LOADING MECHANISM

SECTION
CONTENTS
NOTE:
This section contains information and
specifications for both General Overseas Market
(GOM) and North America. Therefore, ensure the
specifications or procedures you are looking at
are for the proper area.
LM
SERVICE DATA AND SPECIFICATIONS . . LM-2
Inspection and Adjustment . . . . . . . . . . . . . LM-2
Tightening Torque . . . . . . . . . . . . . . . . . . . LM-3
TROUBLE DIAGNOSES AND
CORRECTIONS . . . . . . . . . . . . . . . . . . . . . LM-4
PRECAUTIONS AND PREPARATION . . . . LM-5
Precautions . . . . . . . . . . . . . . . . . . . . . . . . LM-5
FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LM-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . LM-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . LM-6
LIFT CHAINS . . . . . . . . . . . . . . . . . . . . . . . . LM-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . LM-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . LM-7
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . LM-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-8
CARRIAGE ASSEMBLY . . . . . . . . . . . . . . . LM-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . LM-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-11
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . LM-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . LM-13
MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LM-14
Mast Assembly . . . . . . . . . . . . . . . . . . . . . LM-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . LM-18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . LM-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . LM-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . LM-29
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . LM-30
Mast bushing . . . . . . . . . . . . . . . . . . . . . . . LM-31
BOLZONI AURAMO
HN SERVICE MANUAL . . . . FOLLOWING LM-32
 SERVICE DATA AND SPECIFICATIONS

Inspection and Adjustment

Adjustment Specifications
Applied model A1N1 series Applied model A1N1 series
Outer mast-to-inner mast clearance 0.1 - 0.6 3,850 (151.57), 369 (14.53)
mm (in) (0.004 - 0.024) 4,300 (169.29),
0.1 - 0.6 4,750 (187.01),
Mast-to-liner clearance mm (in) 5.150 (202.76)
(0.004 - 0.024)
3F 5,500 (216.54) 384 (15.12)
Mast-to-mast roller rolling surface 0.1 - 0.6
clearance mm (in) (0.004 - 0.024) 6,000 (236.22) 419 (16.50)
Inner mast-to-carriage 6,500 (255.91) 504 (19.84)
0.1 - 0.6 Lift roller lapping
roller side face clearance
(0.004 - 0.024) allowance pitch 7,000 (275.59) 604 (23.78)
mm (in)
(Dimension “L”) 3,600 (141.73),
Inner mast-to-carriage mm (in)
0.1 - 0.6 4,050 (159.45),
roller rolling face clearance 369 (14.53)
(0.004 - 0.024) 4,500 (177.17),
mm (in)
4,900 (192.91)
Mast forward/ 2W, 2F 4/6 3V 5,250 (206.69) 384 (15.12)
backward tilting
angle (°) 3F, 3V 5/5 5,750 (226.38) 419 (16.50)
Carriage lower edge-to-ground distance 6,330 (249.21) 504 (19.84)
76 (2.99)
mm (in) 6,880 (270.87) 604 (23.78)
Lower end of outer mast-to lower Mast inner 50.25-50.31 (1.978-1.981)
end of inner mast (3F, 3V MAST) 0 (0) bushing Diameter
mm (in) outer 59.85-60.23 (2.356-2.371)
mm (in)
25 - 30 wear limit Thickness 3.38 (0.133)
Chain tension mm (in)
(0.98 - 1.18)
2,700 Adjusting shim/roller
(106.30),
3,000 Applied model A1N1 series
283 (11.14)
(118.11), 0.5, 1.0, 2.0
Carriage roller adjustment shim mm (in)
3,300 (0.020, 0.039, 0.079)
(129.92)
Carriage side roller and thrust metal adjustment 0.5, 1.0, 2.0
3,500 shims mm (in) (0.020, 0.039, 0.079)
318 (12.52)
(137.80)
0.5, 1.0
2W Liner adjustment shim mm (in)
3,700 (0.020, 0.039)
343 (13.50)
(145.67)
2,700 105 (4.13)
4,000 - 3,300
(157.48), (106.30 -
Lift roller lapping 4,500 129.92)
383 (15.08) 2W, 2F
allowance pitch (177.17), Inner mast roller
3,500 105, 105.5, 106
(Dimension “L”) 5,000 mm (in)
or more (4.13, 4.15, 4.17)
mm (in) (196.85)
(137.80
2,700 or more)
(106.30),
97, 97.5, 98
3,000 3F, 3V
284 (11.18) (3.82, 3.84, 3.86)
(118.11),
3,300 Upper 97.0 (3.819)
(129.92) Middle mast roller
3F, 3V 105, 105.5, 106
mm (in) Lower
2F 3,500 (4.13, 4.15, 4.17)
354 (13.94)
(137.80) Outer mast roller mm (in) 97 (3.819)
3,700 97, 97.5, 98
404 (15.91) Upper and lower
(145.67) Carriage roller mm (3.819, 3.839, 3.858)
4,000 (in)
484 (19.06) Center 97 (3.819)
(157.48)
Mast roller adjustment shim 0.5, 1.0, 2.0
mm (in) (0.0197, 0.0394, 0.0787)
Lift cylinder adjustment shim mm (in) 1.0 (0.039)
Full-free cylinder adjustment shim 1.0 (0.039)
(2F, 3F mast) mm (in)

LM-2
 SERVICE DATA AND SPECIFICATIONS

Tightening Torque
Unit Nm (kg-m, ft-lb)
Backrest Backrest securing bolt 177 - 225
installation (18 - 23, 131 - 165)
Lift chain Lock nut 92 - 124
installation (9.4 - 13.0, 69 - 93)
Carriage Side roller securing bolt 21 - 26
reassembly (2.1 - 2.7, 16 - 19)
Lift cylinder upper side 78 - 98
bolt (7.9 - 10.0, 58 - 72)
Lift cylinder lower side bolt 44 - 54
(4.4 - 5.6, 32 - 40)
Full-free 128 - 156
2F, 3F
cylinder set (13 - 16, 95 - 115)
bolt
44 - 54
3V
Mast (4.4 - 5.6, 32 - 40)
reassembly U-bolt lock nut 26 - 32
(2.6 - 3.3, 19 - 23)
U-bolt adjusting bolt lock 74 - 94
nut (7.5 - 9.6, 55 - 69)
Chain guide securing bolt 21 - 26
(2W MAST) (2.1 - 2.7, 16 - 19)
Lift chain anchor bolt lock 92 - 124
nut (9.4 - 13.0, 69 - 93)
Mast support cap 89 - 118
securing bolt (9.1 - 12.0, 66 - 87)
Mast Pivot pin lock bolt 26 - 32
installation (2.6 - 3.3, 19 - 23)
Tilt cylinder rod lock nut 108 - 147
(11 - 15, 80 - 108)

LM-3
 TROUBLE DIAGNOSES AND CORRECTIONS

! CAUTION

• The following table lists only typical examples. To perform

Condition
Forks do not raise or lower smoothly.
an accurate diagnosis carefully listen to the user’s
complaints and check the actual vehicle to fully understand
under what conditions the symptoms occur.
Probable cause Corrective action
• Improperly adjusted carriage bracket • Adjust clearances between parts (such
assembly as inner mast, side roller, thrust metal,
carriage roller). Replace faulty parts with
new ones.
• Adjust using shim(s) or liner.
• Improperly adjusted inner mast-to-outer
mast clearance or roller-to-mast clearance
• Insufficient lubrication • Apply grease to contacting/sliding surfaces
of parts.
• Remove foreign matter.
• Caught foreign matter in functional parts
• Adjust.
• Deformed inner mast
• Adjust or replace.
• Bent carriage bracket assembly

Forks rising unstable
Lift rollers fail to rotate.
Mast assembly emits noise.
• Improperly adjusted lift chain(s)
• Solidified grease on rollers or sliding
surfaces or accumulated dirt/dust
• Lift roller(s) are improperly installed.
• Roller(s) are broken or damaged.
• Insufficient lubrication
• Improperly adjusted lift rollers, side rollers
and/or liners
• Worn chain wheels, lift rollers and/or liners
• Damaged lift rollers and/or mast rollers
• Adjust lift chain tension.
• Clean lift rollers and grease.
• Check and adjust lift rollers.
• Replace faulty rollers.
• Apply grease.
• Adjust.
• Replace worn parts.
• Replace damaged rollers.

LM-4
PRECAUTIONS AND PREPARATION

Precautions
• Most of the loading mechanism parts such as forks, mast,
carriages, etc. are heavy. The hoisting and movement of those
objects are inherently dangerous. Therefore, be extremely careful
and always employ an assistant when you remove them.
• When removing/installing cylinder, always perform the procedure
with two persons because of heavy weight, paying attention not to
catch hands by components.
• Be extremely careful to protect your hands, feet, etc., when
performing maintenance work on or moving heavy objects.
• Always assign lifting operations to qualified operators trained in
slinging or hoisting procedures.
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines must be completely bled off.
With Mechanical System
• For lift piping, fully tilt the masts forward, operate the control lever
several times forward, and turn key switch OFF. Operate the
control lever several times backward, and release the residual
pressure from piping.
• For lift piping, place the fork at the lowest position, and operate
the lift lever several times downward.
With Joystick System
• For tilt piping, first place the fork horizontal (tipped slightly forward)
and turn the key switch off. Next, loosen the piping and let set
while the remaining pressure escapes.
• For lift piping, place the fork at the lowest position, turn the key
switch off, loosen the shut-off valve and let the remaining pressure
escape.
• For attachment piping (3rd and 4th)
• Union connector
Place the attachment in neutral, turn the key switch off, loosen
the piping, and let set while the remaining pressure escapes.
• Coupling
Installing and removing the cup may be difficult if the
remaining pressure inside the piping is high. If this is the
case, turn the key switch ON and tip the lever (3rd and 4th)
backwards or forwards, and one of the cups will come off.
Then tip the lever in the other direction and remove the other
cup.

NOTE:
• The fork assembly must be removed as required to make
maintenance work easier to perform.
• Disassembly of the carriage bracket assembly requires the removal
of the forks. Following the removal of forks, remove the carriage
bracket assembly from the mast assembly.
• If the carriage bracket assembly needs not be disassembled upon
removal, remove it with the forks installed to it. This will prevent the
carriage assembly from toppling over.
• When the mast assembly and carriage bracket assembly are to be
removed as a unit, remove the fork assembly beforehand.

LM-5
 FORK

Removal
! CAUTION
• For removal of the fork assembly and carriage assembly as
a unit, refer to “CARRIAGE ASSEMBLY”.
1. Raise the forks approximately 100 to 200 mm (3.94 to 7.87 in)
above the ground.
2. Turn the lock levers 90° at the upper ends of the forks, then
move the forks to the notched portion located in the center of
the carriage assembly.

3. While lifting the tips of the forks, disengage the jaws from the
carriage (finger bar). Lift the upper portions of the forks up and
away from the carriage assembly. Always remove one fork at a
time.

Inspection
• Check the forks for wear (as shown in the figure). If wear exceeds
specifications, replace the forks with new ones.
Standard wear limit:
More than 3 mm (0.12 in)
• Visually check the forks for cracks, deformation or separation of
welds. If necessary, replace with new fork assembly.
• Check the forks using a dye penetration method. If they are
cracked, replace with new ones.

Installation
To install the forks, reverse the order of removal.
! CAUTION

• After installing both forks, check to ensure that the lock

levers are properly locked.

LM-6
 LIFT CHAINS

Removal
1. Support the carriage assembly by placing a wooden block under
it or using a crane.
2. Retract the lift cylinders to loosen the lift chains, then remove the
chain anchor bolts from the carriage.
3. Disengage the lift chains at the lift chain joint links and
adjustment bolts on the mast side. Refer to the illustration of
mast assembly.
4. Removal the lift chains from the chain wheel.

Installation
To install the lift chains, reverse the removal procedures.

! CAUTION
• Before installing the chain anchor bolts, ensure that the lift
chain is not twisted.
• Discard old cotter pins; replace with new ones.
Lock nut:
:92 - 124 Nm (9.4 - 13.0 kg-m, 69 - 93 ft-lb)
Adjustment
! CAUTION
• Before adjusting lift chain tension, park the vehicle on flat
and solid ground.
• On pneumatic tire models, inflate the tires to the specified
pressure.
• As for the 3F and 3V mast, adjust the mast chain and lift
chain.
1. Set the mast assembly in the vertical position and lower the
carriage assembly all the way down.

2. Turning the adjustment nut in or out, adjust the carriage

assembly until its lower end above the ground is within
specifications.
Standard clearance:
76 mm (2.99 in)

3. For the 3F and 3V mast, after the adjustment of the lift chain
mentioned above, raise the carriage gradually to adjust the
adjustment nut of the mast chain so that the difference between
the inner mast lower end and the outer mast lower end conforms
to the standard value.
Standard: 0 mm (0 in)

LM-7
 LIFT CHAINS

Adjustment (Cont’d)

4. With the fork assembly attached to the carriage, adjust the lift
chain adjustment nut so the midpoint of the lift chain can be
pulled (2W mast) or pressed (2F/3F/3V mast) 25 to 30 mm (0.98
to 1.18 in). The left and right lift chains must be equally adjusted.

• Check to ensure that the left and right chains are tensioned
equally.
Lock nut:
: 92 - 124 Nm (9.4 - 13 kg-m, 69 - 93 ft-lb)
5. After making the mast and lift chain tension adjustments,
move the carriage assembly up and down to ensure it moves
smoothly.

NOTE:
Every 200 hours of operation or once a month, whichever occurs
first, apply a coat of motor oil to the lift chains requiring lubrication.

Inspection
• Visually inspect the lift chains for cracks, breaks or damage. If
necessary, replace the left and right lift chains as a unit.
• To check the lift chain for elongation, raise the forks approximately
20 to 30 mm (0.79 to 1.18 in) above the ground.

LM-8
 LIFT CHAINS

Inspection (Cont’d)
NOTE:
• Balance the tension between left and right chains.
• Cracks or breakages often occur at the ends of the lift chains. If
necessary, replace both chains as a unit.
• Elongation often occurs in portions of the lift chain which
experiences contact with the chain wheel.

How To Inspect The Lift Chain (Reference)

1. Tilt the mast to vertical position.
2. Lift the fork to above 5 cm from the ground.
3. Confirm the chain type.
The type of the chain is stamped on the side of the chain.
However, special care is needed for the following chain as the
number stamped on the chain is different from the chain type
number.
Stamp on the chain Chain type
BL5 BL534
BL6 BL634
BL8 BL834
BL10 BL1034
BL12 BL1234

How to count the number of links

4. Apply the chain gauge and measure the chain length counting
the appropriate number of links for the chain type.

Replace the fork chain when the length exceeds the limit.

BL834 (14 links), RS40 (28 links), RS80 (14 links):

Standard length:
355.6 mm (14.000 in)
limit length:
364.4 mm (14.346 in)
BL534 (22 links), BL1034 (11 links), RS50 (22 links),
RS100 (11 links):
Standard length:
349.2 mm (13.748 in)
limit length:
358.0 mm (14.094 in)
BL634 (18 links), BL1234 (9 links), RS60 (18 links),
RS120 (9 links):
Standard length:
342.9 mm (13.500 in)
limit length:
351.4 mm (13.835 in)

LM-9
CARRIAGE ASSEMBLY

Removal
NOTE:
Removal of the carriage assembly and fork assembly as a unit
prevents the carriage assembly from toppling to the ground.
1. Set the mast assembly in the vertical position, then lower the
forks to the ground.
NOTE:
When removing the carriage assembly without forks, attach a lifting
wire/nylon sling, then support the carriage assembly using a hoist or
crane.

2. Disengage the lift chains at the adjusting bolt and lift chain
joint links on the mast side, then drape the lift chains over the
backrest.
3. Slowly raise the inner mast, then remove the carriage assembly
from the mast assembly.

! CAUTION
• Be careful to prevent the mast from catching the removed
lifting chain.

4. Back up the vehicle, then remove the carriage assembly from the
mast assembly.

! CAUTION
• Be sure to lower the inner mast to the ground after backing
the vehicle up.

LM-10
CARRIAGE ASSEMBLY

Inspection
Lift Rollers, Side Rollers And Shims
Check for unsmooth rotation, deformation, stepped wear or
damage.
Replace faulty parts with new ones if necessary.

Carriage Assembly
• Visually check for cracks, deformation or separation at welds. If
necessary, replace with new ones.
• Check the carriage assembly using a dye penetration method. If it
is cracked, replace with a new one.

Adjustment
1. Select suitable rollers so that the clearance between the rolling
contact surface of the inner mast rail and the carriage roller are
within specifications.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available roller sizes:
97.0, 97.5 and 98.0 mm
(3.819, 3.839 and 3.858 in)
Center mast roller diameter (2W/2F/3F mast):
97.0 mm (3.819 in)

2. Measure the inner wall width (A) of the inner mast at three points
(two at upper and lower ends of the inner mast and one in the
center of the inner mast at the cross beam location).

LM-11
CARRIAGE ASSEMBLY

Adjustment (Cont’d)

3. Measure the pitch of the left and right carriage side rollers,
carriage rollers and thrust metals (at points “B”, “B’” and “B””).
NOTE:
• The upper and middle carriage rollers for 2W/2F/3F mast are used
only for lift rollers. The lower carriage roller is guided and rolls to
the right and left within the rail race.
• Independent side rollers are located on the upper portion of the
carriage assembly.
4. Calculate carriage clearances by subtracting the maximum pitch
values of the carriage side rollers, carriage rollers and thrust
metals (B) from the measured minimum inner wall width of the
inner mast (A).
5. Whenever possible, use the same number of adjustment shims
to equalize left and right clearances.
Standard carriage clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available adjustment shims:
For use with carriage side rollers and thrust metals
0.5, 1.0 and 2.0 mm
(0.020, 0.039 and 0.079 in)
For use with carriage rollers
0.5, 1.0 and 2.0 mm
(0.020, 0.039 and 0.079 in)
! CAUTION

• Be extremely careful when adjusting carriage clearances.

Improper adjustment may cause the carriage bracket to
deviate either to the left or right, or tilting of the finger.
These conditions will result in unequal heights for the left
and right forks.

LM-12
CARRIAGE ASSEMBLY

Adjustment (Cont’d)

6. After carriage clearance adjustment, check to ensure that the

carriage assembly moves smoothly without binding.

! CAUTION
• Apply a coat of grease to the roller rolling contact surfaces
and thrust metal contacting surfaces (indicated by arrows in
the figure).

Installation
To install the carriage assembly, reverse the order of removal.
Observe the following:

! CAUTION
• Discard old cotter pins; replace with new ones.

LM-13
 MAST

Mast Assembly
2W Mast

LM-14
 MAST

Mast Assembly (cont’d)

2F Mast

LM-15
 MAST

Mast Assembly (cont’d)

3F Mast

LM-16
 MAST

Mast Assembly (cont’d)

3V Mast

LM-17
 MAST

Removal
! CAUTION
• When removing the mast assembly, ensure the forks are
removed beforehand. This is a precaution to ensure the
safest possible maintenance procedure.

NOTE:
If the carriage assembly need not be disassembled, remove the
carriage assembly together with the forks prior to removing the mast
assembly. Refer to “CARRIAGE ASSEMBLY” for instructions.

1. Remove the hoses (lift hose, attachment hoses, etc.), then plug
their openings to prevent foreign matter from getting into the
hydraulic lines.

! CAUTION
• The oil pressure remaining in hydraulic lines must be
completely bled off.

NOTE:
When removing the lift hose together with the carriage assembly,
relieve oil pressure in the hydraulic lines beforehand. Attach a lifting
wire or nylon sling to the carriage, then suspend it in the air with a
hoist to facilitate access to the mast assembly.

2. Attach a lifting wire or nylon sling to the upper beam of the mast
assembly, then support the mast assembly using a hoist.

! CAUTION
• Be sure to support mast assembly, failure to do so may
cause serious injury or costly damage to the mast or other
equipment.

3. Remove the mast support cap bolts; remove the mast support
cap from the mast support, located at the frame by the inner
sides of the front tires.

LM-18
 MAST

Removal (cont’d)
4. Remove the pivot pin lock bolts, then remove the pivot pins
securing the tilt cylinder to the mast assembly.
5. Turn the key switch to the ON position, retract the tilt cylinder all
the way (tilting the mast assembly backward).

! CAUTION
• Be sure to retract the tilt cylinder all the way, failure to do so
may interfere with the tilt bracket when installing the mast
assembly.

6. Using a hoist, lift the mast assembly up and away from the
vehicle, then lower it horizontally onto blocks.

! CAUTION
• Be careful not to damage brake pipes, etc. while lifting or
moving the mast assembly away from the vehicle.
• When removing the mast assembly and carriage assembly
from the vehicle as a unit, securely fasten the tilt beam
and carriage assembly (finger bar) with a rope or wire.
This prevents carriage assembly movement when mast
assembly is transferred to the ground.
• Always ensure the mast assembly rests on a flat and solid
surface after it has been removed.
• When positioning the mast assembly on the block, be
careful not to damage the mast support.

7. When the mast assembly and carriage assembly are removed as

a unit, remove the carriage assembly from the mast assembly as
follows:
• Attach a lifting wire or nylon sling to the carriage assembly and lift
using a hoist.
• Disengage the lift chains at the lift joint link and adjustment bolt
on the mast side, then place the disengaged lift chains on the
carriage.
• Slide the carriage down and extract it from the lower side of the
inner mast.
! CAUTION

• Do not allow the mast assembly to snag or catch the lift

chain when removing the carriage assembly from the inner
mast.

Disassembly
2W Mast
1. Remove the hydraulic lines from the lift cylinders.
2. Remove the fixing nuts from the upper ends of the lift cylinders.

LM-19
 MAST

Disassembly (cont’d)

3. Draw out the inner masts from the upper end of the outer mast,
then remove the bolts from the lower ends of the lift cylinders
and the U-bolts. Remove the lift cylinders.

4. Remove the chain wheels, if necessary.

5. Slide the inner mast down. Remove the four mast rollers from
the lower end of the inner mast and upper end of the outer mast.

! CAUTION
• Be careful not to catch your hands by sliding mast.
• Be careful not to catch your hands when roller is being
removed from mast.

6. Remove the liners from the outer mast.

7. Attach a lifting wire or nylon sling. Using a hoist, lift the lifting wire
or nylon sling until the inner mast is lifted free of the outer mast.

! CAUTION
• Be sure to remove the mast rollers in advance, otherwise,
inner mast cannot be removed from the outer mast with the
mast rollers installed in position.

LM-20
 MAST

Disassembly (cont’d)
2F/3F/3V Mast
1. Remove the piping connected to the head block (with the chain
wheel) and full-free cylinder.

• Remove the chain wheel from the head block if necessary.

2. Remove the full-free cylinder.

3. Remove the mast chain and chain wheel. (3F/3V mast)
4. Remove the piping connected to the mast cylinder.
5. Remove the mast cylinder mounting bolt (upper and lower) and
the U-bolt, and remove the mast cylinder.

6. Slide the inner mast and middle mast (3F/3V mast) downward,
and remove the mast roller.
! CAUTION

• Do not remove the rollers of the 3F/3V mast at one time.

Remove the rollers of the inner mast first, then those of the
middle mast in this order.
• Be careful not to pinch your hand when the mast slides.
• Be careful not to pinch your hand when the roller is
removed from the mast.

7. Remove the liner from the outer mast and middle mast (3F/3V
mast).
8. Pass nylon slings or wires in the mast of the inner mast first, then
the middle mast (3F/3V mast) in this order. While lifting them by a
hoist, etc., pull them upward over the outer mast.

! CAUTION
• Because the inner mast and the middle mast (3F/3V
mast) cannot be pulled out if the mast roller has not been
removed, special care should be taken.

LM-21
 MAST

Inspection
Lift Rollers
Check for unsmooth rotation, deformation, stepped wear or
damage. If necessary, replace with new ones.
Liners
Check for wear or damage. If necessary, replace with new ones.
Chain Wheels
Check for cracks or damage. If necessary, replace with new ones.
Piping
Check for cracks, breakage or damage. If necessary, replace with a
new one.
Mast Assembly
Check for cracks, damage or breakage at welds. If necessary,
replace with new one as an assembly.
Assembly
! CAUTION

• Assemble the mast assembly while adjusting various parts.

2W Mast
1. Attach a lifting wire or nylon sling to the inner mast. Using a
hoist, lift the inner mast and guide it into position for reinstallation
to the outer mast.
2. Slide the inner mast down, then install the liner and mast rollers.

! CAUTION
• Be sure to install mast rollers in the correct places, since
the inner and outer mast rollers are different in diameter.
Outer mast roller diameter:
97.0 mm (3.819 in)

3. Select suitable mast rollers so the clearances between the rolling

contact surfaces of the inner mast roller and outer mast rail are
within specifications.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available roller sizes:
Mast height: 3,500 or more mm (137.80 or more in):
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
Mast height: 2,700 - 3,300 mm (106.30 - 129.92 in):
105.0 mm (4.13 in)
• Apply a coat of grease to the rolling contact surface of the mast
rail.

! CAUTION
• After adjustment, ensure that the mast assembly moves
smooth.

LM-22
 MAST

Assembly (cont’d)
4. According to the following procedures, adjust the liners.
• Using a thickness gauge, measure the inner mast-to-liner
clearance on each side.
• If the clearance is outside specifications, use the same number
and thickness of shims on each side to adjust the clearance.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available shims:
0.5 and 1.0 mm (0.020 and 0.039 in)

! CAUTION
• When installing the liners after making shim adjustments,
apply a coat of bearing grease to the sliding surfaces of the
liners and mast assembly.
• The liners are push-in type for easy positioning in the mast
assembly.

Adjustments with the mast assembly installed to the vehicle.

• For removal procedure of carriage assembly, refer to “CARRIAGE
ASSEMBLY”. For removal procedure of lift cylinder, refer to HD
section.
• Lower the inner masts approximately 120 mm (4.72 in), then
adjust the shim of liner in the same manner as previously
described.

5. To adjust the mast rollers using adjustment shims, proceed as

follows:
• Adjust the roller pitch (Dimension “L”) for the inner and outer mast
rollers according to the forklift model series, as shown in the table
below.

Unit: mm (in)
Lifting height Dimension “L”
2,700 (106.30), 3,000 (118.11), 3,300 (129.92) 283 (11.14)
3,500 (137.80) 318 (12.52)
3,700 (145.67) 343 (13.50)
4,000 (157.48), 4,500 (177.17), 5,000 (196.85) 383 (15.08)

• Move the inner mast all the way to either side of the inner wall of
the outer mast.
• Using a thickness gauge, measure the clearance between the
mast and mast roller on the opposite side.

! CAUTION
• The mast-to-mast roller clearance must be measured at
four points (upper, lower, left and right).

• Lower the inner mast, then measure the mast-to-mast roller

clearance at or near the center cross beam of the outer mast.
• Using the same number and type of outer mast roller adjustment
shims, equally adjust the outer mast roller-to-inner mast clearance
on the left and right sides of the mast assembly until the clearance
is within specifications.

LM-23
 MAST

Assembly (cont’d)
• Using the minimum clearance value of the measurements obtained
from the upper and middle (at cross beam) portions, select
suitable inner mast roller adjustment shims. The left and right
inner mast roller clearances must be adjusted equally as much as
possible.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available adjustment shims:
0.50, 1.00 and 2.00 mm (0.020, 0.039 and 0.079 in)

6. If previously removed, install the chain wheels on the inner

masts.
7. Secure the lower ends of the lift cylinders using mounting bolts.
: 44 - 54 Nm (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
8. Tighten the stud bolts on the set nuts to the bottom of the
threads. Apply thread lock to the threads of the stud bolt on
the cylinder side. And then tighten and fasten the stud bolt on
the top of the lift cylinder. So that the set nut does not become
loose, secure the stud bolt with a cotter pin.
: 78 - 98 Nm (7.9 - 10.0 kg-m, 58 - 72 ft-lb)

9. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix
with the lock nuts.
: 26 - 32 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
10. Fit the stopper into the hole at the end of the adjusting bolt.
11. Tighten the adjusting bolt, and check that the stopper contacts
with the cylinder. Then, further tighten for 1/2 to 1 turn and
tighten the lock nut.
: 74 - 94 Nm (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
• When tightening the lock nut, make sure that the adjusting
nut does not turn.

12. Install pipes and tubes to their original positions.

13. For the mast assembly and carriage which were removed as
a unit, adjust the carriage lift rollers. After adjusting carriage lift
rollers, attach a lifting wire or nylon sling to the carriage, then
install it to the inner mast using a hoist. For lift roller adjustments,
refer to “CARRIAGE ASSEMBLY”.
14. Place the lift chains on the chain wheels, engage the lift chains
at the chain joint links and adjustment bolts, then install to the
inner mast.

! CAUTION
• Discard the old cotter pins; replace with new ones.

LM-24
 MAST

Assembly (cont’d)
2F/3F/3V Mast

! CAUTION
• When adjusting the 3F/3V masts, do not adjust them at one
time. Adjust the middle mast first, then the inner mast in
this order.
1. Pass nylon slings or wires in the mast of the middle mast (3F/3V
mast) first, then the inner mast in this order. While lifting them by
a hoist, insert them from over the outer mast.
2. Slide the inner mast and the middle mast (3F/3V mast) toward
the bottom of the outer mast, and install the liner, outer mast
roller, and middle mast upper roller.

! CAUTION
• The roller diameters of the mast rollers differ on the inner
mast side, middle mast upper and lower sides (3F/3V mast),
and outer mast side. When installing the mast rollers, be
sure to install them in the proper positions.
Middle mast upper side roller diameter (3F/3V mast):
97.0 mm (3.819 in)
Outer mast roller diameter:
97.0 mm (3.819 in)

• As for the adjustment of other mast rollers, refer to step 4. on the

next page.

3. Adjust the liner using the following procedure.

• Measure the clearance between the mast roller and the liner on
the inside of the inner mast and middle mast (3F/3V mast) using a
thickness gauge.
• When the measured value is out of the standard values, perform
the shim adjustment to the right and left evenly.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0 mm (0.020, 0.039 in)

! CAUTION
• When installing the liner after the shim adjustment, apply
bearing grease to the mast sliding surface.

NOTE:
Because the backup metal is designed to be inserted in the mast, it
can be installed and removed easily.

LM-25
 MAST

Assembly (cont’d)
Adjustment of the mast installed to the vehicle
2F Mast
• Hang the mast using wire, etc., and remove the carriage assembly
and lift cylinder. (As for the removal of the carriage assembly, refer
to “CARRIAGE ASSEMBLY”. As for the removal of the lift cylinder,
refer to HD section.)
• Lower the inner mast by approximately 120 mm (4.72 in), and
perform the shim adjustment mentioned above, and then replace
the liner.

3F/3V Mast
• Hang the mast using a wire, etc., and remove the carriage
assembly. (Refer to “CARRIAGE ASSEMBLY”.)
• Remove the mast chain.
• Remove the mast cylinder. (Refer to HD section.)
• Lower the inner mast by approximately 120 mm (4.72 in), replace
the liner of the middle mast side, and then perform the shim
adjustment.
• Lower the inner mast and middle mast simultaneously for
approximately 120 mm (4.72 in), replace the liner of the outer mast
side, then perform the shim adjustment.

4. Install the inner mast roller, mast roller of the middle mast lower
side, and perform the shim adjustment using the following
procedure.
• Set the roller pitches (Dimension “L”) of the inner mast, middle
mast (3F/3V mast), and outer mast to the dimensions indicated in
the table according to the mast lifting height.
Unit: mm (in)
Lifting height Dimension “L1, L2”
2,700 (106.30), 3,000 (118.11), 3,300 (129.92) 284 (11.18)
3,500 (137.80) 354 (13.94)
2F
3,700 (145.67) 404 (15.91)
4,000 (157.48) 484 (19.06)
3,850 (151.57), 4,300 (169.29), 4,750 (187.01),
369 (14.53)
5,150 (202.76)
5,500 (216.54) 384 (15.12)
3F
6,000 (236.22) 419 (16.50)
6,500 (255.91) 504 (19.84)
7,000 (275.59) 604 (23.78)
3,600 (141.73), 4,050 (159.45), 4,500 (177.17), 369 (14.53)
4,900 (192.91)
5,250 (206.69) 384 (15.12)
3V
5,750 (226.38) 419 (16.50)
6,330 (249.21) 504 (19.84)
6,880 (270.87) 604 (23.78)

LM-26
 MAST

Assembly (cont’d)

! CAUTION
• For the 3F/3V mast, setting the roller pitches of the inner
mast, middle mast, and outer mast at one time may cause
instability. Adjust in two steps, first for the inner and middle
masts, then for the middle and outer masts.
• Fix the mast with a rope or a wire to prevent it from sliding.

• Select the mast rollers so that the clearances between the mast
roller of the inner mast side and the outer mast (middle mast for
3F/3V mast), and between the mast roller of the middle mast lower
side and the rail and roller sliding surface of the outer mast (for
3F/3V mast only) conform to the standard values.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
2F mast roller types (Inner mast):
Mast height: 3,500 or more mm
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
Mast height: 2,700 - 3,300 mm,
105 mm (4.13 in)
3F/3V mast roller types (Middle mast lower side):
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
3F/3V mast roller types (Inner mast):
97.0, 97.5, 98.0 mm (3.82, 3.84, 3.86 in)
• Place the inner mast or the middle mast (for 3F/3V mast only) to
the end of the side, and measure the clearance between the mast
and the mast roller of the reverse side using a thickness gauge.

! CAUTION
• Perform measurement for the mast rollers at four points:
upper, lower, right, and left sides (eight points for 3F/3V
mast).

• Adjust the shim of the mast roller to the right and left as equally as
possible, so that the closest clearance between the mast roller of
the outer mast side and inner mast (middle mast for 3F/3V mast),
and that between the mast roller of the middle mast upper side
and the inner mast (for 3F/3V mast only) conform to the standard
values.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0, 2.0 mm (0.020, 0.039, 0

LM-27
 MAST

Assembly (cont’d)
• Adjust the shim of the mast roller to the right and left as evenly as
possible, so that the closest clearance between the mast roller of
the inner mast side and outer mast (middle mast for 3F/3V mast),
and that between the mast roller of the middle mast lower side
and the outer mast (for 3F/3V mast only) conform to the standard
valves.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0, 2.0 mm (0.020, 0.039, 0.079 in)

• Apply grease to the roller sliding surface of the mast (indicated by

arrows in the figure).

! CAUTION
• After adjustment, check for smooth operation of the mast.

5. Set the mast cylinder to the hole of the lower beam on the outer
mast, and set the piston rod to the cylinder setting bracket on
the inner mast. Tighten the mounting bolts at the upper and
lower ends of the cylinder.
Cylinder upper end:
: 78 - 98 Nm (7.9 - 10.0 kg-m, 58 - 72 ft-lb)
Cylinder lower end:
: 44 - 54 Nm (4.4 - 5.6 kg-m, 32 - 40 ft-lb)

6. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix
with the lock nuts.
: 26 - 32 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
7. Fit the stopper into the hole at the end of the adjusting bolt.

LM-28
 MAST

Assembly (cont’d)
8. Tighten the adjusting bolt, and check that the stopper contacts
with the cylinder. Then, further tighten for 1/2 to 1 turn and
tighten the lock nut.
: 74 - 94 Nm (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
• When tightening the lock nut, make sure that the adjusting
nut does not turn.
9. Install the piping to the mast cylinder.
10. Install the chain wheel and mast chain (3F/3V mast).

11. Install the full-free cylinder. At this time, perform the shim
adjustment so that the inner mast and full-free cylinder become
parallel (2F/3F mast).
Shim: 1.0 mm (0.039 in)
: 128 - 156 Nm (13 - 16 kg-m, 94 - 115 ft-lb)

Mounting bracket of full free cylinder to be inserted into the

notch of inner mast 2nd-beam. After surface A of 2nd-beam
touches surface B of mounting bracket, bolt is to be tightened.
(3V mast)
: 44 - 54 Nm (4.4 - 5.6 kg-m, 32 - 40 ft-lb)

12. Install the piping of the head block (with the chain wheel) and
full-free cylinder.
13. When the mast assembly is removed with the carriage mounted,
adjust the lift roller of the carriage, lift the carriage assembly by
a nylon sling or wire, then install to the inner mast. (As for the
adjustment of the lift roller, refer to “CARRIAGE ASSEMBLY”.)
14. Pass the lift chain in the chain wheel, connect the adjusting bolt
to the chain joint linking section, and then install it to the full-free
cylinder.

! CAUTION
• Replace the cotter pin with a new one.

Installation
1. Attach a lifting wire or nylon sling to the mast assembly, then lift
the mast assembly using a hoist.
! CAUTION

• Before lifting the mast assembly (if equipped with the

carriage assembly), lower the carriage assembly all the
way down. Securely fasten the carriage finger bar to the tilt
beam.
• Make sure the lift chains are placed on the chain wheels.
• Make sure the lift chains are not twisted.

LM-29
 MAST

Installation (cont’d)
2. Apply a coat of multi-purpose grease to the mast mounting
shafts. Then install the bushings.
3. Apply a coat of multi-purpose grease to the outer walls of the
bushings. Place the mast mounting shaft onto the mast support
at the frame, then install the mast support caps.
: 89 - 118 Nm (9.1 - 12.0 kg-m, 66 - 87 ft-lb)
4. Turn the key switch to the ON position. Extend the tilt cylinder
using the tilt lever until the pivot pin holes in the tilt cylinders and
mast are aligned. Insert the pivot pins into the holes, then secure
with the bolts.
: 26 - 32 Nm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)

! CAUTION
• Be careful not to catch your hands by the tilt cylinder and
mast assembly when the tilt lever is operated.

5. Install the lift hoses to their connections.

! CAUTION
• Ensure that the lift hoses shall not be twisted during
installation.

6. Apply a coat of multi-purpose grease to the mast supports and

tilt cylinder pivot pins.
7. Lift and tilt the mast assembly several times. Check that no oil
leaks occur at or around the hydraulic lines, and that the mast
assembly operates smoothly without binding.
8. Check the lift chains for proper tension. If necessary, adjust
the chain tension. For chain tension adjustments, refer to “LIFT
CHAINS”.

Adjustment
Adjusting of cylinder height
To prevent mast from being twisted and deformed, adjust the
cylinder height. Be sure to adjust when reassembling the mast
assembly, especially when replacing only one cylinder.

1. Check that forklift is placed horizontally.

2. Remove upper mounting nuts/bolts of right and left cylinder.
3. Slowly raise mast without load, and then check that right and left
cylinders reach to their stroke end simultaneously.
4. If one cylinder is delayed, adjust delayed cylinder by inserting
shims.
Thickness of shim: 1.0 mm (0.039 in)
5. Repeat the adjustment above until there is no difference between
the right and left cylinders.
6. Ensure that the top of the cylinders are set firmly to the bracket
on the inner (middle) mast, and secure by tightening the
mounting bolts.
Apply Thread Lock to the threads of cylinder mounting bolts.
(2W mast only)
: 78 - 98 Nm (7.9 - 10.0 kg-m, 58 - 72 ft-lb)

LM-30
 MAST

Adjustment (cont’d)
Mast tilt angle adjustment
1. Park the vehicle on flat and solid ground.
2. Tilt the mast assembly all the way forward, then check the left
and right sides of the mast assembly to ensure that the forward
tilt angle is within specifications.

Mast tilting angle

Forward/Backward
2W, 2F 4°/6°
3F, 3V 5°/5°

3. Loosen the lock nuts and turn the tilt cylinder rods using a
wrench until their stroke lengths are within specifications.

! CAUTION
• Adjust the piston rod stroke lengths so the lengths of the
piston rod thread portions do not exceed.
• Adjust the piston stroke lengths so that the tilt angle of the
left and right masts are identical.
• Tilt the mast assembly forward and backward. If the left and
right masts are improperly adjusted, make fine adjustments
of the tilt cylinder stroke lengths as required.

NOTE:
The backward tilt angle of the mast is automatically set by adjusting
the forward tilt angle.

4. After adjusting the forward-backward tilt angle of the mast

assembly, tighten the lock nuts on the tilt cylinders.
: 108 - 147 Nm (11 - 15 kg-m, 80 - 108 ft-lb)
5. Paint alignment marks on mating areas between the tilt cylinder
rod and rod head, and the rod head and lock nut.
6. Operate the mast assembly several times to ensure that it moves
smoothly without binding.

Mast bushing
Mast bushing greasing
• Jack the mast slightly to make sure the grease will go all around
the mast pin.
• Add grease until the new grease comes out all around the mast
pin.
• Clean the exceeding grease.

Checking wear
To check the wear of the mast bushing, measure the thickness of the
bushing in different places. If the wear limit is reached at one of the
places, replace the bushing.
Wear limit is: 3.38 mm (0.133 in)

LM-31
MEMO

LM-32