Mastil PDF

Chapter 12 MAST AND FORKS
1. Simplex Mast ......................................................................................... 12-1

1.1 Mast System.......................................................................................................... 12-1
2. Structure and Functions....................................................................... 12-2
2.1 Simplex (Dual Panoramic) Mast (5V15C to 5V35C).............................................. 12-2
2.2 Mast Operation ...................................................................................................... 12-3
3. Removal and Installation...................................................................... 12-4
3.1 Mast and Lift Bracket Assembly ............................................................................ 12-4
4. Disassembly and Reassembly............................................................. 12-7
4.1 Simplex Mast Disassembly.................................................................................... 12-7
4.2 Simplex Mast Reassembly .................................................................................... 12-9
5. Removal and Installation of Mast Rollers and Strips
without Removing Mast from Truck .................................................. 12-16
5.1 Simplex Mast ....................................................................................................... 12-16
6. Inspection and Adjustment (Simplex Mast)...................................... 12-17
6.1 Forks.................................................................................................................... 12-17
6.2 Chain Tension Inspection and Adjustment .......................................................... 12-18
6.3 Checking Chain Elongation ................................................................................. 12-19
6.4 Adjusting Clearance Between Lift Bracket Roller and Inner Mast ....................... 12-19
6.5 Mast Roller Clearance Adjustment ...................................................................... 12-20
6.6 Mast Strip Clearance Inspection and Adjustment................................................ 12-22
6.7 Tilt Angle Adjustment........................................................................................... 12-22
6.8 Right and Left Lift Cylinder Stroke Inspection and Adjustment ........................... 12-23
7. Troubleshooting (Simplex Mast) ....................................................... 12-24
8. Service Data (Simplex Mast) .............................................................. 12-25
9. Duplex Mast ......................................................................................... 12-27
9.1 Mast System........................................................................................................ 12-27
10. Structure and Functions..................................................................... 12-28
10.1 Duplex (Dual Full-Free Panoramic) Mast (5F15C to 5F35C) .............................. 12-28
10.2 Mast Operation .................................................................................................... 12-29
11. Removal and Installation.................................................................... 12-30
11.1 Mast and Lift Bracket Assembly .......................................................................... 12-30
12. Disassembly and Reassembly........................................................... 12-33
12.1 Duplex Mast Disassembly ................................................................................... 12-33
12.2 Duplex Mast Reassembly.................................................................................... 12-36
12
13.1 Duplex Mast......................................................................................................... 12-43
14. Inspection and Adjustment (Duplex Mast) ....................................... 12-44
14.1 Forks.................................................................................................................... 12-44
14.2 Chain Tension Inspection and Adjustment .......................................................... 12-45
14.3 Checking Chain Elongation ................................................................................. 12-46
14.4 Adjusting Clearance Between Lift Bracket Roller and Inner Mast ....................... 12-46
14.5 Mast Roller Clearance Adjustment ...................................................................... 12-48
14.6 Mast Strip Clearance Inspection and Adjustment................................................ 12-49
14.7 Tilt Angle Adjustment...........................................................................................12-49
14.8 Right and Left Lift Cylinder Stroke Inspection and Adjustment ...........................12-50
15. Troubleshooting (Duplex Mast) ......................................................... 12-51
16. Service Data (Duplex Mast) ................................................................ 12-52
17. Triplex Mast ......................................................................................... 12-54
17.1 Mast System ........................................................................................................12-54
18. Structure and Functions ..................................................................... 12-55
18.1 Triplex (Triple Full-Free Panoramic) Mast (5M15C to 5M35C) ...........................12-55
18.2 Mast Operation ....................................................................................................12-56
19. Removal and Installation .................................................................... 12-57
19.1 Mast and Lift Bracket Assembly ..........................................................................12-57
20. Disassembly and Reassembly ........................................................... 12-60
20.1 Triplex Mast Disassembly....................................................................................12-60
20.2 Triplex Mast Reassembly ....................................................................................12-63
21.1 Triplex Mast .........................................................................................................12-71
22. Inspection and Adjustment (Triplex Mast) ........................................ 12-73
22.1 Forks....................................................................................................................12-73
22.2 Chain Tension Inspection and Adjustment ..........................................................12-74
22.3 Checking Chain Elongation .................................................................................12-75
22.4 Adjusting Clearance between Lift Bracket Roller and Inner Mast .......................12-75
22.5 Mast Roller Clearance Adjustment ......................................................................12-77
22.6 Mast Strip Clearance Inspection and Adjustment................................................12-78
22.7 Tilt Angle Adjustment...........................................................................................12-78
22.8 Right and Left Lift Cylinder Stroke Inspection and Adjustment ...........................12-79
23. Troubleshooting (Triplex Mast).......................................................... 12-80
24. Service Data (Triplex Mast) ................................................................ 12-81
MAST AND FORKS
Chapter 12 MAST AND FORKS
1. Simplex Mast
1.1 Mast System
Following table shows a combination of truck and mast models:
Truck type Mast

5V15C□□
1 ton class
5V20C□□
2 ton class 5V25C□□
5V30C□□
3 ton class
5V35C□□
Note: "□□" presents maximum lift height.

Example: 30 = Lift height of 3000 mm (118 in.)
Mast type and code

Code Mast type
V Simplex mast
5V35C30
214810
Mast serial number location
Example: 5 V 35 C 30
Maximum lifting height
["30" stands for 3000 mm (118 in.)]
Generation of Mast
("A" for the original,
"B" for the first change,
"C" for the second change,
and so on)
Applicable truck model designation
(Example: P7000=7000lb.=3 ton class)
15, 20: 1 ton class, 25: 2 ton class,
30, 35: 3 ton class
Mast type
Generation of truck compatible with
the mast
("2" for the original,
"3" for the first change,
and so on up to "9") 214841
How to read mast model code
12-1
MAST AND FORKS
2. Structure and Functions

2.1 Simplex (Dual Panoramic) Mast (5V15C to 5V35C)
8
2 1
19
9 18
13
20 14 6
21
3
10
15
16
7
11
5
12 17
217350
Major Components (most parts come in pairs, left and right)

1 Outer mast 8 Chain wheel 15 Inner mast roller
2 Inner mast 9 Chain 16 Tilt socket mounting pin
3 Lift bracket 10 Lift bracket upper roller 17 Mast support cap
4 Backrest 11 Lift bracket middle roller 18 Mast strip
5 Forks (2) 12 Lift bracket lower roller 19 Lift cylinder upper mounting bolts
6 Tilt cylinder 13 Side roller 20 Cylinder bracket
7 Lift cylinder 14 Outer mast roller 21 Cylinder clamps
The simplex mast features two lift cylinders placed Lift cylinder 7 of a lift height of 3300 mm (130 in.) or
behind the mast columns, right and left, to provide less is the internal drain type, and is equipped with no
maximum visibility. return hose.
Mast strips 18 are fitted to the top end of outer mast. The lift cylinder of a lift height of 3500 (138 in.) mm or
These strips are for backing up the inner mast when more is equipped with the drain hose.
the mast is tilted backward.
For mast operation, refer to "Mast Operation."
12-2
MAST AND FORKS
2.2 Mast Operation

2.2.1 Operation of Simplex Mast
Mast Operation
The lift cylinders extend, which lifts the forks until the
maximum free-lift height is reached. Lift chain
The cylinders extend further, causing the inner mast to Inner mast
lift at the same speed as the rods while at the same
time causing the forks to lift at the speed twice as fast Lift cylinder
as the inner mast.
Outer mast
Free-lift height
Forks on the Maximum Maximum

ground free lift lift 213908
12-3
MAST AND FORKS
3. Removal and Installation

3.1 Mast and Lift Bracket Assembly
3.1.1 Simplex Mast Removal
For replacing the mast roller without removing the mast from the truck, refer to 5. Removal and Installation of Mast
Rollers and Strips without Removing Mast from Truck, 5.1 Simplex Mast.
7 3
4
1
5
2
217351
Sequence
1 Nut 5 Tilt socket pin
2 Backrest, Lift bracket, Forks 6 Mast support bearing cap, Bushing
3 Return hose (high-lift model) 7 Inner mast, Outer mast, Lift cylinder
4 High-pressure hose
Suggestions for Removal

(1) Removing lift bracket assembly
(a) Tilt the mast forward, and lower the inner mast
to the bottom. Slacken the lift chains, and
remove nuts 1 from the anchor bolts.
(b) Tilt the mast back to vertical position. Raise the
inner mast until lift bracket 2 becomes free.
Then, slowly back the truck away from the lift
bracket and fork assembly.
Note: Before proceeding any mast overhaul, measure
the clearance between the mast and rollers.
Knowing which roller should be replaced or
which shims need adjustment in advance al-
lows efficient maintenance work.
12-4
MAST AND FORKS
(2) Disconnecting high-pressure hoses for lift cylinder

Place the mast in the bottom position, disconnect
hose 4 at the arrow position in the illustration on
the previous page.
(3) Separating tilt cylinders

(a) Hitch a sling to the upper cross-member of the
outer mast, then lift with a hoist.
Be sure to use a hoist having a capacity enough to

support the mast assembly.
(b) Place wood blocks under the tilt cylinder

mounting section and remove the tilt pins, and
separate the mast from the tilt cylinders. 214813
(c) Start the engine, and pull back the tilt lever to
retract the tilt cylinder rods.
Do not touch any levers except the tilt lever while the
engine is running.
Never loosen tilt socket bolts except for tilt cylinder 214814
disassembling.
(4) Removing mast support bearing caps

(a) Mark caps to ensure the caps are reinstalled in
original positions during reassembly.
(b) Remove cap mounting bolts. Dismount the
mast assembly from the truck in the sus-
pended condition. With the lift bracket side fac-
Matching marks
ing up, place the mast assembly horizontally
on wooden blocks on a level ground.
Note: Lay the mast assembly in a space wide enough
to disassemble the parts.
214815
12-5
MAST AND FORKS
3.1.2 Simplex Mast Installation

To install, follow the removal sequence in reverse.
Also follow the instructions given below.
(1) Mast Support
Inner cap
(a) Apply grease to the inner surfaces of caps and Inner
mast support bushings. bushing
(b) 1 ton class:
When installing caps, make sure the wider
chamfered side faces toward the center of the
chassis.
(c) 2, 3 ton classes:
Chamfering is the same both in the right and
left sides. Be sure to reassemble in the same Bushing
position as it was.
(d) When applying grease, place wood blocks
under the mast. By doing so, it is easily 1 ton class Cap
greased.
(2) Adjusting chain tension
Refer to the "Chain Tension Adjustment."
(3) Bleeding lift cylinders
Start the engine, raise and lower the lift bracket
with several strokes to bleed the cylinder.
After proper operation is confirmed, check the oil
level in the hydraulic tank.
2-3 ton classes 213916
12-6
MAST AND FORKS
4. Disassembly and Reassembly

4.1 Simplex Mast Disassembly
10
13
12 11
6
14 11
16 1
7 18
2
4
17 9
8
2 15
5
217395
Sequence
1 Nut 10 Chain wheel
2 Fork, Lift bracket 11 Cylinder clamps, Seats, Shims, Cushion, Collar,
3 Backrest Bolts
4 Lift bracket upper, lower rollers 12 Bolt, Shims
5 Lift bracket lower roller 13 Mast strips, Shims
6 Lift bracket side rollers 14 Outer mast main rollers
7 Chain 15 Inner mast main rollers
8 Hose guard 16 Inner mast
9 Lift hose (high pressure), Rubber hose, T-joint, 17 Lift cylinder
Down safety valve 18 Outer mast
Suggestions for Disassembly

(1) Removing mast strips and main rollers
Remove bolts 11 and 12 to free lift cylinder 18.
Cross the two lift cylinders at the tops. Slide the
inner mast 16 toward the bottom of outer mast 19,
and remove main rollers 14 and 15 and mast
strips 13.
12-7
MAST AND FORKS
(2) Removing inner mast

After removing the main rollers, hitch a sling to the
inner mast cross-member and slide the inner mast
to the upper side of the outer mast to clear the
outer mast roller shafts. Hitch a sling to the inner
mast again and remove it from the outer mast.
217367
Inspections after Disassembly

(1) Mast
(a) Check each roller for wear, binding or other
defects.
(b) Check each roller on rolling surface for pitting
or other defects.
(c) Check the mast member and the welded joints
of cross-members, shafts and supports for
cracks.
(d) Check the mast support bushings for wear or 217368
other defects.
(2) Lift bracket

(a) Check the main rollers and side rollers for
smooth rotation. Inspect each roller for wear
and cracks.
(b) Check the welded portions of the bracket for
cracks.
(c) Check the finger bar for bend or distortion.
Unit: mm (in.)
Straight edge
5 (0.2)
Distortion of finger bar A
maximum
217369
A: Standard value
(3) Lift chains, chain wheels and chain wheel sup- Chain elongation
ports
Unit: mm (in.)/20 links
(a) Measure the length of each chain to make sure Truck type
that the two chains are equal in length. Also Item 1 ton 2 ton 3 ton
check the chains for wear, indication of break- class class class
age and link binding and twisting.
317.5 381 508
A
(b) Check each chain anchor bolt for cracks or Simplex (12.5) (15) (20)
defects on thread. Mast 327 392 523
B
(12.9) (15.4) (20.6)
(c) Check each chain wheel support and chain
wheel for crack or wear. Check that the wheels A: Standard value B: Repair or service limit
rotate smoothly.
(4) Mast strip

Check the mast strips for damage, wear or distor-
tion.
12-8
MAST AND FORKS
4.2 Simplex Mast Reassembly

To reassemble, follow the disassembly sequence in reverse. Also follow the instructions given below.
Suggestions for Reassembly
4.2.1 Installing Lift Bracket Rollers
F 2 F 3
1 2 1 1
No shim required Shim (a)
Thrust plate Thrust plate

6
Minimum clearance G
zero or more
Shim of 1 mm (0.04 in.) thickness Shim (b)
5 Upper roller Middle roller
6
G 4
F 6
1 Shim (d)
3
Shim (c)
1 G1
4 Lower roller Side roller
214830
Reassembly
1 Lift bracket 4 Lift bracket lower roller
2 Lift bracket upper roller 5 Side roller
3 Lift bracket middle roller 6 Inner mast
The lift bracket has three main roller bearings at one Adjust the clearance to the specification with shims (a)
side and the side roller at both sides as shown. and (b) for the middle roller and with shim (c) for the
Clearances F, G and G1 must be maintained between lower roller.
these rollers and thrust surface of the inner mast for
Unit: mm (in.)
smooth operation.
0.1 to 0.5
Clearance G
(0.004 to 0.020)
Clearance G
Clearance between roller side surface and inner mast
thrust surface (right-to-left play): Clearance F
Clearance G is used for determining the correct Clearance between roller circumference and inner
amount of shims at the bearing seat. mast thrust surface (back-to-front play):
Move the lift bracket to the top of the inner mast and Clearance F is used for determining the proper size of
slide the bracket to either the left-most or rightmost the rollers.
position. Select appropriate diameter rollers so that the clear-
Take measurements of clearance G between the side ance meets the specification. Make sure the rollers
surface of roller and inner mast. rotate smoothly when installed.
Unit: mm (in.)
Clearance F 1.0 (0.04) or less
Note: It is not necessary to adjust the lift bracket up-
per roller with shims.
12-9
MAST AND FORKS
Clearance G1
Clearance between side roller circumference and
inner mast side roller thrust surface: Move the side
roller to the upper end of the inner mast and slide the
lift bracket to either the left-most or rightmost position.
Take measurement of clearance G1 between the
roller circumference and inner mast.
Adjust the clearance with shims (d) to the specifica-
tion.
Unit: mm (in.)
0.1 to 0.5
Clearance G1
(0.004 to 0.020)
(1) Choosing correct roller diameters

Unit: mm (in.)
Measure clearance F for upper rollers 2, middle
Truck type
rollers 3 and lower rollers 4. If the measured clear-
ances do not conform to the standard values, Size (diameter) 2 ton class
1 ton class
replace with rollers of correct diameters listed in 3 ton class
the table on the right. S 99 (3.90) 113.8 (4.48)
Note: For measuring procedures, refer to "Inspection M 100 (3.94) 115 (4.53)
and Adjustment." L 101 (3.98) 116 (4.57)
Make sure that the rollers rotate smoothly when LL 102 (4.02) 117 (4.61)
installed.
(2) Adjusting clearance G between the middle roller

Lift bracket middle roller
and thrust plate Inner mast
Lift bracket
Note: The following adjustment is not required for the
upper roller. Roller stopper
Shim (a)
Measure clearance G between the middle roller
and thrust plate. If the measured clearance does Shim (b) Thrust plate
not conform to the standard value, adjust clear- G
ance G in the manner described below. 0.1 to 0.5 mm
(0.004 to 0.020 in.)
Note: For measuring procedures, refer to "Inspection
and Adjustment."
213936
Adjusting method
If clearance G is excessive, increase the thickness Unit: mm (in.)
of shims (a) as required. Increase the thickness of
Truck type
shims (b) by the same amount that are added to
shims (a). Shim (a) is available in two sizes: 1 mm Item 2 ton class
1 ton class
(0.04 in.) and 0.5 mm (0.02 in). Shim (b) is avail- 3 ton class
able in only one size, 1 mm (0.04 in.). If shims (a) Shim (a) 2 (0.079) 1.5 (0.059)
are increased by 0.5 mm (0.02 in.), shims (b) do Shim (b) 2 (0.079)
not need to be increased by the equal amount.
At the factory, shims (a) and (b) are usually adjusted to
the values shown in the table on the right for the ship-
ment.
12-10
MAST AND FORKS
(3) Adjusting clearance G between the lower rollers

and inner mast Lift bracket lower roller Inner mast
Lift bracket
Measure clearance G between the lower rollers G
and inner mast. If the measured clearance does 0.1 to 0.5 mm
not conform to the standard value, adjust clear- (0.004 to 0.020 in.)
Shim (c)
ance G in the manner described below.
and Adjustment."
Adjusting method
If clearance G is excessive, increase the thickness
213937
of shims (c) as required.
At the factory, shims (c) are usually adjusted to 1.5
mm (0.059 in.) for the shipment.
(4) Installing Mast Rollers

To install main rollers on shafts, use a driving tool.
Be careful not to strike the outer roller surface with
the driving tool. The side of the roller with larger
chamfering must face toward the outside.
Make sure the rollers rotate smoothly when
installed.
213938
(5) Adjusting clearance G1 between the side roller

and inner mast Lift bracket
Inner mast
Measure clearance G1 between the side roller's Shim (d)
rolling contact surface and inner mast. If the mea-
sured clearance does not conform to the standard Side roller
Roller mounting
value, adjust clearance G1 in the manner bolts
described below.
Note: For measuring procedures, refer to "Inspection G1
Lift bracket
and Adjustment."
Adjusting method
213939
If clearance G1 is excessive, increase the thick-
ness of shims (d) as required.
At the factory, shims (d) are usually adjusted to 1.5
mm (0.059 in.) for the shipment.
12-11
MAST AND FORKS
4.2.2 Installing Mast Rollers

Mast rollers are identical in shape and size with lift
bracket lower rollers.
G
Unit: mm (in.) 0.1 to 0.5 mm
(0.004 to 0.020 in.)
Clearance F 1 (0.04) maximum
0.1 to 0.5
Clearance G F
(0.004 to 0.02) (Upper mast) 1 mm (0.04 in.)
or less
Shim (e)
(1) Measure clearance F between the rollers' rolling
contact surfaces and masts.
If the measured clearances do not conform to the
Inner mast Outer mast
standard values, replace with rollers of correct
diameters listed in the table below. G
0.1 to 0.5 mm
Lift bracket (0.004 to 0.020 in.)
Note: For measuring procedures, refer to "Inspection lower roller F 1 mm (0.04 in.)
and Adjustment." or less
Shim (f)
Unit: mm (in.)
(Lower mast)
Truck type
Size (diameter) 2 ton class
1 ton class
3 ton class
Lift bracket
S 99 (3.90) 113.8 (4.48)
213940
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.61)
For installation of mast rollers, follow the same pro-

cedures for the lift-bracket rollers.
(2) Measure clearance G between the rollers and

masts. If the measured clearances exceed the
standard value, increase the thicknesses of shims
(e) and (f) under the roller seats as required.
At the factory, shims (e) and (f) are usually adjusted to
the values shown in the table below for the shipment.
Unit: mm (in.)
Truck type
Item 2 ton class
1 ton class
3 ton class
Shim (e) 2 (0.079) 1 (0.039)
Shim (f) 2 (0.079) 1 (0.039)
12-12
MAST AND FORKS
4.2.3 Installing Mast Strips (all mast models)

(1) Measuring and adjusting clearance G2 between
the mast strip and inner mast Shim (k)
Maintain a clearance between the mast strip and 0.1 to 0.5 mm

(0.004 to 0.020 in.)
inner mast. Insert a thickness gauge to measure G2 Outer mast
clearance G2. Adjust the clearance with shims (k)
Mast strips
to 0.1 to 0.5 mm (0.004 to 0.02 in.).
Unit: mm (in.)
0.1 to 0.5
Clearance G2
(0.004 to 0.02)
Shim (k)
Inner mast
Adjusting method 213942
ness of shims (k) as required.
Check the smooth movement by moving slowly up
and down the bracket.
At the factory, shims (k) are usually adjusted to 1mm
(0.04 in.) for the shipment.
4.2.4 Installing second lift cylinder

(1) Install the cylinder brackets to the lift cylinders as
shown in the illustration on the right.
Set bolt
(2) Set the lift cylinders complete with the brackets
between the outer and inner masts. Inner mast
(3) Install the lift cylinder rods to the inner mast as Shim (l)
shown in the illustration. If shims (I) are used, be
sure to reinstall them. Usually shims (I) are not
Cylinder bracket
used.
213943
(4) Secure the lower end of each lift cylinder to the

outer mast with the mounting bolt.
Outer mast
Mounting bolt
214822
12-13
MAST AND FORKS
(5) With the cylinder rods fully retracted and the cylin-
ders set vertically, measure clearance H.
Adjust the clearance to be 1.6 mm (0.063 in.) or
less by adding or removing shims (m).
Unit: mm (in.)
Clearance H 1.6 (0.063) or less
Shim (m)
Adjusting method
If clearance H is excessive, add shims (m). Nor-
mally on a new truck, the second lift cylinders are
not fitted with shims (m). If the clearance is 3.2 mm
213944
(0.126 in.) or more, make sure to include a 3.2 mm
(0.126 in.) thick sheet in the shim pack that is to be
installed.
(6) After reassembly, perform an operation test to
check if the stroke of the left and right cylinders is
the same. Refer to "Right and Left Lift Cylinder
Stroke Inspection and Adjustment."
4.2.5 Connecting Chains (Simplex mast model)

Connect each chain to the lift bracket using the upper
Upper chain anchor kit Chain
chain anchor kit assembled as shown in the illustra- 1
tion. The link plate 3 (with a stamped mark) should be 3
4
on the side opposite to the link 1.
Stamped
mark 2
Joint
Lower chain anchor kit
217228
1 Link
2 Center plate (without mark)
3 Link plate (with a stamped mark)
4 Split pin
12-14
MAST AND FORKS
4.2.6 Installing Hydraulic Lines

General precautions
Use care not to let abrasive dust or dirt to enter the For assembling Elbow Connector (a fitting with
hydraulic system. straight threads and O-ring seal) indicated by C, fol-
low the procedure in "Installation of a fitting with
Apply a film of oil to O-rings before installation.
straight threads and O-ring seal" shown below.
Simplex mast
Tightening torque
Unit: N·m (kgf·m) [lbf·ft]
Truck model
Item Lift cylinder
1, 2 ton 3 ton
classes class
58.8 ± 5.9 A
Nut A (6.0 ± 0.6)
[43.2 ± 4.2]
49.0 ± 4.9
Nut (5.0 ± 0.5) D
B B
[36.1 ± 3.6]
Nut C 39.2 ± 3.9 58.8 ± 5.9

(4.0 ± 0.4) (6.0 ± 0.6) Lift cylinder
[28.9 ± 2.8] [43.2 ± 4.2] A
Nut D Down safety valve
C
217370
Installation of a fitting with straight threads and O-

ring seal Shape varies by fitting type
1
(1) Apply grease or hydraulic oil to the O-ring and O- 2
ring seat on the housing side.
(2) Tighten the fitting by hand. Once O-ring seal 5 is 4
3
placed in the position of housing and washer 4 5
comes in contact with the surface of housing, turn
it back to adjust the mounting direction. Never 6
loosen more than 1 turn.
214084
(3) Tighten lock nut 3 to the specified torque. Elbow with nut
1 End of fitting body

(connects to tube)
2 Fitting body
3 Lock nut
4 Backup washer
5 O-ring seal
6 End of fitting that goes into the housing
12-15
MAST AND FORKS
5. Removal and Installation of Mast Rollers and Strips without Removing

Mast from Truck
5.1 Simplex Mast
The mast rollers and strips can only be removed or
Lift cylinder upper mounting bolt
installed when the inner mast is positioned lower than
the outer mast. This can be achieved as follows:
(1) Disconnect the lift bracket assembly.
(2) Lift the front of the truck by 150 to 200 mm (5.91
Cylinder bracket
to 7.87 in.), and place blocks to support the truck.
(3) Remove the set bolts at the top of the lift cylin-
ders. Place a sling around the inner mast. Lift the
inner mast using a hoist connected to the sling in
order to disengage the lift cylinders' piston rods
Lift cylinder
from the inner mast. Remove the hose guard.
Shim
(4) Remove the lift cylinder clamp bolts, and separate
the lift cylinders from the outer mast. Pull out the
lift cylinders from the seats at the bottom of the
outer mast. Tilt the cylinders until they rest on the
outer mast cross member. Using a rope, fix the Parts for
cylinders onto the cross member. cylinder clamp
(5) Using the hoist, slowly lower the inner mast until
the mast contacts the lift cylinders. Shim
(6) The main rollers of the inner and outer masts can Parts for
now be removed. Remove the mast strips and cylinder
shims before attempting to remove the main roll- clamp
ers, as they tend to drop easily.
Mast strips
(7) Adjust shims for the main rollers and mast strips
as required. 217371
To reassemble, follow the disassembly sequence in

reverse.
213951
12-16
MAST AND FORKS
6. Inspection and Adjustment (Simplex Mast)

The inspection and adjustment in this chapter can be done without dismounting or disassembling.
Conduct inspection whenever a defect is suspected.
6.1 Forks
Fork calipers perform two tasks at once.

OUTSIDE INSIDE They measure the thickness of the fork arm
JAWS JAWS shank (Fig. 1) and then automatically
100% 90% indicate what a 10% wear factor would be when
the calipers are applied to the blade cross section (Fig. 2).
NEW FORK ARM

SHANK CROSS
50 mm (2 in.) SECTION = 100%
Figure 1
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
Not for use on full tapered forks. 217126
Forks are often mistreated and forgotten. As insub- Maintenance shops may bend forks back into shape,
stantial as they seem, neglecting forks could make weld on them, or drill holes through them. Lift truck
them dangerous. users can add attachments to the truck that will put
Forks carry larger loads than almost any lifting device stress on the forks. Drum clamps and portable booms
but there are no mandatory requirements for mainte- can be supported on the forks–but what is contained
nance or inspection. in the drum or on the boom hook makes the differ-
ence in safety.
You can find thousands of extra parts for lift trucks in
some fleet repair shops, but you'll seldom see spare Forks are often used to open rail car doors and break
forks. Even when all the trucks on the fleet are the loads out or away from other loads. They are also
same, fleet maintenance managers rarely order spare used to pick up capacity loads not seated against the
forks. Forks can last a long time if treated properly, but fork shank and to pick up off-balanced loads far from
they can be deceptive. Careful inspection is required the side of the truck. The fork tips are sometimes
to ensure forks are not worn. inserted under other fork trucks to lift them during
maintenance operations.
It's true that most forks are customized to the truck by
model and capacity: They are big, heavy and thought Lift trucks may collide with building columns and
of as indestructible. However, forks can be abused or walls, and though the forks show no discernible bend,
ruined in the course of daily work. they may be damaged beyond safety.
Here are some examples of ways that forks can be Any time excessive heat is applied to any part of a
damaged: fork during repair, hidden damage may occur.
Forks can be overloaded either by picking up a load The fork itself is a concern but so are the hooks that
too far out on the forks, or simply by picking up loads secure them to the lift carriage.
heavier than the truck rating.
6.1.1 DESIGNED TO TAKE A BEATING

Forks for counterbalanced and straddle lift trucks are fork manufacture include the steel, the bend and thick-
not just bent bars of steel. The manufacturing process ness of the heel, the welding of the hooks that hold
is careful and precise with many checks and inspec- them on the carriage, and the heat treatment of the fin-
tions critical to their safety. Some factors essential to ished product.
12-17
MAST AND FORKS
6.2 Chain Tension Inspection and Adjustment
Turn the engine/main key to the (OFF) position before

inspecting or adjusting lift chains, anchor bolts and
nuts. Place blocks under the forks when they are
raised. Failure to do so can result in serious injury or
death due to a sudden movement of heavy compo-
nents.
Inspection of chain tension

(1) Place the mast vertical on a level ground, then
lower the forks to the ground. Make sure that the 213960
lift cylinders are fully retracted.
(2) Raise the forks approx. 100 mm (4.0 in.) from the
ground.
Anchor bolt
(3) Turn the key to the (OFF) position.
(4) Place blocks approx. 90 mm (3.5 in.) high under 2 Clamp
the forks.
(5) Push the chains at the middle point between the
chain wheel and chain fixed end on the lift
bracket. 3 Double nut (upper)
Check the right and left chains for even tightness. 1 Double nut (lower)
If tension on the right and left chain is uneven, 214826
adjust the tension.
Tightening torque
Adjustment of right and left chain balance Truck type
(1) Remove the blocks placed under the forks. Start Item 1 ton class
the engine. 3 ton class
2 ton class
(2) Lower the forks to the ground and tilt forward until +49 +5 +49 +5
98 0 (10 0 ) 147 0 (15 0 )
the tips come in contact with the ground. The Nuts 1, 3 +36 +36
[72 0 ] [108 0 ]
chains are now slack to facilitate the adjustment.
(3) Stop the engine.
(4) Loosen the double nut (lower) 1. Then upper nut
3. After the adjustment, raise and lower the lift bracket
several times. Then check the position of lift bracket
(5) Turn double nut (upper) 2 to adjust the chain ten-
when the lift cylinder is fully retracted. Make sure the
sion.
protrusion of each lift bracket main roller does not
(6) Start the engine, and place the mast vertical exceed 40% of the roller diameter. If it exceeds, elon-
again. gation of chains is suspected.
(7) Repeat (2) through (5) of the procedure in
"Inspection of chain tension," to check the chain
tension and adjust it as needed. Inner mast
Lift bracket
lower roller
Tightening of nuts after adjustment
(1) Hold the anchor bolt with a wrench so as not to
twist the chain, then tighten the clamp 2.
(2) Hold the double nut (upper) 3 with a wrench and
tighten double nut (lower) 1 to the specified 40% of the roller
diameter or less
torque.
213962
12-18
MAST AND FORKS
6.3 Checking Chain Elongation

(1) Apply maximum load evenly on both forks and
expand the chains.
(2) Measure the length of 20 links of chain. When the
length exceeds the service limit specified in the
table below, replace the chain.
Chain elongation
Truck type
Item 1 ton 2 ton 3 ton
20 links
class class class
317.5 381 508
A
(12.5) (15) (20)
Simplex Mast
327 392 523
B
(12.9) (15.4) (20.6) 217133
A: Standard value (new) B: Service limit
6.4 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(1) Back-to-front clearance check on lift bracket main
rollers F
(a) Raise the forks slightly from the ground.
(b) Insert a bar between the upper part of lift
bracket and the inner mast, and push the inner
mast to one side. Using feeler gauges, mea-
sure clearance F between the main roller and
inner mast on the opposite side.
Unit: mm (in.)
Clearance F 1.0 (0.04) or less F 213966
(c) If clearance is out of specification, use oversize
rollers.
For roller replacement procedure, refer to
"Choosing correct roller diameters" on (1).
(2) Right-to-left clearance check on lift bracket main

rollers and side rollers
(a) Raise the mast to the top.
(b) Set a dial indicator on the inner mast with its
contact point rested on the side of the lift
bracket.
(c) Go over to the opposite side of the mast, and
slide the lift bracket to one side with a bar. Set
the indicator to zero.
(d) Insert a bar between the inner mast and lift 213967
bracket on the indicator side, and push the lift
bracket to the opposite side.
12-19
MAST AND FORKS
(e) Insert a bar between the inner mast and lift

bracket on the indicator side, and slide the lift Upper roller Upper roller
bracket to the opposite side. Read the indica- G
tor. This reading is clearance G between the
middle roller and thrust plate. If clearance is Thrust plate Thrust plate
out of specification, it is necessary to add
shims to the seat of the roller to adjust to cor-
rect clearance.
Note: Upper rollers are free from checking and adjust-
ing.
Unit: mm (in.) 213968
0.1 to 0.5
Clearance G
(0.004 to 0.02)
For adjustment, refer to "Adjusting clearance G1

between the middle roller and thrust plate" on 4.2.1(2).
(f) Lower the lift bracket slightly from the top so
that the side roller comes in contact with the
inner mast. G1
Measure the clearance G1 between the side
roller and inner mast. If clearance is out of
specification, it is necessary to add shims to
the seat of the roller bracket to adjust to correct
clearance. Side roller Side roller
For adjustment and installation procedures,
refer to "Adjusting clearance G1 between the
side roller and inner mast" on 4.2.1(5).
213969
(g) With the lift bracket positioned at the top, check
clearance G between the lower roller and inner
mast. If clearance is out of specification, it is
necessary to add shims to the seat of the roller
to adjust to correct clearance.
refer to "Adjusting clearance G between the
lower rollers and inner mast" on 4.2.1(3). Lower roller
G
213970
6.5 Mast Roller Clearance Adjustment

(1) Back-to-front clearance check on mast main roll-
ers
(a) Tilt the mast fully backward. F
(b) Using feeler gauges, measure clearance F
between the inner mast lower roller and outer
mast.
Unit: mm (in.)
Clearance F 1 (0.04) or less

rollers. For mast roller replacement and instal- 213971
lation procedures, refer to "Installing mast roll-
ers" on 4.2.2 Installing Mast Rollers.
12-20
MAST AND FORKS
(2) Right-to-left clearance inspection on inner mast

main rollers
(b) Set a dial indicator on the inside of the outer
mast with its contact point rested on the inner
mast.
push the inner mast against the outer mast.
Set the indicator to zero.
G
213972
(d) Insert a bar between the outer and inner masts

on the indicator side, and push the inner mast
to the opposite side.
(e) Read the indicator. This reading is clearance G
between the outer mast roller and inner mast.
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
(f) If clearance G is out of specification, adjust it G

by shims.
213973
refer to "Installing mast rollers" on 4.2.2 Install-
ing Mast Rollers.
(3) Right-to-left clearance check on outer mast main

rollers
(b) Set a dial indicator on the outer mast with its
contact point rested on the inner mast.
G
push the outer mast against the inner mast
with a bar. Set the indicator to zero.
213974
to the opposite side. G
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
(f) If clearance G is out of specification, adjust it

by shims.
213975
refer to "Installing mast rollers" on 4.2.2 Install-
ing Mast Rollers.
12-21
MAST AND FORKS
6.6 Mast Strip Clearance Inspection and Adjustment

(1) Check clearance G2 with the clearance between
the outer mast rollers and inner mast rolling con- G2
tact surface setting to zero (0) in maximum lift
position.
Unit: mm (in.)
0.1 to 0.5
Clearance G2
(0.004 to 0.02)
213976
(2) If clearance G2 is out of specification, adjust it by
adding or removing shims.
For adjustment procedure, refer to "Measuring
and adjusting clearance G2 between the mast
strip and inner mast" on 4.2.3 Installing Mast
Strips (all mast models).
(3) After all clearances are adjusted, move the mast
and lift bracket slowly to ensure that they move
smoothly through their full stroke.
6.7 Tilt Angle Adjustment

(1) Adjust the tire pressure correctly and park the
truck on a level ground.
(2) Tilt the mast fully backward and stop the engine.
(3) Measure the backward tilt angle of the mast at
both sides.
(4) To adjust the tilt angle, loosen the bolt of tilt cylin-
der socket, and adjust the rod length by turning
the rod. Adjust the cylinder so that there is no dif-
ference in tilt angle between the cylinders, right
and left.
217372
Note: It is not necessary to adjust the forward tilt an-
gle if the backward tilt angle is properly adjust-
ed.
Standard tilt angle

Forward Backward
Mast model
angle angle
Simplex mast 6° 10°
(5) After adjusting the tilt angle, tighten the socket

bolts to the specified torque.
153 to 182
Tightening torque for tilt cylinder
(15.6 to 18.6
socket bolt
[112.8 to 134.5]
12-22
MAST AND FORKS
6.8 Right and Left Lift Cylinder Stroke Inspection and Adjustment
(1) Slowly raise the inner mast, and observe how the
piston rods, left and right, stop at the moment the
inner mast reaches its maximum height.
(2) If the top of the inner mast jolts at that moment,
make a shim adjustment.
Abnormal condition can be detected by a little
time lag in stopping between the piston rods, left
and right, and shaking of the rod with a longer cyl-
inder stroke.
213978
(3) Adjusting method

(a) Raise the inner mast, place blocks under the
right and left sides of the inner mast, and lower
the mast until it rests on the blocks.
(b) Remove the set bolt at the top of lift cylinder
which showed earlier stroke end, retract the
piston rod, and insert shims at the top of piston
rod end.
Note: When retracting the piston rod, push the lift le-
ver to lowering direction for releasing the oil in
213824
the cylinders.
(c) Extend the piston rod, and tighten the cylinder

set bolt. Remove the blocks from under the
inner mast. Set bolt
(d) Slowly lower the inner mast to the bottom to Inner mast
ensure the piston rods move smoothly and that
the left and right lift cylinders come to the end Shim (l)
of stroke simultaneously at the maximum lift
position of inner mast. Cylinder bracket
213943
12-23
MAST AND FORKS
7. Troubleshooting (Simplex Mast)
Clearance between lift rollers and side rollers incorrect Readjust clearance.
Lift bracket and
Relubricate side rollers and replace
inner mast do not Rollers not rotating smoothly on their shafts
other rollers.
move smoothly.
Mast strip clearance incorrect Adjust shims.
Too much clearance on side rollers Readjust by adding shims.
Lift bracket or inner
Lift chains unequally tensioned Readjust chain tension.
mast are not in a
level position. Shim adjustments unequally made on between left and
Remove or add shims.
right lift cylinders (at maximum height)
Mast makes noise. Rollers not rotating smoothly on their shafts Check and adjust or replace rollers.
Lift cylinder Lift cylinder packing damaged Replace.
descends due to a
load (Drift). Sliding (inside) surface of lift cylinder tube damaged Replace.
Whole mast shakes. Mast-support bushing or metal worn Retighten or replace.
Mast is distorted. Off-center loading or overload Replace mast assembly.
Distortion of finger bar
Fork tips differ in
Distortion of forks Repair or replace.
height.
Uneven loading
12-24
MAST AND FORKS
8. Service Data (Simplex Mast)

Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
mm (in.)/ A 317.5 (12.5) 381 (15) 508 (20)
Chain Chain elongation
20 links B 327 (12.9) 392 (15.4) 523 (20.6)
S A 99 (3.90) 113.8 (4.48) 113.8 (4.48)
M A 100 (3.94) 115 (4.53) 115 (4.53)
Main roller external diameter
Rollers L A 101 (3.98) 116 (4.57) 116 (4.57)
LL A 102 (4.02) 117 (4.61) 117 (4.61)
Side roller external diameter A 42 (1.65) 42 (1.65) 42 (1.65)
Width of outer mast B A 610 (24) 670 (26.4) 670 (26.4)
Dimension Simplex
Width of inner mast B2 A 516 (20.3) 568 (22.4) 568 (22.4)
(Reference) Mast
Width of lift bracket C A 408 (16.1) 458 (18) 458 (18)
Clearance between main
roller circumference and A 1.0 (0.04) or less
mast thrust surface F
Mast
roller side surface and mast A 0.1 to 0.5 (0.004 to 0.02)
thrust surface G
Clearance between inner
A 0.1 to 0.5 (0.004 to 0.02)
mast and mast strip G2
roller circumference and A 1.0 (0.04) or less
Clearances
inner mast F
Clearance between middle
roller side surface and inner A 0.1 to 0.5 (0.004 to 0.02)
mast thrust plate G
Lift bracket
Clearance between lower
roller side surface and inner A 0.1 to 0.5 (0.004 to 0.02)
mast thrust surface G
Clearance between side
roller circumference and A 0.1 to 0.5 (0.004 to 0.02)
inner mast surface G1
Distortion of finger bar A 5 (0.2) or less
A: Standard value B: Repair or service limit
12-25
MAST AND FORKS
F G2
G
F
G1
F
G
G
B2
C
Lift bracket
The mast is slightly wider at the lower than at the upper.

r.
Always measure the clearance at the upper portion of the mast. 214828
12-26
MAST AND FORKS
9. Duplex Mast
9.1 Mast System
Truck type Mast

5F15C□□
1 ton class
5F20C□□
2 ton class 5F25C□□
5F30C□□
3 ton class
5F35C□□

Example: 30 = Lift height of 3000 mm (118.1 in.)
Mast type and code

Code Mast type
F Duplex mast
5F25C30
214831
Example: 5 F 25 C 30
["30" stands for 3000 mm
(118.11 in.)]
Generation of Mast
and so on)
30, 35: 3 ton class
Mast type
the mast
12-27
MAST AND FORKS
10.Structure and Functions

10.1 Duplex (Dual Full-Free Panoramic) Mast (5F15C to 5F35C)
Notice: For hydraulic lines, refer to “12.2.7 Installing Hydraulic Lines.”
6 2 12 1
13
14 15 3
17
8
7
22 4
10
16 19
9
11
20 5
21 18
214833

1 Outer mast 9 Inner mast roller 17 Backrest
2 Inner mast 10 Tilt socket mounting pin 18 Forks
3 Tilt cylinder 11 Mast support cap 19 Lift bracket upper roller
4 First lift cylinder (one) 12 Mast strip 20 Lift bracket middle roller
5 Second lift cylinder 13 Lift cylinder upper mounting bolts 21 Lift bracket lower roller
6 Chain wheel 14 Cylinder bracket 22 Side roller
7 Chain 15 Cylinder clamps
8 Outer mast roller 16 Lift bracket
In the duplex mast, the first cylinder raises the forks The first cylinder is equipped with the upstroke cush-
without increasing the overall mast height (free-lift) ioning including internal drain and the second cylinder
until the upper edge of the backrest exceeds the top of equipped with the down cushioning.
the mast.
The mast assembly consists of the inner mast, outer
For mast operation, refer to "Mast Operation" on 10.2
mast, lift bracket, first lift cylinder and second lift cylin-
Mast Operation.
ders.
The first lift cylinder raises the lift bracket, while the
second cylinders operate the inner mast and lift
bracket.
12-28
MAST AND FORKS
10.2 Mast Operation

10.2.1 Operation of Duplex Mast
The first lift cylinder extends, bringing the forks to the
maximum free-lift height.
When the first lift cylinder rod has reached the end of Inner mast
the stroke, the second lift cylinders take over to directly First lift cylinder
lift the inner mast to the maximum lift height. Second
lift cylinder
Free-lift
Reverse the lifting sequence to activate the lowering height Outer mast
mechanism.
Forks on the Maximum Maximum

12-29
MAST AND FORKS
11.Removal and Installation

11.1.1 Duplex Mast Removal
For replacing the mast roller without removing the mast from the truck, refer to "Removal and Installation of Mast
Rollers and Strips without Removing Mast from Truck."
3
6
5
214834
Sequence
1 Nut 4 Tilt socket pin
2 Backrest, Lift bracket, Forks 5 Mast support bearing cap, Bushing
3 High-pressure hose 6 Mast, Lift cylinder

(a) Lower the lift bracket, and place wood blocks
under the assembly.
Tilt the mast forward, and lower the inner mast
remove nuts 1 from the anchor bolts. 1
inner mast until lift bracket 2 becomes free.
214829
Note: Before proceeding any mast overhaul, measure
12-30
MAST AND FORKS
(2) Disconnecting high-pressure hoses for the lift cyl-

inder
Place the mast in the bottom position, disconnect
hose 3 at the arrow position in the illustration of
"19.1.1 Triplex Mast Removal.

214835

mounting section and remove the tilt socket
pins, and separate the mast from the tilt cylin-
ders.
engine is running.
214814
Never loosen tilt socket bolts except for during tilt cyl-
inder disassembling.
Note: Lay the mast assembly in a space wide enough Matching marks
214837
12-31
MAST AND FORKS
11.1.2 Duplex Mast Installation

(1) Mast Support

Inner cap
(b) 1 ton class:

chassis.
Chamfering is the same both in the right and Bushing
left sides. Be sure to reassemble in the same
position as it was.
(d) When applying grease, place wood blocks 1 ton class Cap
under the mast. By doing so, it is easily
greased.
In the duplex mast, the second lift cylinders are
provided with air bleeding screws.
After installing the mast, start the engine, raise
and lower the lift bracket with several strokes and
loosen the screws to bleed.
12-32
MAST AND FORKS
12.Disassembly and Reassembly

12.1 Duplex Mast Disassembly
16
10
15
14 8
13
9
15
1
11
6
5
6 8
12
A
A
1
4
12
2 9 1
3
2
17
217373
Sequence
1 Lift hose (high pressure), Clamp 10 Bolts, Washers, Shims
2 Shims, Bolts, Washers 11 Mast strips, Shims
3 First lift cylinder 12 Mast rollers
4 Chain guard 13 Inner mast
5 Chain wheel support, Pin 14 Second lift cylinder
6 Chain wheels, Snap rings 15 Cylinder bracket
7 Hose guard, Bolt, Washer 16 O-ring, Plugs
8 High-pressure hose 17 Outer mast, Grease nipples
9 Seats, Shims, Cushions, Collars
Note: The lift bracket disassembly procedure is the

same as for the simplex mast.
12-33
MAST AND FORKS
Start by
With the lift bracket facing up, place the mast horizon-
3
tally on wood blocks.
Place a wood block as a wedge to prevent the inner
mast from sliding.
Before disassembling the mast and fork assembly,

measure and record all clearances between each lift
bracket and roller and between each mast and roller.
Recorded measurements will be helpful when replac-
213927
ing rollers or selecting shims to adjust clearances.
(1) Removing first lift cylinder
(a) Remove retaining bolts 2 from the first lift cylin-
der.
(b) Hitch slings on the first lift cylinder, and gently
remove the cylinder. Use two slings. Wind or
tie slings securely to prevent slipping.
(2) Removing main rollers and mast strips
(a) Remove clamp bolts 9 from the second lift cyl- 11 12
inders.
(b) Remove bolts 10 from the upper rod sections
of the second lift cylinders, and place the cylin-
ders on the outer mast.
(c) Check the number of shims and shim thick-
ness at the rod end sections.
(d) Lower the inner mast, then remove main rollers
12 and mast strips 11. 12
213928

Using slings, lift and remove inner mast, steering 18
it clear of the roller shaft sections of outer mast.
14
213929
12-34
MAST AND FORKS

(1) Mast
defects.
or other defects.
cracks.
(d) Check the mast support bushings for wear or 213924
other defects.
(2) Lift bracket

and cracks.
cracks.
Unit: mm (in.)
Distortion of finger bar A 5 (0.20) maximum Straightedge
A: Standard value 217134
(3) Lift chains, chain wheels and chain wheel sup- Chain elongation
ports
(a) Measure the length of each chain to make sure Truck type
that two chains are equal in length. Also check Item 1 ton 2 ton 3 ton
the chains for wear, indication of breakage, link class class class
binding and twist.
317.5 381 508
A
(b) Check each chain anchor bolt for cracks or (12.50) (15.00) (20.00)
Duplex mast
defects on thread. 327 392 523
B
(12.87) (15.43) (20.59)
(c) Check each chain wheel support and chain
wheel for crack or wear. Check that the wheels A: Standard value B: Repair or service limit
rotate smoothly.
(4) Mast strip
tion.
12-35
MAST AND FORKS
12.2 Duplex Mast Reassembly

F 2 F 3
1 2 1 1
Thrust plate Thrust plate

6
Minimum clearance G
zero or more
Shim of 1 mm (0.04 in.) thickness Shim (b)
5 Upper roller Middle roller
6
G 4
F 6
1 Shim (d)
3
Shim (c)
1 G1
214830
Reassembly
side and the side roller at both sides as shown. and (b) for the middle roller and with shim (c) for the
Unit: mm (in.)
smooth operation.
0.1 to 0.5
Clearance G
(0.004 to 0.020)
Clearance G
slide the bracket to either the left-most or rightmost the rollers.
Unit: mm (in.)
Note: It is not necessary to adjust the lift bracket up-
per roller with shims.
12-36
MAST AND FORKS
Clearance G1
roller to the upper end of the inner mast and slide the
lift bracket to either the left-most or rightmost position.
tion.
Unit: mm (in.)
0.1 to 0.5
Clearance G1
(0.004 to 0.020)

Unit: mm (in.)
Truck type
1 ton class
the table on the right. S 99 (3.90) 113.8 (4.48)
and Adjustment." L 101 (3.98) 116 (4.57)
The rollers should rotate smoothly when installed. LL 102 (4.02) 117 (4.61)

and thrust plate Inner mast
Lift bracket
Shim (a)
Measure clearance G between the middle roller Shim (b) Thrust plate
and thrust plate. If the measured clearance does G
not conform to the standard value, adjust clear- 0.1 to 0.5 mm
(0.004 to 0.020 in.)
Note: For measuring procedures, refer to "Inspection 213936
and Adjustment."
Adjusting method
shims (b) by the same amount that are added to
shims (a). Shim (a) is available in two sizes: 1 mm
(0.04 in.) and 0.5 mm (0.020 in.). Shim (b) is avail-
able in only one size, 1 mm (0.04 in.). If shims (a)
are increased by 0.5 mm (0.020 in.), shims (b) do
At the factory, shims (a) are usually adjusted to 1 mm
(0.04 in.) and shims (b) to 2 mm (0.08 in.) for the ship-
ment.
12-37
MAST AND FORKS

Lift bracket
Shim (c)
and Adjustment."

At the factory, shims (c) are usually adjusted to 1 mm
(4) Installing Mast Rollers

installed.
213938

and inner mast Lift bracket
Inner mast
Measure clearance G1 between the side roller's Shim (d)
sured clearance does not conform to the standard Side roller
Roller mounting
described below.
Lift bracket
and Adjustment."
213939
Adjusting method
At the factory, shims (d) are usually adjusted to 1 mm
12-38
MAST AND FORKS

G
Unit: mm (in.) 0.1 to 0.5 mm
(0.004 to 0.020 in.)
0.1 to 0.5
Clearance G F
(0.004 to 0.020) (Upper mast) 1 mm (0.04 in.)
or less
(1) Measure clearance F between the rollers' rolling Shim (e)
standard values, replace with rollers of correct Inner mast Outer mast
diameters listed in the table below.
G
0.1 to 0.5 mm
Note: For measuring procedures, refer to "Inspection Lift bracket (0.004 to 0.020 in.)
and Adjustment." lower roller F 1 mm (0.04 in.)
or less
Unit: mm (in.) Shim (f)
Truck type (Lower mast)
1 ton class
3 ton class
S 99 (3.90) 113.8 (4.48) Lift bracket
M 100 (3.94) 115 (4.53)
213940
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.61)
For installation of mast rollers, follow the proce-

dures for the lift-bracket rollers.

(e) and (f) under the roller seats as required.
At the factory, shims (e) and (f) are usually adjusted to
the values shown in the table below for the shipment.
Unit: mm (in.)
Truck type
Item 2 ton class
1 ton class
3 ton class
Shim (e) 2 (0.08) 1 (0.04)
Shim (f) 2 (0.08) 1 (0.04)
12-39
MAST AND FORKS
12.2.3 Installing mast strip

the mast strip and inner mast Shim (k)
Maintain clearance between the mast strip and 0.1 to 0.5 mm

(0.004 to 0.020 in.)
inner mast. Insert a thickness gauge to measure G2 Outer mast
Mast strips
to 0.1 to 0.5 mm (0.004 to 0.020 in.).
Unit: mm (in.)
0.1 to 0.5
Clearance G2
(0.004 to 0.020)
Shim (k)
Inner mast
and down the bracket.
At the factory, shims (k) are usually adjusted to 1 mm
12.2.4 Installing second lift cylinder

Set bolt
(2) Set the lift cylinders complete with the brackets
Cylinder bracket
used.
ders positioned vertically, measure clearance H.
213943
Unit: mm (in.)
Clearance H 1.6 (0.06) maximum
Adjusting method
not fitted with shims (m). If the clearance is 3.2 mm
installed.
Shim (m)
the same. Refer to "14.8 Right and Left Lift Cylin-
der Stroke Inspection and Adjustment."
213944
12-40
MAST AND FORKS
12.2.5 Installing first lift cylinder

(1) With the masts positioned vertically and fully low-
ered, temporarily install the first lift cylinder com-
plete with the original shims to the inner mast.
Mounting bolt
(2) Position the first lift cylinder vertically, and mea-
sure the clearance, if any, between the cylinder
brackets and the cylinder mounts on the inner
mast. Remove any clearance by adding shims.
Shim
The perpendicularity of the cylinder in the lateral
direction can be checked by measuring the dis- First lift cylinder
tances between the cylinder and the side face of
the inner mast. The difference of the distance at 214839
the top and bottom should be ± 1 mm (0.04 in.).
The perpendicularity of the cylinder in the longitu-
dinal direction can be checked by visually inspect-
ing for the parallelism between the cylinder and the
front face of the inner mast. The cylinder should
not be inclined forward, not even slightly. The cylin-
der slightly inclined backward is acceptable.
Each shim is 1 mm (0.04 in.) thick.
At the factory, a shim pack of 2 mm (0.08 in.) is usually
inserted between the cylinder bracket and the inner
mast on the standard model for the shipment.
(3) After shimming is completed, install and tighten

the mounting bolts.
Note: Depending on the truck model, the direction in
which the mounting bolts are inserted may be
different from what is shown in the illustration.
12.2.6 Connecting Chains
Attach each chain to the lift bracket as shown. When
attaching, maintain clearance between them using
nuts to allow for the tension of the chain.

Truck type Chain
Item 1 ton class
3 ton class
2 ton class
0 0 Lock nut
56.0 -9.8 84.3 -11.8 (single nut side)
Lock nut 0 0
(single nut side) (5.71 -1.00) (8.60 -1.20)
[41.30
0
-7.23]
0
[62.18 -8.70] Lock nut
(double nut side)
+49 +49
98 0 1470
Lock nut +5.00 +5.00
(double nut side) (9.99 0 ) (14.99 0 )
+36.14 +36.14
[72.82 0 ] [108.42 0 ]
Lift bracket
214840
12-41
MAST AND FORKS

General precautions
Use care not to let abrasive dust or dirt enter the For Elbow Connector assembly, (a fitting with straight
hydraulic system. threads and O-ring seal) indicated by C in the illustra-
tion, follow the procedure in "Installation of a fitting
with straight threads and O-ring seal" shown below.
Duplex Mast
Tightening torque
Truck model
Item 1-2 ton 3 ton F
Second cylinder
classes class
58.8 ± 5.9 58.8 ± 5.9 E
Nut A (6.0 ± 0.6) (6.0 ± 0.6)
[43.4 ± 4.35] [43.4 ± 4.35]
49.9 ± 4.9 49.9 ± 4.9
Nut B (5.0 ± 0.5) (5.0 ± 0.5)
[36.1 ± 3.61] [36.1 ± 3.61] Second
cylinder
D
A
Nut C
39.2 ± 3.9
(4.0 ± 0.4)
[28.9 ± 2.88]
Nut D B
58.8 ± 5.9 Down safety valve A
(6.0 ± 0.6) E C
[43.4 ± 4.35]
Nut E B
58.8 ± 5.9
(6.0 ± 0.6)
[43.4 ± 4.35] E
Nut F First cylinder
Down safety valve
D 217374

ring seal
(1) Apply grease or hydraulic oil to the O-ring and O- Shape varies by fitting type
1
ring seat in the housing side. 2
(2) Turn lock nut 3 to move it fully to the fitting body 2.
Place washer 4 and O-ring seal 5 against the lock 4
nut. 3
5
(3) Tighten the fitting by hand. Once O-ring seal 5 is
6
placed in the position of housing and washer 4
comes in contact with the surface of housing, turn
214084
it back to adjust the mounting direction. Never
Elbow with nut
(4) Tighten lock nut 3 to the specified torque.
1 End of fitting body
(connects to tube)
2 Fitting body
3 Lock nut
4 Backup washer
5 O-ring seal
12-42
MAST AND FORKS
13.Removal and Installation of Mast Rollers and Strips without Removing

Mast from Truck
13.1 Duplex Mast
(2) Remove the first cylinder as follows:
(a) Hitch a sling on the first lift cylinder, and sus-
pend it with a crane. Wind the rope securely to
prevent slipping.
(b) Remove the cylinder mounting bolts. Using the
hoist, slowly lift and remove the first cylinder.
(3) Place the inner mast lower than the outer mast.
Follow the following procedures:
(a) Lift the front of the truck by 150 to 200 mm
(5.91 to 7.87 in.), and place wood blocks to
support the truck.
(b) Remove the set bolts at the top of the second
lift cylinders. Place a sling around the inner
mast. Lift the inner mast using a hoist con-
213952
nected to the sling in order to disengage the
second lift cylinders' piston rods from the inner
mast. Remove the hose guard.
(c) Remove the second lift cylinder clamp bolts
and separate the lift cylinders from the outer
mast. Pull out the second lift cylinders from the
seats at the bottom of the outer mast. Tilt the
cylinders until they rest on the outer mast cross
member. Using a rope, fix the cylinders onto
the cross member.
(d) Using the hoist, slowly lower the inner mast
until the inner mast contacts the second lift cyl- 213951
inders fixed to the cross member.
(e) The main rollers of the inner and outer masts
can now be removed. Remove the mast strips
and shims before attempting to remove the
main rollers, as they tend to drop easily.
(f) Adjust shims for the main rollers and mast
strips as required.
To reassemble, follow the disassembly sequence in

reverse.
12-43
MAST AND FORKS
14.Inspection and Adjustment (Duplex Mast)

The inspection and adjustment in this chapter can be Conduct inspection whenever a defect is suspected.
done without dismounting or disassembling.
14.1 Forks

NEW FORK ARM

SHANK CROSS
50 mm (2 in.) SECTION = 100%
Figure 1
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
ence in safety.

12-44
MAST AND FORKS

inspecting and adjusting lift chains, anchor bolts and
nuts. Place wood blocks under the forks when they are
nents.

215442
(1) Place the mast vertical and on level ground, then
lower the forks to the ground. Make sure that the
lift cylinders are fully retracted.
(2) Raise the forks approx. 100 mm (3.94 in.) from
the ground. 3 Clamp

2 Double nut
(4) Place wood blocks approx. 90 mm (3.54 in.) high
(upper)
under the forks.
1 Double nut
(5) Push the chains at the middle point between the (lower)
chain wheel and chain fixed end on the lift Anchor bolt
bracket. 215443
Check the right and left chains for even tightness.
If tension on the right and left chain is uneven, Tightening torque
adjust the tension. Unit: N·m (kgf·m) [lbf·ft]
Item 1 ton class
(1) Remove the wood blocks under the forks. Start 3 ton class
+49 +49
(2) Lower the forks to the ground and tilt forward until 98 0 147 0
+5.00 +5.00
the tips come in contact with the ground. The Nuts 1, 2 (9.99 0 ) (14.99 0 )
+36.14 +36.14
chains are now slack to facilitate the adjustment. [72.28 0 ] [108.42 0 ]
(4) Loosen double nut (lower) 1, then upper nut 2.
(5) Turn double nut (upper) 2 to adjust the chain ten-
After the adjustment, raise and lower the lift bracket
sion.
several times. Then check the position of lift bracket
(6) Start the engine, and position the mast vertical when the lift cylinder is fully retracted. Make sure the
again. protrusion of each lift bracket main roller does not
exceed 40% of the roller diameter. If it exceeds, elon-
(7) Repeat steps (2) through (5) of the procedure in
gation of chains is suspected.
tension and adjust it as needed.

Inner mast
(1) Hold the anchor bolt with a wrench so as not to
twist the chain, then tighten the upper nut Lift bracket
2. lower roller

tighten double nut (lower) 1 to the specified
torque.
40% of the roller
diameter or less
213962
12-45
MAST AND FORKS

expand the chains.
(2) Measure 20 links of chain. When the length
exceeds the service limit specified in the table
below, replace the chain.
Chain elongation
Truck type
class class class
318 381 508
A
(12.52) (15.00) (20.00) 20 links
Duplex mast
327 392 523
B
(12.87) (15.43) (20.59)
213965
14.4 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
rollers F
bracket and the inner mast, and slide the inner
Unit: mm (in.)
F 1 (0.04) maximum F 213966

rollers.
"Choosing correct roller diameters" on (1)
Choosing correct roller diameters.

bracket.
bracket on the indicator side, and slide the lift
12-46
MAST AND FORKS

rect clearance.

ing.
213968
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
between the middle roller and thrust plate" on 12.2.1
and thrust plate.

inner mast. G1
side roller and inner mast" on 12.2.1 (5) Adjust-
ing clearance G1 between the side roller and 213969
inner mast.
(g) With the lift bracket at the top, check clearance

G between the lower roller and inner mast. If
clearance is out of specification, it is necessary
to add shims to the seat of the roller to adjust
to correct clearance.
lower roller and inner mast" on 12.2.1 (3) Lower roller
Adjusting clearance G between the lower roll-
ers and inner mast.
G
213970
12-47
MAST AND FORKS

ers
mast.
Unit: mm (in.)
F 1 (0.04) maximum

rollers. For mast roller replacement and instal- 213971


main rollers
mast.
Set the indicator to zero.
G
213972

Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)

by shims. 213973
refer to "Installing mast rollers" on 12.2.2
Installing Mast Rollers.

rollers
G
push the outer mast against the inner mast
with a bar. Set the indicator to zero (0).
213974
12-48
MAST AND FORKS

on the indicator side, and push the inner mast G
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)

by shims. 213975

position.
Unit: mm (in.)
0.1 to 0.5
G2
(0.004 to 0.020)

For adjustment procedure, refer to "Measuring
213976
strip and inner mast" on 12.2.3 Installing mast
strip.

both sides.
and left.
217372
ed.
12-49
MAST AND FORKS
Standard tilt angle

Forward Backward
Mast model
angle angle

153 to 182
(15.6 to 18.6
socket bolt
[112.8 to 134.5]

inder stroke.
213978

(a) Raise the inner mast, place blocks under the
right and left sides of the inner mast, and lower
the mast until it rests on the blocks.
rod end.
213824
the cylinders.

set bolt. Remove the blocks from under the
inner mast. Set bolt
213943
12-50
MAST AND FORKS
15.Troubleshooting (Duplex Mast)
Lift bracket and
other rollers.
move smoothly.
Mast strip clearance incorrect Adjust shim.
mast are not in a
descends due to a
Fork tips differ in
height.
Uneven loading
12-51
MAST AND FORKS
16.Service Data (Duplex Mast)

Unit: mm (in.)
Truck type
Item
mm (in.) A 317.5 (12.50) 381 (15.00) 508 (20.00)
Chain Chain elongation /
20 links B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48) 113.8 (4.48)
M A 100 (3.94) 115 (4.53) 115 (4.53)
Rollers L A 101 (3.98) 116 (4.57) 116 (4.57)
LL A 102 (4.02) 117 (4.61) 117 (4.61)
Width of outer mast B A 610 (24.02) 670 (26.38) 670 (26.38)
Dimension
Duplex mast Width of inner mast B2 A 516 (20.13) 568 (22.36) 568 (22.36)
(Reference)
Width of lift bracket C A 408 (16.06) 458 (18.03) 458 (18.03)
roller circumference and A 1 (0.04) or less
mast thrust surface F
Mast 0.1 to 0.5
roller side surface and mast A
(0.004 to 0.020)
thrust surface G
Clearance between inner 0.1 to 0.5
A
mast and mast strip G2 (0.004 to 0.020)
roller circumference and A 1 (0.04) or less
Clearances
inner mast F
0.1 to 0.5
roller side surface and inner A
(0.004 to 0.020)
mast thrust plate G
Lift bracket
0.1 to 0.5
(0.004 to 0.020)
Clearance between side
0.1 to 0.5
roller circumference and A
(0.004 to 0.020)
inner mast surface G1
12-52
MAST AND FORKS
F G2
G
F
G1
F
G
G
B2
C
Lift bracket
The mast is slightly wider at the lower than at the upper.

r.
Always measure the clearance at the upper portion of the mast. 214828
12-53
MAST AND FORKS
17.Triplex Mast
17.1 Mast System
Triplex mast
Truck type Mast

5M15C□□
1 ton class
5M20C□□
2 ton class 5M25C□□
5M30C□□
3 ton class
5M35C□□

Example: 43 = Lift height of 4300 mm (169.29 in.)
Mast type and code

Code Mast type
M Triplex mast
5M35C43
214852
Example: 5 M 35 C 43
["43" stands for 4300 mm
(169.29 in.)]
Generation of Mast
and so on)
30, 35: 3 ton class
Mast type
the mast
12-54
MAST AND FORKS
18.Structure and Functions

18.1 Triplex (Triple Full-Free Panoramic) Mast (5M15C to 5M35C)
Note: For hydraulic lines, refer to "Installing Hydraulic Lines"
28
24 11
25 26 8
10
23
12 2 19 1
27 20
7
3 19
12
4
21
14 13
22
9 17
16
18
15
5
217375

1 Outer mast 10 Second lift chain 19 Mast strip
2 Middle mast 11 Hose pulley 20 Lift cylinder upper mounting bolts
3 Inner mast 12 Hose guard 21 Cylinder bracket
4 Tilt cylinder 13 Outer mast roller 22 Cylinder clamps
5 First lift cylinder (one) 14 Middle mast upper roller 23 Lift bracket
6 Second lift cylinder 15 Middle mast lower roller 24 Backrest
7 First lift chain wheel 16 Inner mast roller 25 Lift bracket upper roller
8 Second lift chain wheel 17 Tilt socket mounting pin 26 Lift bracket middle roller
9 First lift chain 18 Mast support cap 27 Lift bracket lower roller
28 Side roller
In the triplex mast, the free-lift height extends to the The first lift cylinder raises the lift bracket, while the
top of the mast, and the overall mast height remains second cylinder operates the three-stage telescopic
the same until the upper edge of the backrest exceeds mechanism and lift bracket.
the top of the mast.
The first lift cylinder is equipped with the upstroke
The mast assembly consists of the inner mast, middle cushioning and the second cylinder equipped with the
mast, outer mast, lift bracket, first lift cylinder and sec- down cushioning and both cylinders have no return
ond lift cylinders. hose by internal drain.
For mast operation, refer to "Mast Operation" on 18.2

Mast Operation.
12-55
MAST AND FORKS
18.2 Mast Operation

18.2.1 Operation of Triplex Mast
Mast Operation
First lift chain
The first lift cylinder extends, bringing the forks to the
maximum free-lift height.
Inner mast
First lift cylinder
When the first lift cylinder rod has reached the end of
Middle mast
the stroke, the second lift cylinders take over to lift the Second lift
middle mast while at the same time the second lift chain
chain lifts an assembly of the forks, inner mast and first Second lift
lift cylinders. cylinder
Free-lift
height Outer mast
Reverse the lifting sequence to activate the lowering
mechanism. Forks on the Maximum Maximum
12-56
MAST AND FORKS
19.Removal and Installation

19.1.1 Triplex Mast Removal
For replacing the mast roller without removing the mast from the truck, refer to 21. Removal and Installation of Mast
Rollers and Strips without Removing Mast from Truck, 21.1 Triplex Mast.
4
5
217376
Sequence
1 Nut 4 Tilt pin
2 Backrest, Lift bracket, Forks 5 Mast support cap, Bushing
3 High-pressure hose 6 Mast, Lift cylinder

(a) Tilt the mast forward, and lower the inner mast
remove nuts 1 from the anchor bolts.
inner mast until lift bracket 2 becomes free. 1
Note: Before proceeding any mast overhaul, measure 217377
12-57
MAST AND FORKS
(2) Disconnecting high-pressure hoses for lift cylinder

Place the mast in the bottom position and discon-
nect hose 3 at the arrow position in the illustration
on the previous page.

217384

mounting section and remove the tilt pins, and
separate the mast from the tilt cylinders.
engine is running.
217385
Never loosen tilt socket bolts except for tilt cylinder

disassembling.

Note: Lay the mast assembly in a space wide enough Match marks
217386
12-58
MAST AND FORKS
19.1.2 Triplex Mast Installation

(1) Mast Support
Inner cap
(b) 1 ton class:

chassis.
Chamfering is the same both in the right and Bushing
left sides. Be sure to reassemble in the same
position as it was.
(d) In order to easily grease, place wood blocks 1 ton class Cap
underneath the mast. By doing so, it is easily
greased.
Start the engine, raise and lower the lift bracket
with several strokes to bleed the cylinder.
12-59
MAST AND FORKS
20.Disassembly and Reassembly

20.1 Triplex Mast Disassembly
16 18
10 17
1
16
1
24
27 20
11
29
23 23 21
25
26 20
13
22
7 8
6 20
8 20
7 9
28 15
30
5
20
3 14
2 4
12 19 217378
Sequence
1 Hose for first lift cylinder, Clamp, 11 Main rollers, Shims 20 Hose, Clamp, Bolt, Washer
Bolt, Washer 12 Main rollers, Shims 21 Joint, Connector, Bolt, Washer
2 Bolt, Washers 13 Inner mast 22 Bolts, Seats, Cushions, Collars
3 Shims 14 Nuts 23 Cushions, Shims, Bracket
4 First lift cylinder 15 Lift chains (for second lift cylin- 24 Bolts, Washers, Shims
5 Chain guard ders) 25 Second lift cylinder
6 Chain wheel support, Pin 16 Chain guards, Bolt, Washers 26 Mast strips, Shims
7 Snap rings, Chain wheel 17 Snap rings, Chain wheel 27 Main rollers, Shims
8 Nuts (chain for second lift cylin- 18 Snap rings, Hose pulleys, Shafts, 28 Main rollers, Shims
der) Snap rings, Chain wheels 29 Middle mast
9 Clamp 19 Hose guards, Bolt, Washer 30 Outer mast, Grease nipples
10 Mast strips, Shims
Note: The lift bracket disassembly procedure is the same as for the simplex mast.
Start by
With the lift bracket facing up, place the mast horizontally on wood blocks.
Place a wood block as a wedge to prevent the inner and middle masts from sliding.
Before disassembling the mast and fork assembly, measure and record all clearances between each lift bracket and
roller and between each mast and roller. Recorded measurements will be helpful when replacing rollers or selecting
shims to adjust clearances.
12-60
MAST AND FORKS

(1) Removing first lift cylinder 4
4
(a) Remove retaining bolts from the first lift cylin-
der.
(b) Hitch slings on the first lift cylinder, and gently
remove the cylinder. Use two slings. Wind or
tie slings securely to prevent slipping.
217387
(2) Removing inner mast and main rollers

12
Lower inner mast 12 until main rollers 10, 11 can
be removed. Remove the rollers and mast strips 9
9.
11
10 217388

Using slings, lift and remove inner mast 12, steer-
ing it clear of the roller shaft sections of the middle
mast.
12
217389
(4) Removing main rollers 26, 27 from middle mast

28 and outer mast 29. 28
Remove the bolts that are holding second lift cyl- 24
inders 24. Place the cylinder rod ends on the
outer mast. Lower middle mast 28 until main roll-
ers 26, 27 can be removed. Then, remove the
main rollers. 27
29
26 217390
12-61
MAST AND FORKS

(1) Mast
defects.
or other defects.
cracks.
217391
(d) Check the mast support bushings for wear or
other defects.
(2) Lift bracket

and cracks.
cracks.
Unit: mm (in.)
Distortion of finger bar A 5 (0.2) maximum Straightedge
A: Standard value 217134
(3) Lift chains, chain wheels and chain wheel sup-

ports
(a) Measure the length of each chain to make sure
Chain elongation
that the two chains are equal in length. Also
check the chains for wear, indication of break- Unit: mm (in.)/20 links
age and link binding and twisting. Truck type
(b) Check each chain anchor bolt for cracks or
class class class
defects on thread.
317.5 381 508
(c) Check each chain wheel support and chain A
(12.5) (15) (20)
wheel for crack or wear. Check that the wheels Triplex mast
327 392 523
rotate smoothly. B
(12.9) (15.4) (20.6)
(4) Mast strip A: Standard value B: Repair or service limit
tion.
12-62
MAST AND FORKS
20.2 Triplex Mast Reassembly

F 2 F 3
1 2 1 1
Thrust plate Thrust

6 plate
Minimum clearance G
zero or more
1 mm (0.04 in.) Shim (b)

5 thick shim Upper roller Middle roller
6
G 4
F 6
1 Shim (d)
3
Shim (c)
1 G1

217379
Reassembly
side and a side roller at both sides as shown. and (b) for the middle roller and with shim (c) for the
smooth operation. Unit: mm (in.)
0.1 to 0.5
Clearance G Clearance G
(0.004 to 0.020)
press the bracket to either the left-most or rightmost the rollers.
Note: It is not necessary to adjust the lift bracket up- Unit: mm (in.)
per roller with shims. Clearance F 1 (0.04) maximum
12-63
MAST AND FORKS
Clearance G1
roller to the upper end of the inner mast and press the
lift bracket to either the leftmost or rightmost position.
tion.
Unit: mm (in.)
0.1 to 0.5
Clearance G1
(0.004 to 0.020)

Unit: mm (in.)
Truck type
1 ton class
the table to the right. S 99 (3.90) 113.8 (4.48)
and Adjustment." L 101 (3.98) 116 (4.57)
The rollers should rotate smoothly when installed. LL 102 (4.02) 117 (4.61)

and thrust plate. Inner mast
Lift bracket
Shim (a)
Measure clearance G between the middle roller
and thrust plate. If the measured clearance does Shim (b) Thrust plate
not conform to the standard value, adjust clear- G
ance G in the manner described below. 0.1 to 0.5 mm
(0.004 to 0.020 in.)
and Adjustment." 213936
Adjusting method Unit: mm (in.)
If clearance G is excessive, increase the thickness Truck type
Item 2 ton class
shims (b) by the same amount that are added to 1 ton class
shims (a). Shim (a) is available in two sizes: 1 mm 3 ton class
(0.04 in.) and 0.5 mm (0.020 in.). Shim (b) is avail- Shim (a) 2 (0.08) 1.5 (0.06)
able in only one size, 1 mm (0.04 in.). If shims (a) Shim (b) 2 (0.08)
are increased by 0.5 mm (0.020 in.), shims (b) do
At the factory, shims (a) and (b) are usually adjusted to
the values shown in the table on the right for the ship-
ment.
12-64
MAST AND FORKS

Lift bracket
Shim (c)
and Adjustment."
Adjusting method
213937
At the factory, shims (c) are usually adjusted to 1 mm
(4) Installing main rollers

installed.
213938

Lift bracket Inner mast
and inner mast
Shim (d)
Measure clearance G1 between the side roller's
Roller Side roller
sured clearance does not conform to the standard mounting
described below.
Lift bracket
and Adjustment."
Adjusting method
217380
At the factory, shims (d) are usually adjusted to 1 mm
12-65
MAST AND FORKS

G G 0.1 to 0.5 mm
Unit: mm (in.) (0.004 to 0.020 in.)
0.1 to 0.5 F F
Clearance G
(0.004 to 0.020) (Upper mast) 1 mm (0.04 in.) or less
Shim (g) Shim (h)
(1) Measure clearance F between the rollers' rolling
standard values, replace with rollers of correct Middle Outer mast
diameters listed in the table below. Inner mast mast G G
0.1 to 0.5 mm
Note: For measuring procedures, refer to "Inspection (0.004 to 0.020 in.)
F F
and Adjustment." 1 mm
(0.04 in.) or less
Shim (i)
Unit: mm (in.) Shim (j)
(Lower
Truck type mast)
1 ton class
3 ton class Lift bracket
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53) 213941
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.61)
For installation of mast rollers, follow the proce-

dures for the lift-bracket rollers.

(g) - (j) under the roller seats as required.
At the factory, shims (g) - (j) are usually adjusted to the
values shown in the table below for the shipment.
Unit: mm (in.)
Truck type
Item 2 ton class
1 ton class
3 ton class
Shim (g) 1 (0.04) 1 (0.04)
Shim (h) 2 (0.08) 1 (0.04)
Shim (i) 2 (0.08) 1 (0.04)
Shim (j) 2 (0.08) 1 (0.04)
12-66
MAST AND FORKS
20.2.3 Installing mast strip

Shim (k)
the mast strip and inner mast
0.1 to 0.5 mm
Maintain clearance between the mast strip and (0.004 to 0.020 in.)
G2
inner mast. Insert a thickness gauge to measure Outer mast
to 0.1 to 0.5 mm (0.004 to 0.020 in.). Shim (k)
Unit: mm (in.)
Clearance G2 0.1 to 0.5 (0.004 to 0.020 )
Mast strips
Inner mast
Adjusting method Middle mast
214854
and down the bracket after the clearance is
adjusted.
At the factory, shims (k) are usually adjusted to 1 mm
20.2.4 Installing Lift Cylinders

Set bolt
(2) Place the lift cylinders complete with the brackets
Cylinder bracket
used.
213943
ders positioned vertically, measure clearance H.
Unit: mm (in.)
Clearance H 1.6 (0.06) maximum Shim (m)
Adjusting method
not fitted with shims (m). If the clearance is 3.2 mm 214855
installed.
the same. Refer to 22.8 Right and Left Lift Cylin-
der Stroke Inspection and Adjustment.
12-67
MAST AND FORKS
20.2.5 Installing first lift cylinder

(Duplex and Triplex Masts)
(1) With the masts set vertically and fully lowered,
temporarily install the first lift cylinder complete
with the original shims to the inner mast.
Mounting bolt
(2) Position the first lift cylinder vertically, and mea-
sure the clearance, if any, between the cylinder
brackets and the cylinder mounts on the inner
mast. Remove any clearance by adding shims.
Shim
The perpendicularity of the cylinder in the lateral
direction can be checked by measuring the dis- First lift cylinder
tances between the cylinder and the side face of
the inner mast. The difference of the distance at 214839
the top and bottom should be ± 1 mm (0.04 in.).
The perpendicularity of cylinder in the longitudinal
direction can be checked by visually inspecting for
the parallelism between the cylinder and the front
face of the inner mast. The cylinder should not be
inclined forward, not even slightly. The cylinder
slightly inclined backward is acceptable.
Each shim is 1 mm (0.04 in.) thick.
At the factory, a shim pack of 2 mm (0.08 in.) is usually
inserted between the cylinder bracket and the inner
mast for the shipment.
(3) After shimming is completed, install and tighten
the mounting bolts.
Note: Depending on the truck model, the direction in
which the mounting bolts are inserted may be
different from what is shown in the illustration.
20.2.6 Connecting Chains

Attach each chain to the lift bracket as shown.
When attaching, create a clearance between them
using nuts to allow for the tension of the chain.

Truck type Chain
Item 1 ton class
3 ton class
2 ton class
0 0 Lock nut
56.8 -9.8 84.3 -11.8 (single nut side)
Lock nut 0 0
(single nut side) (5.79 -1) (8.6 -1.2)
[42
0
-7.2]
0
[62.2 -8.7] Lock nut
(double nut side)
+49 +49
98 0 147 0
Lock nut +5 +5
(double nut side) (10 0) (15 0)
+36 +36
[72 0 ] [108.5 0 ]
Lift bracket
214840
12-68
MAST AND FORKS

General precautions
Use care not to let abrasive dust or dirt enter the For assembling Elbow Connector (a fitting with
hydraulic system. straight threads and O-ring seal) indicated by F, fol-
low the procedure in "Installation of a fitting with
straight threads and O-ring seal" shown below.
Triplex Mast
Tightening torque
A
Truck model
Item 1-2 ton 3 ton
classes class
A A
58.8 ± 5.9 58.8 ± 5.9
Nut A (6.0 ± 0.6) (6.0 ± 0.6) Second cylinder
[43.4 ± 4.35] [43.4 ± 4.35]
49.0 ± 4.9 49.0 ± 4.9 Down safety valve
Nut B (5.0 ± 0.5) (5.0 ± 0.5)
[36 ± 3.6] [36 ± 3.6]
A
39.2 ± 3.9 58.8 ± 5.9 A
Nut C (4.0 ± 0.4) (6.0 ± 0.6) First cylinder
[28.9 ± 2.88] [43.4 ± 4.35] E
39.2 ± 3.9 58.8 ± 5.9
Nut D (4.0 ± 0.4) (6.0 ± 0.6)
[28.9 ± 2.88] [43.4 ± 4.35] D
58.8 ± 5.9 58.8 ± 5.9
Nut E (6.0 ± 0.6) (6.0 ± 0.6)
[43.4 ± 4.35] [43.4 ± 4.35]
A
Down safety valve
B
C
Second cylinder
217381
12-69
MAST AND FORKS

ring seal
(1) Apply grease or hydraulic oil to the O-ring and O- Shape varies by fitting type
1
ring seat in the housing side. 2
(2) Turn lock nut 3 to move it fully to the fitting body 2.

Place washer 4 and O-ring seal 5 against the lock 4
nut. 3
5
(3) Tighten the fitting by hand. Once O-ring seal 5 is
6
placed in the position of housing and washer 4
comes in contact with the surface of housing, turn 214084
it back to adjust the mounting direction. Never Elbow with nut
(4) Tighten lock nut 3 to the specified torque. 1 End of fitting body
(connects to tube)
2 Fitting body
3 Lock nut
4 Backup washer
5 O-ring seal
12-70
MAST AND FORKS
21.Removal and Installation of Mast Rollers and Strips without Removing

Mast from Truck
21.1 Triplex Mast
(2) Remove the first lift cylinder as follows:
(a) Place a sling around the cylinder. Using a hoist
connected to the sling, slightly lift the cylinder.
The sling should be hitched firmly around the
cylinder to prevent the cylinder from slipping
down.
(b) Remove the cylinder mounting bolts. Using the
hoist, slowly lift and remove the first lift cylinder.
(3) Place the inner mast lower than the middle mast.
Follow the following procedures:
(a) Lift the front of the truck by 150 to 200 mm
(5.91 to 7.87 in.), and place wood blocks to
support the truck.
(b) Place a sling around the upper cross member
of the inner mast. Using a hoist connected to 217382
the sling, slightly lift the inner mast.
(c) Remove the guards for the second lift chain
wheels.
(d) Disconnect the second lift chains at the outer
mast ends, and place the loose ends on the
floor beyond the inner mast.
(e) Lower the inner mast to such a height that
allows the mast rollers to be removed.
(f) Support the inner mast with wood blocks.
(g) The main rollers of the inner and middle masts 217383
can now be removed. Remove the mast strips
and shims before attempting to remove the
main rollers, as they tend to drop easily.
(h) Adjust shims for the main rollers and mast
strips as required.
With the mast disassembled as above, the second lift

cylinders cannot be removed.
12-71
MAST AND FORKS
(4) Place the middle mast lower than the outer mast
as follows:
(a) Lift the inner mast to the height of the middle
mast, then place wood blocks for support.
(b) Hitch slings to both middle mast and inner
mast, and lift them with a hoist.
(c) Remove set bolts from the upper sections of
the second lift cylinders, then lift the middle
mast and inner mast to separate the second lift
cylinder from the middle mast. 217410
(d) Remove two lift cylinder clamps, dismount the
second lift cylinders from the mounting sec-
tions at the lower outer mast section. Tilt the
cylinders by moving the top sections towards
the center of the truck. Using a rope, fix the cyl-
inders onto the cross member.
(e) Lower the middle mast and inner mast until the
mast rollers (outer mast upper roller and mid-
dle mast lower roller) can be removed.
(f) Support the middle mast and inner mast with
wood blocks.
(g) The main rollers of the inner and outer masts
can now be removed. It is recommended that
before attempting to remove the main rollers,
remove the mast strips and shims as they tend
to drop easily.
(h) Adjust shims for the main rollers and mast
strips as required.
For reassembling, follow the disassembly sequence
in reverse.
12-72
MAST AND FORKS
22.Inspection and Adjustment (Triplex Mast)

The inspection and adjustment in this chapter can be Conduct inspection whenever a defect is suspected.
done without dismounting or disassembling.
22.1 Forks

NEW FORK ARM

SHANK CROSS
50 mm (2 in.) SECTION = 100%
Figure 1
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
ence in safety.

12-73
MAST AND FORKS

inspecting and adjusting lift chains, anchor bolts and
nuts. Place wood blocks below the forks when they are
nents.

(1) Place the mast vertically and on level ground. 215459
Then lower the forks to the ground. Make sure

that the lift cylinders are fully retracted.
(2) Raise the forks approx. 100 mm (3.94 in.) from Anchor bolt
the ground.
2 Clamp
(4) Place wood blocks approx. 90 mm (3.54 in.) high
under the forks.
(5) Push the chains at the middle point between the 3 Double nut (upper)
chain wheel and chain fixed end on the lift 1 Double nut (lower)
bracket. 214826
Check the right and left chains for even tightness.
If tension on the right and left chain is uneven, Tightening torque
adjust the tension. Unit: N·m (kgf·m) [lbf·ft]
Item 1 ton class
(1) Remove the wood blocks under the forks. Start 3 ton class
+49 +49
(2) Lower the forks to the ground and tilt forward until 98 0 147 0
+5.00 +5.00
the tips come in contact with the ground. The Nuts 1, 3 (9.99 0 ) (14.99 0 )
+36.14 +36.14
chains are now slack to facilitate the adjustment. [72.82 0 ] [108.42 0 ]
(4) Loosen the double nut (lower) 1. Then loosen the
clamp 2.
(5) Adjust the chain tension by turning the double nut After the adjustment, raise and lower the lift bracket
(upper) 3. several times. Then check the position of lift bracket
when the lift cylinder is fully retracted. Make sure the
(6) Start the engine, and position the mast vertical
protrusion of each lift bracket main roller does not
again.
exceed 40% of the roller diameter. If it exceeds, elon-
(7) Repeat (2) through (5) of the procedure in gation of chains is suspected.
tension and adjust it as needed.
Inner mast
Lift bracket
(1) Hold the anchor bolt with a wrench so as not to lower roller
twist the chain, then tighten the clamp 2.
tighten double nut (lower) 1 to the specified
torque.
40% of the roller
diameter or less
213962
12-74
MAST AND FORKS

expand the chains.
(2) Measure 20 links of chain. When the length
exceeds the service limit specified in the table
below, replace the chain.
Chain elongation
Truck type
class class class
317.5 381 508
A
(12.50) (15.00) (20.00) 20 links
Triplex mast
327 392 523
B
(12.87) (15.43) (20.59)
213965
22.4 Adjusting Clearance between Lift Bracket Roller and Inner Mast
rollers F
bracket and the inner mast, and slide the inner
Unit: mm (in.)
F 1 (0.04) maximum F 213966

rollers.
"Choosing correct roller diameters" on 20.2.1
(1) Choosing correct roller diameters.
bracket.
(c) Go over to the opposite side of the mast and
bracket on the indicator side, and slide the lift
12-75
MAST AND FORKS

rect clearance.
ing.
213968
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)

between the middle roller and thrust plate" on 20.2.1
and thrust plate.
inner mast. G1
side roller and the inner mast" on (5) Adjusting
clearance G1 between the side roller and inner 213969
mast.
(g) With the lift bracket at the top, check clearance

G between the lower roller and inner mast. If
clearance is out of specification, it is necessary
to add shims to the seat of the roller to adjust
to correct clearance.
lower roller and inner mast" on (3) Adjusting Lower roller
clearance G between the lower rollers and
inner mast.
G
213970
12-76
MAST AND FORKS

ers
mast.
Unit: mm (in.)
F 1 (0.04) maximum
(c) If clearance is out of specification, use oversize 213971

rollers. For mast roller replacement and instal-

main rollers
mast.
Set the indicator to zero (0).
G
213972

on the indicator side, and slide the inner mast
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)

by shims. 213973

rollers
G
slide the outer mast against the inner mast with
a bar. Set the indicator to zero.
213974
12-77
MAST AND FORKS

on the indicator side, and slide the inner mast G
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)

by shims. 213975


position.
Unit: mm (in.)
0.1 to 0.5
G2
(0.004 to 0.020)

For adjustment procedure, refer to "Measuring 213976
strip and inner mast" on 20.2.4 (1) Measuring and
adjusting clearance G2 between the mast strip
and inner mast.

both sides.
and left.
217372
ed.
12-78
MAST AND FORKS
Standard tilt angle

Forward Backward
Mast model
angle angle

153 to 182
(15.6 to 18.6
socket bolt
[112.8 to 134.5]
inder stroke.
213978

(a) Raise the inner mast, place wood blocks under
the right and left sides of the inner mast, and
lower the mast until it rests on the wood blocks.
rod end.
213824
the cylinders.

set bolt. Remove the wood blocks from under
the inner mast. Set bolt
213943
12-79
MAST AND FORKS
23.Troubleshooting (Triplex Mast)
Lift bracket and
other rollers.
move smoothly.
Mast strip clearance incorrect Adjust shims.
mast are not in a
descends due to a
Fork tips differ in
height.
Uneven loading
12-80
MAST AND FORKS
24.Service Data (Triplex Mast)

Unit: mm (in.)
Truck type
Item
mm (in. ) / A 317.5 (12.50) 381 (15.00) 508 (20.00)
Chain Chain elongation
20 links B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48) 113.8 (4.48)
M A 100 (3.94) 115 (4.53) 115 (4.53)
Rollers L A 101 (3.98) 116 (4.57) 116 (4.57)
LL A 102 (4.02) 117 (4.61) 117 (4.61)
Width of outer mast B A 610 (24.02) 670 (26.38) 670 (26.38)
Dimension Width of middle mast B1 A 516 (20.13) 568 (22.36) 568 (22.36)
Triplex mast
(Reference) Width of inner mast B2 A 426 (16.77) 468 (18.43) 468 (18.43)
Width of lift bracket C A 318 (12.52) 358 (14.1) 358 (14.1)
Clearance between main roller
circumference and mast thrust A 1 (0.04) or less
surface F
Mast 0.1 to 0.5
side surface and mast thrust A
(0.004 to 0.020)
surface G
Clearance between inner mast 0.1 to 0.5
A
and mast strip G2 (0.004 to 0.020)
circumference and inner mast A 1 (0.04) or less
Clearances
F
0.1 to 0.5
(0.004 to 0.020)
mast thrust plate G
Lift bracket
0.1 to 0.5
(0.004 to 0.020)
Clearance between side roller
0.1 to 0.5
circumference and inner mast A
(0.004 to 0.020)
surface G1
12-81
MAST AND FORKS
G
G2
G1
F G
G
B2
F
G
G
B1
C
Lift bracket
Mast width is slightly wide at the lower portion than at the upper portion.
Measure the clearance at the mast upper position.
214859
12-82

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Chapter 12 MAST AND FORKS

1. Simplex Mast ......................................................................................... 12-1

Chapter 12 MAST AND FORKS

Truck type Mast

Note: "□□" presents maximum lift height.

Mast type and code

2. Structure and Functions

Major Components (most parts come in pairs, left and right)

2.2 Mast Operation

Forks on the Maximum Maximum

3. Removal and Installation

Suggestions for Removal

(2) Disconnecting high-pressure hoses for lift cylinder

(3) Separating tilt cylinders

Be sure to use a hoist having a capacity enough to

(b) Place wood blocks under the tilt cylinder

(4) Removing mast support bearing caps

3.1.2 Simplex Mast Installation

2-3 ton classes 213916

4. Disassembly and Reassembly

Suggestions for Disassembly

(2) Removing inner mast

Inspections after Disassembly

(2) Lift bracket

(4) Mast strip

4.2 Simplex Mast Reassembly

4.2.1 Installing Lift Bracket Rollers

No shim required Shim (a)

Thrust plate Thrust plate

4 Lower roller Side roller

(1) Choosing correct roller diameters

(2) Adjusting clearance G between the middle roller

(3) Adjusting clearance G between the lower rollers

(4) Installing Mast Rollers

(5) Adjusting clearance G1 between the side roller

4.2.2 Installing Mast Rollers

For installation of mast rollers, follow the same pro-

(2) Measure clearance G between the rollers and

4.2.3 Installing Mast Strips (all mast models)

Maintain a clearance between the mast strip and 0.1 to 0.5 mm

4.2.4 Installing second lift cylinder

(4) Secure the lower end of each lift cylinder to the

4.2.5 Connecting Chains (Simplex mast model)

Lower chain anchor kit

4.2.6 Installing Hydraulic Lines

Nut C 39.2 ± 3.9 58.8 ± 5.9

Installation of a fitting with straight threads and O-

1 End of fitting body

5. Removal and Installation of Mast Rollers and Strips without Removing

To reassemble, follow the disassembly sequence in

6. Inspection and Adjustment (Simplex Mast)

Fork calipers perform two tasks at once.

NEW FORK ARM

Not for use on full tapered forks. 217126

6.1.1 DESIGNED TO TAKE A BEATING

6.2 Chain Tension Inspection and Adjustment

Turn the engine/main key to the (OFF) position before

Inspection of chain tension

6.3 Checking Chain Elongation

(2) Right-to-left clearance check on lift bracket main

(e) Insert a bar between the inner mast and lift

For adjustment, refer to "Adjusting clearance G1

6.5 Mast Roller Clearance Adjustment

For installation of mast rollers, follow the same pro-

Maintain a clearance between the mast strip and 0.1 to 0.5 mm

To reassemble, follow the disassembly sequence in

Adjusting method 213937

For installation of mast rollers, follow the proce-

Maintain clearance between the mast strip and 0.1 to 0.5 mm

To reassemble, follow the disassembly sequence in