show the lifting capacity in kg for one fork and the
centre of gravity distance in mm. The markings often also show the original thickness.
• measure the blade thickness at the centre of the shank (position B).
6.2.4.3.5 Fork tip
As soon as a fork tip is worn, it must be shortened or the complete fork changed.
6.2.4.3.6 Fork angle
Measure 500 mm along the fork blade and 500 mm along the back of the fork and mark
these positions. Measure the diagonal distance between these two points and use the table.
The distance must be within the acceptable values in accordance with Table 19, page 81,
otherwise the forks must not be used.
Table 19. Fork angle

The results Measurement result
Optimal 707 mm
Acceptable 695-713 mm
6.2.4.3.7 Difference in height between the tips of the forks
A. Difference in height between the forks

The difference in height between the fork tips must not exceed 3% of the fork blade length.
Example: fork length 1150 mm - max. height difference 34 mm.
If the difference in height between the fork blades is greater than 3%, the forks must not be
used.
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6.2.4.3.8 Locking device
Figure 54. Locking device

The function of the locking device is to prevent the fork from moving sideways by itself.
Check that the originally fitted locking device works as intended. If this is not the case, the
forks must not be used until the fault in the locking device has been rectified.
6.2.4.3.9 Worn fork hook
Sideways forces and long periods of use can result in bent fork hooks. If this has occurred,
the forks must not be used.
6.2.4.3.1 Fork labelling

0
The fork markings must be clearly legible and include the lifting capacity in kg for one fork,
and the centre of gravity distance in mm. If the markings are illegible, the forks must not be
used. See Figure 53, page 80.
Older forks do not have these markings, but may be used anyway. The prohibition applies to
forks which have markings but are damaged.
6.2.4.4 Inspection of welded and telescopic fork carriages

6.2.4.4.1 General
CAUTION!
Inspection of the forks must be carefully performed by trained personnel.
The purpose of the inspection is to detect damage, faults, deformation, etc. A fork carriage
showing this kind of damage may not be used until it has been repaired.
6.2.4.4.2 The fork blade is bent
A. Ruler B. Deformation location

The fork blade must not be bent downwards by more than a certain proportion of the length
of the fork. If the fork blade is bent too much, the fork carriage must be straightened or
replaced.
l= fork blade length in mm.
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k= measurement in mm between the fork blade tips and a ruler.

Measurement when a blade must be straightened: greater than k=l/33. Example: k=1150/33=
34 mm.
NOTE!
Repairs must be carried out by a licensed welder.
6.2.4.4.3 Crack formation
1. Front welded joints 2. Rear welded joints

Check whether the forks are cracked. Take extra care when welding joints at the front (item
1) and rear (item 2). If cracks are detected, the fork carriage must be replaced or repaired.
NOTE!
6.2.4.4.4 Fork angle
Measure 500 mm along the fork blade and 500 mm along the back of the fork and mark
these positions. Measure the diagonal distance between these two points and use the table.
The distance must be within the acceptable values in accordance with Table 20, page 83,
otherwise the forks must not be used.
Table 20. Fork angle

The results Measurement result
Optimal 707 mm
Acceptable 695-713 mm
6.2.4.4.5 Difference in height between the tips of the forks
A. Difference in height between the forks

The difference in height between the fork tips must not exceed 3% of the fork blade length.
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Example: fork length 1150 mm - max. height difference 34 mm.

If the difference in height between the fork blades is greater than 3%, the forks must not be
used.
NOTE!
6.2.4.4.6 Locking device and chain
The function of the locking device is to secure the telescopic forks to the fork carriage. Check
that the locking device (item 1) works as intended.
Check that the chain (item 2) is correctly tensioned and in good condition. Adjust by means
of the adjusting screw (item 3) as necessary.
Check that the thrust rollers (item 4) spin freely and are not jammed.
The fork carriage must not be used until any faults have been rectified.
6.2.5 Fork carriage

6.2.5.1 Adjusting the fork carriage
1) The thrust rollers have a specific clearance to the roller surfaces.
2) The lateral play is adjusted by adjusting the number of shims behind the load rollers,
and by replacing the rollers.
For the amount of permitted play, see Section 6.2.2.3, page 73.
6.2.5.2 Dismantling the fork carriage

1) Lower down the fork carriage on to a Euro pallet, or equivalent.
2) Remove the lift chain.
3) Lift up the inner mast with truck’s standard hydraulic system until the fork carriage is
released.
CAUTION!
Observe great caution!
4) Reverse the truck away.
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6.2.6 Fork carriage with telescopic forks (TF)

6.2.6.1 Dismantling the TF fork carriage
The fork carriage only needs to be lifted out of the frame when replacing fork carriage rollers.
To lift out, see the instructions for dismantling the type of frame the truck is equipped with.
1) Lift the fork carriage to a suitable height to dismantle the over-cogging protection on the
back of the fork carriage (see Figure 55, page 85).
Figure 55. Over-cogging protection

2) Lower the fork carriage to a suitable height to achieve a comfortable working position;
make sure that the forks are fully withdrawn.
3) Pull the battery plug out from the electrical panel plug to disconnect the current to the
truck’s electrical system.
4) Release the flexible cable to the fork drive motor by loosening the two nuts that hold the
motor’s end head, and then remove the cables connections to the motor.
5) Release the bolts (item 1) enough to be able to adjust the chain tensioning bolt (item 2).
Screw the bolt to the left so that the chain slackens and the chain lock (item 3) can be
removed (see Figure 56, page 86).
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Figure 56. Chain tensioning bolt

6) Remove the bolts completely and lift off the drive assembly.
7) Loosen the screws on the forks and pull off the forks (see Figure 57, page 86).
Figure 57. Fork bracket

8) Release the chain adjuster (item 1, see Figure 58, page 87).
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Figure 58. Chain adjustment

9) Remove the chain lock (item 2) and remove the chains (item 3, see Figure 58, page
87).
10) Remove the sprockets from the tips of the roller joists.
11) Remove the side thrust rollers (see Figure 59, page 87).
Figure 59. Side thrust rollers

12) Remove the outer lock rings holding the side bearings for the shaft (item 1, see Figure
60, page 88).
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Figure 60. Outer lock rings for side and centre bearings
13) Remove the centre bearing (item 2, see Figure 60, page 88). Drive the shaft to one
side so that the side bearing is pressed out from the fork carriage. Remove the bearing
and lift the shaft out from the fork carriage.
14) Note the order in which the gear, circlips and spacers are fitted, and then work them off.
6.2.6.2 Assembling the TF fork carriage

1) Fit the sprockets in the tips of the roller joists. Lightly grease the bearing inside and
outside before fitting.
2) Fit the rear shaft with sprocket, stop rings and bearing housing. Check that the shaft is
not tensioned skew by rotating it by hand at least one turn in each direction.
3) Fit and adjust the fork chains so that they run parallel with the sprockets, and so that
they give 2-4 mm in the middle. Lock the sprockets, stop rings and chain tensioners.
Lightly grease the chains along their entire length.
4) Fit the over-cogging guard.
5) Fit and adjust the roller attachments by using a fork, so that the play is less than 0.3
mm. Ensure that the forks are centred on the roller joists. Remember to lock with the
screws.
6) Lightly grease all the roller surfaces along their entire length, and fit the forks.
7) Fit the complete motor. Fit and adjust the lower motor chain so that it runs parallel
between the sprockets, and so that it gives 2-4 mm in the middle. Lock the motor
attachment and the sprocket. Lightly grease the chain along its entire length.
8) Remove the plug in the gearbox and check the oil level, which should reach to the
centre of the output shaft. Replenish if necessary.
6.2.6.3 Checking the TF fork carriage after assembly

Test run the fork carriage and check that:
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• the forks do not jam.

• the forks go fully in and out.
• the chains run parallel between the sprockets.
• there is no abnormal noise.
• the overload clutch slips in the end positions.
6.2.6.4 Adjusting the overload clutch (TF)

The spring tension is not adjustable, since the tensioning nut (item 1) must be fully screwed
in and locked with stop screws. The bearing (item 2) and sprocket (item 3) must be lightly
lubricated with cold-resistant grease (-35°C), see Figure 61, page 89.
WARNING!
There must not be any grease on friction surfaces. If there is any damage to the
overload clutch, it must be completely replaced.
Figure 61. Overload clutch
6.2.6.5 Replacing the fork drive motor (TF)

1) Release the cable bracket and the cover over the engine, and lift them off.
2) Note the connection of the electric cables, and release them.
3) Remove the bolts.
4) Lift the motor straight up.
Figure 62. Fork drive motor and gearbox
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6.2.6.6 Replacing the coupling between the fork drive motor and the gearbox (TF)
1) Remove the motor, refer to Section 6.2.6.5, page 89.
2) Release the coupling by unscrewing the stop screw and pulling off the coupling.
3) Push on a new and tighten it with the stop screw.
4) Loosen and pull off the coupling half located in the gear, and fit a new one.
5) Fit the motor, connect the cables, and test drive.
6.2.6.7 Replacing the fork drive motor wiring (TF)

1) Lift the forks approx. one metre above the floor.
2) Release the bracket holding the electric cable at the motor.
3) Remove the cover over the drive motor end, where the electric cable goes in.
4) Remove the panel over the component box, including all the clips holding the cable.
5) Check the markings and positioning of the electric cables.
6) Release the cable and pull it out.
7) Move the springs over to the new cable, put it in place, and connect it.
8) Fit the cover and bracket over the drive motor.
9) Clamp the cable securely and lift the forks a number of times to check that it is not
trapped, catches, or rubs against anything.
10) Fit the panels.
6.2.7 Vertically adjustable straddle legs

6.2.7.1 Adjusting the vertically adjustable straddle legs
1) Place the truck on a level surface and lower the forks and straddle lift.
2) heck that the distance between the floor and top of the forks corresponds with Table 21,
page 91. Measure at four places:
• at each fork tip
• on each side behind the forks
3) Check that the distance is the same between mast and guides. If necessary adjust to
obtain equal distances by means of the adjusting screws, both at the top and bottom.
4) The side play of the mast must not exceed 0-0.5 mm. Because of the tolerance in the
linearity of the mast section a maximum amount of play of 1.5 mm is permitted at the
“worst point”, with the mast raised or lowered. This means that if for example the play is
0.5 mm with the straddle lift raised, the play with the straddle lift at its lower position
should be max 1.5 mm, and vice versa.
5) Check the play between the roller surfaces on the mast and the guides. For the amount
of permitted play, see Section 6.2.2.3, page 73.
6) Check that the forks are horizontal.
7) If the fork tips point upwards, shims above the pressure plate should be removed
(assuming that the forks are straight).
8) If the fork tips point downwards, shims should be added above the pressure plate
(assuming that the forks are straight).
90 A-Ergo
06 Mast system
Figure 63. Positioning of shims

9) When the forks are parallel, check the height. The cylinders can be extended if it is not
high enough.
10) Test lift, and check that the straddle legs do not lift skew. If so, adjust the length of the
cylinders until the best lifting movement is obtained.
11) Check measure, and if necessary make further adjustments.
Table 21. Measuring the height of the vertically adjustable straddle legs/forks
Truck with vertically adjustable straddle legs
Distance to the fork upper surface Max 95 mm
Distance to top of straddle leg Max 90 mm
Min 85 mm
6.2.7.2 Dismantling and assembling of the vertically adjustable straddle legs

1) Lift up the straddle legs with the truck. Place a block under the fork tips and lower down
the straddle legs, whereby the load wheel is lifted from floor level.
2) Tap out the retaining pin through the shaft and drive out the shaft that holds the fork
wheel.
3) Tap out the retaining pin at the pressure link arm and pull out the load wheel, pull rods
and pressure link arm as a complete assembly.
4) Tap out the shafts from the ends of the pull rods.
5) Check for wear and replace damaged parts if necessary.
6) Refit in the reverse order.
7) Check the lifting movement. If the straddle lift pulls at an angle it must be adjusted, see
Section 6.2.7.1, page 90.
6.2.8 Side stabilisers

6.2.8.1 Checking the side stabiliser
1) Position the truck on a level surface.
2) Fix a tape measure with the zero at the top edge of one fork. Lift until the stabiliser
switch in the mast breaks, i.e. until the mast stops, and measure the height. The lift
height should be at 3000 mm +/- 25 mm.
3) Extend the stabilisers until the motor stops. Check that the wheels are pressed against
the floor and check the residual suspension. See Table 22, page 92.
A-Ergo 91
06 Mast system
Table 22. Check values for side stabilisers

When the stabilizers are extended at full speed, the spring should be compressed by 4-9 mm
when the pump motor has stopped. Irregularities in the floor are absorbed by the spring in the
top of the cylinder (see Figure 64, page 92).
Residual suspension with fully extended stabilizers and a level floor surface. 5-10 mm
Figure 64. Check points for side stabilisers
6.2.8.2 Longitudinal adjustment of the side stabilizers

• Mechanical adjustment is performed by adjusting the upper or lower end of the cylinder.
6.3 Diagnostics and trouble shooting

6.3.1 Troubleshooting chart
Table 23. Symptom/Action table
Symptom Possible cause Procedure
Play in the mast Insufficient shims for the mast rollers Repeat the shimming procedure
The mast lowers Mast rollers shimmed too tight Repeat the shimming procedure
unevenly and jerks
No lubricating grease on the mast roller Grease the roller surfaces
surfaces
The mast squeaks No lubricating grease on the mast roller Grease the roller surfaces
surfaces
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Service Manual A-Ergo — D003936, C, GBR, Translated

6.1 Design and function 63

6.2 Repair and maintenance instructions 67

6.3 Diagnostics and trouble shooting 92

Table 17. Mast types

6.1.2 Fork carriage

Figure 27. Fork carriage with fixed forks

Figure 28. Fork carriage with laterally adjustable forks

Figure 29. Fork carriage with extendable/telescopic forks

Figure 30. Overload clutch

6.1.3 Vertically adjustable straddle legs

Figure 31. Vertically adjustable straddle legs

6.1.4 Side stabilisers

Figure 32. Stabilizers

6.2 Repair and maintenance instructions

Figure 33. Blocking up the chassis

Figure 34. Suspending the mast

Figure 35. Vertically adjustable straddle legs

Figure 36. Spacer/guide screw

Figure 37. Secure the guides together

Figure 38. Upper screw attachment, mast

7) Remove the hydraulic connections.

Figure 39. Hydraulic connection

6.2.1.2 Mounting the mast/straddle legs on to the chassis

Figure 40. Example of suspended mast

Figure 41. Secure the guides together

Figure 42. Spacer/guide screw

Figure 43. Shims

If the mast has vertically adjustable straddle legs:

Figure 44. Removing the spacer/guide screw

6.2.2 Dismantling the mast

6.2.2.2 Adjustment of the side lean in the top position

6.2.2.3 Adjusting the play in the mast

6.2.2.4 Changing the DFTV mast

Figure 45. Screw, lifting stop

Figure 46. Position for dismantling intermediate masts

6.2.2.5 Changing the TFV mast

Figure 47. Position for dismantling intermediate masts

6.2.2.6 Replacing a TV mast

Figure 48. Position for dismantling intermediate masts

6.2.2.7 Replacing a T mast

Figure 49. Position for dismantling intermediate masts

6.2.3 Lift chains

Figure 50. Screw, lifting stop

6.2.3.2 Re-fitting the chains

6.2.3.3 Checking the lift chains

Figure 51. Chain dimensions

Chain P (nominal) Pitch P (true) Actual Measureed over 25 Maximum stretch

Figure 52. Twisted pin

6.2.4.2 Adjusting the lowest height on welded forks

Table 18. Height of forks over floor in rest position

6.2.4.3 Inspection of forged forks

Worn fork hook ISO/5057

6.2.4.3.2 The fork blade is bent

A. Ruler B. Deformation location

6.2.4.3.3 Crack formation

A. Attachment hooks B. Heel

Figure 53. Wear/markings

Worn forks must not be welded or repaired in any other way.

6.2.4.3.5 Fork tip