616838-05b - Mechanical Maintenance - 58509

NSP Service Manual
5.11.2 Mast unit maintenance
This section presents the regular maintenance procedures for mast units. Regular
maintenance ensures that the truck and its mast unit remain in good working condition
and safe for its users.
5.11.2.1 Daily maintenance
• Check the mast unit externally for any oil leaks.

• Check all the wheels for damages or outer wear.
• Switch on the current and test the operation of the lifting hydraulics by lifting and
lowering the forks.
• Check that all the fastenings of the mast chains are in order.¨
• Check the condition of the forks. For instructions, see section 5.11.7.
5.11.2.2 Monthly maintenance
• Check the tightness of all the screws, nuts and pipe / hose connections.
• Check the tension of the mast chains. All chain pairs should have equal tension to
ensure proper load distribution and mast operation. For instructions on how to
check the mast chain tension and adjust the chains, see sections 5.11.9.2 and
5.11.9.3.
• Grease all unpainted areas in the mast channels.
5.11.2.3 Annual maintenance (600 h)
• Clean and lubricate the mast chains. The main and free lift chains have been
lubricated at the factory. Avoid removal or contamination of the factory-applied
lubrication. Do not wash, sand blast, etch, steam clean or paint the chains. If the
chains require lubrication, see the lubricant and fluid recommendations in section
5.11.3.
• Check the chains for stretching. For instructions, see section 5.11.9.1.
• Check all the cylinder attachments.
• Check the cylinders for any damages, nicks, marring or scratches.
Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 69 (322)
NSP Service Manual
5.11.3 Lubricant and fluid recommendations
5.11.3.1 Mast chains
For the best chain life, use graphite or molybdenum type lubricants (e.g. sprays), which
evaporate, leaving the graphite or molybdenum on the chain.
CAUTION
Using oil or grease to lubricate the chains in dusty or sandy riding conditions may
cause dirt particles to stick to the chains, resulting in rapid wear from abrasion.
5.11.3.2 Mast channels
For the lubrication of the mast channels, use lubrication grease NLGI No. 2 containing
molybdenum disulphide.
5.11.4 Removing the mast unit
CAUTION
Before you remove the mast unit from the truck, lower the mast unit and support the
truck frame properly so that the load wheels are slightly lifted from the ground.
Before you disconnect any hydraulic pipes or hoses, make sure that all pressure is
released from the hydraulic system.
5.11.4.1 Simplex mast
1. Support the truck frame against the

floor.
NSP Service Manual
2. Remove the locking pin from the

chain anchor attached to the lifting
carriage.
3. Remove the two nuts from the chain
anchor.
4. Remove the chain anchor from the
mounting hole.
5. Remove the chain anchor from the
chain.
6. Remove the level rod.
7. Attach a lifting device to the lifting

carriage and lift it out of the lifting
carriage.
8. Support the mast unit by attaching a lifting device to the lift points at the top of the
mast and tightening the lifting ropes/chains.
NSP Service Manual
9. Remove the bolts attaching the mast

unit to the truck frame.
10. Move the mast approximately 5-

10 cm away from the truck.
11. Remove the hydraulic connector

connecting the mast unit to the
hydraulic aggregate.
12. Plug the hydraulic connector on the
mast unit side to prevent oil leakage.
NSP Service Manual
13. Remove the mast unit using the

lifting device.
5.11.4.2 Duplex mast
1. Lift the forks up.

2. Remove the locking bolts
underneath the lifting carriage.
3. Lower the forks.
NSP Service Manual

floor.
5. Support the mast unit by attaching a

lifting device to the top of the internal
mast and tightening the lifting
ropes/chains.
6. Remove the locking pin(s) from the

chain anchor(s) attached to the
lifting carriage.
anchor(s).
8. Remove the chain anchor(s) from
the mounting hole(s).
the chain(s).
10. Lift the mast unit up from the first

internal mast.
11. Remove the lifting carriage.
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10 cm away from the truck

NSP Service Manual

lifting device.
5.11.4.3 Triplex mast

3. Lower the forks.
NSP Service Manual

floor.

ropes/chains.
6. Remove the locking pin(s) from the

chain anchor(s) attached to the
lifting carriage.
anchor(s).
the mounting hole(s).
the chain(s).
10. Lift the mast unit up from the first

internal mast.
NSP Service Manual


10 cm away from the truck.

NSP Service Manual

lifting device.
5.11.4.4 Simplex mast with initial lift

floor.
2. Remove the locking pins from the

chain anchors attached to the lifting
carriage.
anchors.
4. Remove the chain anchors from the
mounting holes.
chains.
NSP Service Manual
6. Remove the level rod.
7. Attach a lifting device to the lifting

carriage and lift it out of the mast
unit.
8. Support the mast unit by attaching a lifting device to the lift points at the top of the
mast and tightening the lifting ropes/chains.
9. Disconnect the hydraulic hose.

NSP Service Manual
11. Remove the screws of the initial lift

cylinder.
12. Remove the bolts attaching the top

and bottom initial lift leverages to the
truck frame.
13. Remove the top and bottom initial
leverage shafts.

lifting device.
NSP Service Manual
5.11.4.5 Duplex and triplex masts with free lift and initial lift

3. Lower the forks.

floor.
NSP Service Manual

ropes/chains.

chain anchors attached to the lifting
carriage.
anchors.
mounting holes.
chains.
10. Lift the mast unit up from the (first)

internal mast.
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12. Remove the screws of the initial lift

cylinder.
13. Disconnect the hydraulic hose.

15. Remove the bolts attaching the top

and bottom initial lift leverages to the
truck frame.
16. Remove the top and bottom initial
leverage shafts.
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lifting device.
5.11.5 Disassembly of the mast unit
The steps provided in the following sections guide you through the disassembly of the
different types of mast units.
WARNING
During the disassembly of the mast unit, mark down the direction of the different
hydraulic connectors, the correct attachment points, direction of the rollers and the
correct positioning of the hydraulic hoses and pipes.
During the assembly of the mast unit, make sure that all the hydraulic connections,
attachment points, roller directions and hose and pipe positions are the same as before
disassembly.
Prepare a drip pan to catch any remaining oil in the pipes and hoses before
disconnecting each pipe. Take appropriate actions to prevent dust and dirt from
entering in the opening of the pipe and valve connections.
NSP Service Manual
5.11.5.1 Simplex mast
1. Slide the chain off the chain wheel.
2. Remove the locking pin from the top

chain anchor.
3. Remove the two nuts from the top
chain anchor.
4. Remove the top chain anchor from
the mounting hole.
the chain.
6. Remove the pin attaching the chain

yoke to the free lift cylinder.
7. Remove the chain yoke from the
free lift cylinder.
NSP Service Manual
8. Remove the free lift cylinder collar.

9. Remove the free lift cylinder.
10. Remove the circlips from the lifting

carriage’s main rollers.
11. Remove the ball bearings from the
main rollers.
12. Remove the main rollers from the
lifting carriage.
13. Remove the nuts of the main rollers.
14. Remove the screws of the main
rollers.
5.11.5.2 Simplex mast with initial lift
1. Remove the lock pin of the top initial

lift leverage.
2. Remove the top initial lift leverage
from the mast unit.
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chain anchor.
chain anchor.
the mounting hole.
the chain.
8. Remove the pin attaching the chain

yoke to the free lift cylinder.
free lift cylinder.
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12. Lay the mast unit down onto a pallet

or a strong table.
13. Remove the lock pins from the

bottom initial lift leverage’s shafts.
14. Remove the bottom initial lift
leverage’s shafts from the mast unit.
15. Remove the bottom initial lift
leverage from the mast unit.
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main rollers.
lifting carriage.
rollers.
5.11.5.3 Duplex mast with one lift cylinder

chain anchor.
chain anchor.
the mounting hole.
the chain.
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6. Remove the hydraulic pipe/hose.

or a strong table.
8. Remove the locking pins attaching

the chain yoke to the top of the
internal mast.
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9. Remove the circlip from the bottom

of the lift cylinder.
10. Support the lift cylinder and lift the

internal mast slightly up so that the
chain yoke comes loose.
11. Remove the lift cylinder.

12. Remove the locking pin attaching
the chain yoke to the lift cylinder.
13. Remove the chain yoke from the lift
cylinder.
NSP Service Manual
14. Remove the bottom guidance

rollers.
15. Loosen the guidance rollers holding

the internal mast straight.
16. Slide the internal mast out, tilting it

slightly upward at the end.
17. Remove the guidance rollers from

the mast unit and internal mast.
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18. Remove the circlip from the main

rollers of the internal mast.
19. Remove the main rollers.

main rollers.
lifting carriage.
rollers.
5.11.5.4 Duplex mast with two side cylinders
1. Slide the chains off the chain

wheels.
NSP Service Manual

top chain anchors.
chain anchors.
4. Remove the top chain anchors from
the mounting holes.
5. Remove the top chain anchors from
the chains.
6. Remove the hydraulic pipe/hoses.

or a strong table.
NSP Service Manual

the chain yokes to the top of the
internal mast.
9. Slide the internal mast slightly out so
that the chain yoke comes loose
from the top of the internal mast.
the chain yokes to the side
cylinders.
11. Remove the chain yokes from the
side cylinder.
12. Remove the circlips from the bottom

of the side cylinders.
13. Remove the bottom hydraulic

connector from the side cylinders.
14. Remove the side cylinder collars.
15. Remove the side cylinder.
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rollers.



NSP Service Manual


main rollers.
lifting carriage.
rollers.
5.11.5.5 Duplex mast with free lift
NSP Service Manual

chain anchor.
chain anchor.
the mounting hole.
the chain.
6. Remove the hydraulic connections

from the cylinders.
7. Remove the pipe/hose clips.
8. Remove the hydraulic pipe/hoses.
9. Remove the locking pin attaching

the chain yoke to the free lift
cylinder.
free lift cylinder.
NSP Service Manual


or a strong table.
14. Remove the screws attaching the

side cylinder hydraulic connectors to
the top of the internal mast.
15. Remove the hydraulic hose
connectors from the side cylinder
hydraulic connectors.
16. Remove the side cylinder hydraulic
connectors.
NSP Service Manual
17. Remove the circlips from the bottom

of the side cylinders.
18. Remove the bottom hydraulic

connector from the side cylinders.
19. Remove the side cylinder collars.
20. Remove the side cylinders.

rollers.

NSP Service Manual




main rollers.
lifting carriage.
rollers.

616838-05b - Mechanical Maintenance - 58509

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NSP Service Manual

5.11.2 Mast unit maintenance

5.11.2.1 Daily maintenance

• Check the mast unit externally for any oil leaks.

5.11.2.2 Monthly maintenance

5.11.2.3 Annual maintenance (600 h)

5.11.3 Lubricant and fluid recommendations

5.11.3.1 Mast chains

5.11.3.2 Mast channels

5.11.4 Removing the mast unit

5.11.4.1 Simplex mast

1. Support the truck frame against the

2. Remove the locking pin from the

6. Remove the level rod.

7. Attach a lifting device to the lifting

9. Remove the bolts attaching the mast

10. Move the mast approximately 5-

11. Remove the hydraulic connector

13. Remove the mast unit using the

5.11.4.2 Duplex mast

1. Lift the forks up.

3. Lower the forks.

4. Support the truck frame against the

5. Support the mast unit by attaching a

6. Remove the locking pin(s) from the

10. Lift the mast unit up from the first

12. Remove the bolts attaching the mast

13. Move the mast approximately 5-

14. Remove the hydraulic connector

16. Remove the mast unit using the

5.11.4.3 Triplex mast

1. Lift the forks up.

3. Lower the forks.

4. Support the truck frame against the

5. Support the mast unit by attaching a

6. Remove the locking pin(s) from the

10. Lift the mast unit up from the first

12. Remove the bolts attaching the mast

13. Move the mast approximately 5-

14. Remove the hydraulic connector

16. Remove the mast unit using the

5.11.4.4 Simplex mast with initial lift

1. Support the truck frame against the

2. Remove the locking pins from the

6. Remove the level rod.

7. Attach a lifting device to the lifting

9. Disconnect the hydraulic hose.

11. Remove the screws of the initial lift

12. Remove the bolts attaching the top

14. Remove the mast unit using the

1. Lift the forks up.

3. Lower the forks.

4. Support the truck frame against the

5. Support the mast unit by attaching a

6. Remove the locking pins from the

10. Lift the mast unit up from the (first)

12. Remove the screws of the initial lift

13. Disconnect the hydraulic hose.

15. Remove the bolts attaching the top

17. Remove the mast unit using the

5.11.5 Disassembly of the mast unit

5.11.5.1 Simplex mast

1. Slide the chain off the chain wheel.