4000 SRM 1148 Fork Repair
Legend for Figure 1
A. TWO-STAGE LFL
MAST
B. TWO-STAGE FFL MAST
C. THREE-STAGE F
FL MAST
D. FOUR-STAGE FFL MAST
1. OUTER MAST
2. INNER MAST
3. INTERMEDIATE MAST
4. HOOK
5. FREE-LIFT CYLINDER
6. CARRIAGE BAR
7. CROSSMEMBER
8. FIRST INTERMEDIATE MAST
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power, and remove
key. Put a DO NOT OPERATE tag in the operator’s
compartment. Disconnect battery and put a tag or
lock on battery connector.
5. Install another safety chain (9.5 mm (3/8 in.)
minimum) between the top or bottom bar of the
carriage (6) and a crossmember on the outer
mast as a secondary safety device. Install a DO
NOT REMOVE tag on the safety chain(s).
Fork Repair
The forks are held on the carriage by hooks. The
forks are kept in position by pins that fit through the
top fork hooks and into slots in the top bar carriage.
If pin does not remain engaged in carriage slot, re-
place with new pin. Always check that the pins for
the forks keep the forks in position on the carriage.
Replace damaged fork pin parts. The forks can be
removed from the carriage by aligning the forks with
the fork removal notch. The fork removal notch is in
the bottom bar of the carriage.
REMOVE
WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
A fork can be removed from the carriage for replace-
ment of the fork or other maintenance. Slide the fork
to the fork removal notch in the bottom bar of the car-
riage. See Figure 2 and Figure 3. Lower the fork onto
blocks so the bottom hook of the fork moves through
the fork removal notch. See Figure 3. Lower the car-
riage further so the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away
from the fork or use a lifting device to move the fork
away from the carriage.
INSTALL
Movetheforkandcarriagesothetophookonthe
fork can engage the upper carriage bar. Raise the
carriage to move the lower hook through the fork re-
moval notch. Slide the fork on the carriage so both
upperandlowerhooksengagethecarriagebars.En-
gagethelatchpinwithanotchintheuppercarriage
bar.
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Figure 2. Hook Fork Removal
3
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