This article covers everything you need to know about forklift masts.
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What Is a Forklift Mast?A forklift mast, also called an upright, is the part of the forklift that lifts, lowers, and positions the load.
The mast is the “working” part of the forklift that allows vertical movement
In other words, it’s the component that actually does the primary work that a forklift is designed to do.
There are different types of forklift masts to fit different jobs and material handling specifications.
We’ll cover those later on.
Forklift Mast TerminologyThe following are some important forklift mast terms you should know:
The maximum fork height (MFH) is how high the forks will actually go when you fully extend the mast.
The maximum fork height is how high the forks go when fully extended
It’s measured from the ground to the top of the forks.
Unlike maximum fork height, the overall raised height is measured from the top of the mast (or load backrest) when the mast is fully extended.
This measurement is important to know since a fully extended mast can damage overhead obstructions like semi-trailer ceilings and sprinkler systems.
This is the height of the mast when it’s fully lowered.
It’s measured from the floor to the top of the mast.
This measurement is important because it determines what areas you can fit the lift into within your facility.
For instance, if you have 8-foot door heights, you’ll need a forklift with a collapsed height of fewer than 8 feet.
This refers to the amount of free lift available.
What is free lift on a forklift?
It’s the ability of the carriage to rise without making the inner rails protrude from the top of the mast.
Why is this important?
Because a free lift forklift can lift in low-height areas like semi-trailers without damaging the ceiling.
The Components of a Forklift Mast
What are forklift masts made of?
Answer: High-strength steel.
But beyond material composition, forklift masts have different parts to them.
These forklift mast parts include:
Rails are the actual structure of the mast.
There’s an outer rail and nested inner rails.
As the hydraulic cylinders put pressure on the lift chains, the inner rails rise from the top – just like a telescope.
The rails allow the forklift mast to extend up to its maximum fork height (MFH).
The carriage is a solid steel frame that fits inside the mast rails.
It’s the part of the forklift that actually moves the load up and down.
Forks or other attachments mount on the carriage along with the load backrest.
The load backrest bolts onto the carriage.
Its job is to prevent the load from tumbling backward off the forks (and even onto the forklift itself).
Forklift masts have built-in bearings and rollers which provide the means for moving the rails and carriage.
There are four types of forklift mast bearings:
These guide each mast stage as it travels upward. They also attach the carriage to the mast rails
These limit the carriage’s lateral movement as it travels up the mast
These transfer the carriage load sideways to the mast to prevent twisting
These exist within a flanged pulley which keeps the mast chains in place and guides them as the mast is raised and lowered
Also called hydraulic cylinders, lift cylinders harness hydraulic power to pull the lift chains and raise the mast rails.
This allows the lift truck to fulfill its main function: Raising and lowering the load.
Lift cylinders can be of 2 types:
Free lift, which is located in the center of the mast:
Outboard, which is located outside the mast:
Lift cylinders use the highest volume of hydraulic fluid and typically push only in one direction.
However, negative lift cylinders also exist.
This style of cylinder applies force upward and downward.
They’re used primarily in marina forklifts, which need to lower the forks below ground level and into the water to place or retrieve boats.
Tilt cylinders provide forward and backward movement to the mast.
They’re double-acting hydraulic cylinders, allowing them to both push and pull.
Most forklifts have two tilt cylinders.
One connects the mast assembly to the right side of the forklift chassis.
And the other is attached to the left side.
This provides uniform control when tilting forward or backward.
And it prevents twisting during operation.
Forklift mast chains are the linkages that raise or lower the carriage.
The forklift mast chain functions in combination with lift cylinders and rails to do this.
The anchors are what secure the chains to the carriage and mast rails.
How Do Forklift Masts Work?
Forklift masts use hydraulic pressure for movement.
How does this happen?
The hydraulic system has a series of pumps, cylinders, pistons, and fluids that work together to create the hydraulic pressure that lifts and lowers forklift loads.
Here’s the process:
Watch this video to see how a forklift mast works:
To lower the mast and load, the process explained above happens in the opposite direction.
Additionally, a flow valve regulates the flow of hydraulic fluid.
And this helps prevent gravity from dropping the load uncontrollably.
Forklift Mast Types
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There are 4 different forklift mast designs.
Let’s go through each one.
A single-stage forklift mast – also called a simplex mast – has one mast channel.
As a result, simplex forklift masts have very limited lifting heights.
But what they lack in lifting height they make up for in visibility.
That’s because they have fewer components within them to obstruct the operator’s view.
A two-stage – also called a double or duplex – mast has two channels or sections.
Of its two sections, the outer section doesn’t move.
But the inner section does rise up to hoist the carriage.
These masts may or may not have a free lift cylinder.
If they do not have one, they’re called a “V” mast, which stands for “view.”
If they have a free lift cylinder, they’re called an “FV” mast, which stands for “free-lift view.”
For a 5,000 lbs. capacity forklift, a 2-stage mast without free lift can range from 80″ to 159″.
For those with free lift, the range is 120″ to 140″.
What is a 3-stage mast on a forklift?
Answer: It’s a mast that has three sections.
These masts are the most common type you’ll see.
Also called triplex, three-stage upright (TSU), or FSV, these masts all have free lift cylinders.
Because they can reach greater heights – from 159″ to 238″ – they’re popular in warehousing, construction, and rental fleets.
A four-stage – or quad – mast uses four sets of rails with an added set of chains to give four stages of lifting with full free lift.
Other names for a four-stage mast are:
Thanks to its four sets of moving rails, a quad mast forklift provides the highest reach – 278″ or more.
This is very useful in high stacking warehousing.
But a 4 stage forklift does have its drawback: Greatly reduced visibility.
That’s because of the extra rails and hoses within the mast, which make it harder to see through.
As a result, operators of quad mast forklifts must take extra care when driving and lifting.
The most common lift height for a sit-down rider forklift is 189 inches.
That’s about 15 feet.
But certain specialty forklifts like reach trucks can reach 301 inches or – 25 feet – more.
You’ll find these trucks in warehouses with extra-tall racking.
How to Choose the Right Mast: 4 Key FactorsThe last thing you want when buying or renting a forklift is to choose the wrong mast for your application.
So to make the right choice, consider the following factors:
How high do you need to lift to store or retrieve materials or products?
When selecting your forklift mast, add 6 inches to your highest racking shelf.
That’s because your forklift mast height should provide enough space to access your stored materials.
How much weight do you need to lift?
Keep in mind that the taller the mast, the lower the lifting capacity.
For example, a 5,000 lbs. cushion forklift with a 131.5″ V mast is rated to lift 5,000 lbs. at full extension.
But that rating drops to only 2,900 lbs. for a 241.5″ quad mast.
Thus, you’ll need a larger capacity lift truck to accommodate taller masts.
How tall are your door openings?
You’ll need to make sure your collapsed mast is under that height.
Are you working in low-height areas like semi-trailers or rail cars?
You’ll need either a free lift or trucker’s mast forklift to ensure you don’t damage the roof.
A trucker’s mast is a shortened 2-stage mast without free lift.
They have a much shorter lift height – usually around 6-feet.
And they’re designed for stacking within semi-trailers.
Their advantage is that the shortened mast will not extend far enough to damage the trailer ceiling.
Less visibility = higher risk of accidents.
Simplex or duplex masts without free lift have fewer components to obscure operators’ views.
If you don’t need free lift, it might be best to go with one of these masts since they provide the best visibility.
Conclusion
That’s it: Forklift masts explained.
Which type of forklift mast is appropriate for your operation?
If you need a forklift for outdoor work on a construction site or for agricultural applications, you need an all-terrain forklift. Below, we describe the many benefits of choosing an all-terrain forklift for outdoor applications, the different types of all-terrain truck lifts, and more.
Before we get into the many advantages that all-terrain forklifts offer for certain applications, we should explain what an all-terrain forklift is. Also referred to as a rough-terrain forklift, all-terrain truck lifts are specially modified and engineered to operate in difficult and harsh outdoor conditions.
While we often see forklifts zipping around warehouses on smooth, concrete floors to move supplies and equipment, there are many applications where a forklift is needed to venture into less forgiving working conditions. All-terrain forklifts come with special features and modifications that allow them to work in construction sites, lumber yards, or any other outdoor application that may need a forklift.
One of the most noticeable differences between a normal forklift meant for indoor warehouse duty and an all-terrain forklift is the tires. Rough-terrain truck lifts must operate on harsh surfaces like gravel, dirt, or sand; typical forklift tires would struggle on such surfaces.
All-terrain forklifts come with special, heavy-duty tires with deeper grooves for enhanced traction and durability in even the toughest environments. There are two types of tires for rough-terrain truck lifts: solid pneumatic tires that are puncture-proof and foam/air-filled pneumatic tires that are not as durable but can work indoors and in most outdoor applications.
While classes one through three of forklifts are battery-powered electric truck lifts, all-terrain forklifts need a bit more muscle and power and are therefore equipped with diesel engines. The greater power output of the diesel engine in rough-terrain forklifts gives them greater acceleration and power to get the job done in more difficult circumstances than typical forklifts.
The diesel engine is also convenient for forklift operators that use the truck lift for applications like construction, roadwork, or agriculture and operate in rural or isolated areas away from an electrical power source. While an electric forklift typically has a battery life of eight hours, a diesel forklift can keep running as long as it has enough fuel.
Rough-terrain forklifts also have the advantage of an optimized drivetrain for greater traction and control on uneven and rugged surfaces. Most standard forklifts for indoor and warehouse use are rear-wheel drives.
All-terrain forklifts can’t rely on the comfortable working conditions that most truck lifts see, so most are either front-wheel drive with a four-wheel drive option or all-wheel drive. With the available drivetrain options, all-terrain forklifts can rough it over the toughest terrain without worrying about getting stuck in the mud, sand, or gravel.
Another way that all-terrain forklifts are different from typical truck lifts is their increased ground clearance. A rough-terrain forklift may have to scale steep crests and hills when working in an outdoor environment like a construction site or roadwork site, and if it doesn’t have sufficient ground clearance, it can get stuck or damaged quickly.
All rough-terrain forklifts offer greater ground clearance to avoid bottoming out—typically around a foot of clearance, while most forklifts have just four inches. The extra ground clearance also helps the truck lift’s balance and improves traction in slick and tough terrain.
Rough-terrain forklifts also have numerous attachment options and modifications available for operators who need to change the typical forks for a different application. All-terrain forklift attachments are especially useful for construction sites and other environments where a forklift is required to perform multiple duties.
Buckets for telehandler forks allow operators to easily move materials like dirt, sand, and gravel for transportation or site clean-up. Carriage attachments for all-terrain forklifts allow operators to efficiently handle awkwardly shaped loads for handling equipment and various materials. Whatever you need to get the job done, there’s likely a forklift attachment available to help.
Another benefit of choosing an all-terrain forklift is that they’re much more durable than other truck lifts and often require much less maintenance and repairs. If a forklift breaks down during work, it can halt the entire operation while parts are repaired or replaced, so operators in tough environments want the most durable truck lifts available.
Rough-terrain forklifts are built to withstand the most punishing conditions and difficult work environments without breaking down. But if your forklift ever does break down and you need aftermarket forklift parts, Intella Parts can ensure you get high-quality parts at an affordable price!
While all rough-terrain forklifts feature many benefits, not every all-terrain truck lift is the same. There are three common types of all-terrain forklifts: vertical-mast, variable-reach, and truck/trailer-mounted, each offering unique advantages for certain applications.
Vertical-mast rough-terrain forklifts are ideal for applications that require frequent lifting of loads straight up and down. While that may sound like something all forklifts can do, these forklifts aren’t for indoor use and don’t offer free lift capabilities.
Vertical-mast all-terrain forklifts feature two small rear tires and two large front tires to give the truck lift better balance when lifting heavy loads on uneven surfaces. These truck lifts are commonly found on construction sites, roadwork sites, and dockyards.
Variable-reach all-terrain forklifts are also known as telehandlers and feature a telescopic boom lift at the front that can extend to various heights. The advantage of these truck lifts is that they can lift and move loads in multiple directions and come with outriggers for better stability.
The horizontal reach of variable-reach forklifts makes them most useful in construction, masonry, and agricultural applications.
Lastly, there’s the truck/trailer-mounted rough-terrain truck lift. As the name suggests, these lifts are mounted to a vehicle or trailer for easy transportation and typically only come with three tires—two in the front and one on the back.
These rough-terrain forklifts are best utilized in applications that require constant loading and unloading, like recycling and distribution. Not all truck/trailer-mounted forklifts are rated for rough-terrain work, so ensure you get a certified model to operate in all terrains before use.
We hope our guide has helped you understand the advantages of all-terrain forklifts. If you ever need to replace a part or add an accessory or modification to your forklift, Intella Parts has a massive selection of parts from renowned brands like Toyota, Hyster, Caterpillar, and more. Contact our staff if you need help finding the right part for your forklift.
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