Mitsubishi FD70N Part 3 Mast & Forks

CHAPTER 12 MAST AND FORKS
Chapter 12 MAST AND FORKS

1. Simplex Mast
1.1 Mast System
The following table shows a combination of forklift truck and mast models.
Truck classifications Mast

FD70N 4V70Dcc
Note: cc represents maximum lift height. Example: 30 = 3000 mm (118.11 in.) lift height
Mast type and code
Code Mast
V Simplex mast
Mast serial number location
609576
How to read mast model code
４ V 70 Ｄ 30
5
4
3
2
1 609596
1. Major change (2, 3, 4,......... 9) 4. Order of the minor change (A, B, C,........ Z)
2. Indicates mast type 5. Maximum lifting height (30: 3000 mm [118.11 in.])
3. Applicable truck class (7.0 ton class in this example)
12-1
1.2 Structure and Functions
8
9
14
1
2
5 15 4
3
10
7 13
13
11
8 12
10 8
11
12 13
9
1) 2) 3) 4) 5)
506109
1. Outer mast 12. Lift bracket lower roller
2. Inner mast 13. Side roller
3. Lift bracket 14. Chain wheel
4. Lift cylinder 15. Tilt Cylinder
5. Lift chain 1) Detail of outer mast main rollers
6. Backrest 2) Detail of lift bracket upper rollers
7. Forks 3) Detail of lift bracket lower rollers and inner mast main
8. Mast strip rollers
9. Outer mast main roller 4) Detail of side roller
10. Lift bracket upper roller 5) Detail of mast strip
11. Inner mast main roller
Note: For hydraulic lines, see 12-18 "Installing Hydraulic

Lines".
12-2
The simplex mast provides good visibility by placing both All lift cylinders have an external drainage system, thus, they
lift cylinders behind the outer mast columns. are equipped with return hoses.
Mast strips are installed at the top end of outer mast in order For mast operation, see "Mast Operation" on next page.
to support the inner mast when the mast is tilted backward.
Mast operation
The forks can reach the maximum free-lift height when the
lift cylinders are extended.
Further extension of the lift cylinders causes the inner mast
to lift at the same speed as the cylinder rods, which causes
the forks to lift twice as fast as the inner mast at the same
time.
See "11. HYDRAULIC SYSTEM".
Free lift
Free lift height means the maximum elevation of the forks
with the mast in a vertical position and its height
unchanged.
4
4)
1) 2) 3)
502138
1. Lift cylinder 1) Forks on the ground
2. Lift chain 2) Maximum free lift
3. Inner mast 3) Maximum lift
4. Outer mast 4) Free lift height
12-3
1.3 Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the forklift truck, see 12-20 "Removing and Installing Mast Rollers
and Strips Without Removing Mast From Forklift Truck".
6
7
3 8
2
1 3
2
1
506110
1. Split pin 6. High-pressure hose
2. Double nut 7. Tilt socket pin
3. Upper nut 8. Mast support cap, Bushing
4. Load backrest extension, Lift bracket, Forks 9. Inner mast, Outer mast, Lift cylinder
5. Return hose
1.4 Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly

(1) Tilt the mast forward and lower the inner mast to the 3
bottom so that the lift chain is slack. Then remove split
pin 1, double nut 2, and upper nut 3 from the lift chains.
(2) Tilt the mast backward to the vertical position and lift
the inner mast until the lift bracket 4 becomes free.
Then, slowly move the forklift truck away from the lift 2
bracket.
Note: Before overhauling the mast assembly, be sure to 4
measure the clearance between the mast and the
1
rollers. This helps to improve work efficiency by
609577
understanding which roller is to be replaced or the
necessity of shim adjustment. See 12-25 "Adjusting 1. Split pin 3. Upper nut
Mast Roller Clearance". 2. Double nut 4. Lift bracket
R CAUTION
Place wood blocks under the lift bracket to prevent it from falling down before the lift bracket is removed from the forklift truck.
12-4
Disconnecting lift cylinder return hose

1)
(1) Turn the engine OFF and disconnect hose at the hose
clamp on the return connector side (arrow in the 2
illustration).
2)
(2) Lower the mast.
1 3)
609580
1. Return hose 1) To right lift cylinder
2. Return connector 2) To left lift cylinder
3) To tank
Disconnecting lift cylinder high-pressure hoses

Lower the mast to the bottom, and then disconnect hose at
the location indicated by the arrow.
609579
Separating tilt cylinders

(1) Attach a sling to the rings on the crossmember at the
top of the outer mast, then lift the outer mast with a
hoist.
609581
R CAUTION
When removing and installing the mast assembly with a hoist, be sure to use a hoist with enough lift capacity.
(2) Place wood blocks under the tilt cylinder mounting

section and remove the tilt socket pins 1, and separate
the mast from the tilt cylinders. 2
(3) Start the engine, and retract the tilt cylinder rods 2 with
the tilt lever.
609583
1. Tilt socket pin 2. Tilt cylinder rod
12-5
R CAUTION
- Do not touch any levers except the tilt lever while the engine is running.
- Never loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps

(1) Make a matchmark on each cap.
(2) Remove cap mounting bolts from the mast and
disconnect the mast assembly from the forklift truck by
hoisting. Lay the mast assembly horizontally on a hard 1)
and level surface with the lift bracket side facing up.
Note: Lay the mast assembly in a space large enough for
disassembly work.
1) 609582
1) Matchmark
12-6
1.5 Suggestions for Installing Mast and Lift Bracket Assembly
To install follow the removal sequence in reverse and also

follow the instructions below:
Mast support
(1) Apply a thick coat of grease on the inner surface of the
caps and the mast support bushings.
(2) Install the mast supports in the same direction as they
were installed. (The larger chamfered side of the
bushing shall face the center of forklift truck body).
(3) For greasing, place wood blocks under the mast so that
the mast is off the ground.
(4) Tighten the mast support bolts to the specified torque.
1
2
3)
1)
2)
609584
1. Bushing 1) Bushing internal view
2. Cap 2) Cap internal view
3) Chamfer
Item Tightening torque

490 ± 49 N·m
Mast support bolt (49.97 ± 5.0 kgf·m)
[361.41 ± 36.14 lbf·ft]
Adjusting chain tension

For chain tension adjustment, see 12-22 "Inspecting and
Adjusting Chain Tension".
Bleeding lift cylinders

Move the lift bracket up and down several times to bleed air
trapped in the piston end of the lift cylinder.
After the proper operation of the forklift truck is confirmed,
check the oil level in the hydraulic tank.
12-7
1.6 Disassembly Sequence of Mast and Lift Bracket
A 9
14 11
10
4
A 12
9
1 8 7
6 16
5
15
5
3 13 6
506111
1. Forks, Lift bracket 9. Cylinder clamps, Seats, Shims, Cushion,
2. Backrest Collar, Clamp bolt
3. Lift bracket lower rollers, Snaprings 10. Set bolt, Shims, Washer
4. Lift bracket upper rollers, Snaprings 11. Mast strip, Shims
5. Lift bracket side rollers, Brackets, Shims 12. Outer mast main rollers, Shims
6. Lift hose (for high pressure), Rubber hose, 13. Inner mast main rollers, Shims
Down safety valve, Connector, Elbow 14. Inner mast
7. Return hose 15. Lift cylinder
8. Snapring, Chain wheel 16. Outer mast, Grease nipple
12-8
Bar type lift bracket
11
8 13
9 7
12
6
54
3
7
2
10
10
609747
1. Forks, Lift bracket 7. Cylinder clamps, Bolt, Seat, Cushion, Collar
2. Side rollers, Bracket, Grease nipple, Shim 8. Bolt, Shims
3. Main rollers, Snapring 9. Mast strip
4. Rubber hose, Connector, Elbow, O-ring, 10. Main rollers, Snapring
Down safety valve 11. Inner mast
5. Hose, Clamp 12. Lift cylinder
6. Chain wheel, Chain guard, Snapring 13. Outer mast
1.7 Suggestions for Disassembling Mast and Lift Bracket
Removing mast strips and main rollers

Remove the clamp bolt and set bolt to free the lift cylinders,
then cross the two lift cylinders at the top. Slide the inner
mast down from the outer mast, and remove the main
rollers and the mast strips.
Removing inner mast

After removing the main rollers from the mast, attach a sling
to the crossmember of the inner mast, and slide the inner
mast upward from the outer mast. Attach a sling to the inner
mast again and gently pull out the inner mast from the
outer mast by clearing the outer mast roller shafts.
609586
12-9
1.8 Inspecting Mast and Lift Bracket
Mast
(1) Check each roller for binding, wear, and cracks.
(2) Check each roller on rolling surface for pitting or other
defects.
(3) Make sure that rollers rotate smoothly on the rolling
face.
(4) Check welded joints of mast member, crossmembers,
shafts, supports, and tilt brackets for cracks.
(5) Check the mast support bushings for wear or other
defects.
609587
Lift bracket
(1) Check the main rollers and side rollers for binding,
wear, and cracks.
(2) Check welded areas of lift bracket for cracks.
(3) Check the finger bar for bend or distortion.
1
506112
1. Straightedge
Item Standard
Distortion of finger bar 5 mm (0.20 in.) or less
Lift chains, chain wheels, and chain wheel supports

(1) Measure the length of each chain to make sure that the
two chains are equal in length. Also check the chains for
wear, indication of breakage, link binding, and twisting.
(2) Check each chain anchor bolt for cracks or thread
damage.
(3) Check the chain wheel support and the chain wheel for
cracks, wear, and binding.
(4) Measure chain length. To check for elongation, see 12-
23 "Measuring Chain Elongation".
Item Standard Limit

635 mm 654 mm
Chain length (20 links)
(25.00 in.) (25.75 in.)
Mast strip
Check for damage, scoring, or distortion.
Item Standard Limit

4 mm 2.5 mm
Thickness of mast strip
(0.16 in.) (0.098 in.)
See "11. HYDRAULIC SYSTEM".
12-10
1.9 Assembly Sequence of Lift Bracket Roller
1 2 5
7 4
1)
1
5
7
4 8
1 4) 3)
2
5 6
4) 4
1
2)
8 5
1 7 3)
3 7
4 3
506113
1. Lift bracket 1) Clearance between upper roller rolling face
2. Lift bracket upper roller and inner mast
3. Lift bracket lower roller 2) Clearance between lower roller rolling face
and inner mast
4. Side roller
3) Clearance between side roller rolling face
5. Inner mast and inner mast
6. Outer mast 4) Shim thickness for side roller
7. Grease nipple
8. Shim (a)
12-11
1.10 Adjusting Lift Bracket Clearance
The lift bracket has 2 main roller bearings on one side, and
side rollers on both sides as shown in the illustration.
The clearances are necessary so that the lift bracket can
move up and down smoothly along the inner mast.
Clearance between main roller rolling face and inner

mast
Clearance between roller circumference and inner mast
thrust face (back-to-front play)
Clearance 1) and 2) is used for determining the proper size
of the rollers.
Select a roller of correct diameter so that the clearance
meets the specified value. Check that the rollers rotate
smoothly when installed.
Item Standard
Clearance between main roller 1.0 mm
rolling face and inner mast (0.039 in.) or less
Clearance between side roller rolling face and inner

mast
The clearance between the side roller surface and the inner
mast side roller thrust surface is created, when the opposite
side of the clearance between the side roller surface and the
inner mast side roller thrust surface is adjusted to 0 mm
(0.00 in.) with the side rollers being placed at the top of the
inner mast.
Adjust the number of shims (a) so that the clearance meets
the specified value.
Item Standard
Clearance between side roller 0.2 to 1.0 mm
rolling face and inner mast (0.008 to 0.039 in.)
Selecting roller of correct outer diameter

Measure the clearance between the upper and lower rollers'
rolling faces and the mast. If the measured clearances do
not meet the specified value shown in the table, replace the
roller with a roller of the correct diameter. Use the same size
of upper and lower rollers.
Note: For clearance measurement, see 12-24 "Adjusting
Clearance Between Lift Bracket Roller and Inner Mast".
Make sure that the rollers rotate smoothly when installed.
Item Specified value

S 149 mm (5.87 in.)
Roller size
(outside M 150 mm (5.91 in.)
diameter)
L 151 mm (5.94 in.)
12-12
Installing rollers
To install main rollers on shafts, use a driving tool, and be
careful not to strike the outer roller surface. The side of the
roller with larger chamfering must face toward the outside.
Make sure the rollers rotate smoothly when installed.
506114
Adjusting clearance between side roller rolling face

and inner mast
2) 4
Measure the clearance between side roller rolling face and 2
inner mast. If the measured clearance does not meet the 3
standard, adjust the clearance as follows: 1
Clearance Between Lift Bracket Roller and Inner Mast". 4
(1) If the clearance is too large, increase shim thickness (a) 1)
as required. Shim (a) is available in two thicknesses: 0.5
and 1 mm (0.020 and 0.04 in.) 506075
1. Side roller 1) Clearance between side roller
2. Inner mast rolling face and inner mast
3. Lift bracket 2) Shim (a)
4. Roller mounting bolt
12-13
1.11 Installing Outer/Inner Mast Rollers
Mast rollers have the same shape and same size as the lift
bracket lower roller, and the mast rollers have the same 2)
standard for clearances between the rollers and the masts.
Clearance between main roller side face and inner
mast 1)
Clearance between roller side face and inner mast thrust 6
face (right and left clearance):
- Use clearance 2) to determine if the thickness of shim of
3
bearing seat is correct.
- Lift the forks to maximum lift height, and measure the 2 1
clearance 2) between roller side face and mast when 2)
the other side of clearance of the roller side face and
mast is 0 mm. 4
- Adjust the clearance 2) with shim (b) to the specified 1)
value.
7 3
506076
1. Outer mast 6. Mast upper side
2. Inner mast 7. Mast lower side
3. Shim (b) 1) Clearance between main roller
4. Lift bracket lower rolling face and mast
roller 2) Clearance between main roller
5. Lift bracket side face and mast
Item Standard
Clearance between main 1.0 mm
1)
roller rolling face and mast (0.039 in.) or less
Clearance between main 0.2 to 1.0 mm
2)
roller side face and mast (0.008 to 0.039 in.)
Measuring clearance between main roller rolling face

and mast
If measured clearance does not meet the specified value,
replace the roller with a roller of the correct diameter in the
table below.
Note: For measurement, see 12-25 "Adjusting Mast Roller
Clearance".
Item Specified value

S 149 mm (5.87 in.)
Roller size
diameter)
L 151 mm (5.94 in.)
12-14
Installing rollers
Installation of mast rollers is exactly the same as for lift
bracket rollers. See 12-11 "Assembly Sequence of Lift
Bracket Roller".
Measuring the clearance between main roller rolling

face and mast
If measured clearance is larger than the specified value,
adjust the clearance by increasing the number of shims (b)
under the roller seats.
Clearance".
(1) If the clearance is too large, add shim (b).
(2) Shims (b) are available in two thicknesses: 0.5 and 1 mm
(0.020 and 0.04 in.).
1.12 Installing Mast Strips
Adjusting clearance between mast and mast strip

Measure the clearance by inserting a feeler gauge between 4 3
mast and mast strip. Adjust the number of shims (c) so that
the clearance is within the range of 0.2 to 0.5 mm (0.008 to 1)
0.020 in.).
2
1
4
609588
1. Inner mast 4. Shim (c)
2. Mast strip 1) Clearance between mast and
3. Outer mast mast strip
Item Standard
Clearance between mast 0.2 to 1.0 mm
1)
and mast strip (0.008 to 0.039 in.)
(1) If the clearance is too large, increase the number of

shims (c) as required.
(2) After shim adjustment, slowly move the lift bracket up
and down to check for smooth movement.
12-15
1.13 Installing Lift Cylinders
(1) Install cylinder brackets on lift cylinders.

(2) Place lift cylinders between outer and inner masts.
(3) Install each lift cylinder in the mounting hole of the 1
outer mast by aligning the cylinder end with the spring
pin.
609590
1. Spring pin
(4) Install lift cylinder rods on inner mast as shown in the

illustration on the right. Do not forget to install shims if 3
they were installed.
Note: Be sure to tighten the set bolt securely in the cylinder
rod. 2
4
502159
1. Cylinder bracket 3. Set bolt
2. Inner mast 4. Shim
(5) Measure the clearance by placing the cylinders

vertically with cylinder rods fully retracted.
Adjust shim thickness (d) so that the clearance is 1.6 1
mm (0.063 in.) or less. 2
If the clearance is too large, increase shim thickness (d).
If the clearance is 3.2 mm (0.126 in.) or more, be sure to
insert a 3.2 mm (0.126 in.) thick seat in the shim pack.
1
1)
609589
1. Seat 1) Clearance between cylinder
2. Shim (d) bracket and seat
Item Standard
Clearance between cylinder 1.6 mm (0.063 in.)
1)
bracket and seat or less
(6) After assembly, check both lift cylinders for smooth

stroke movement, and adjust the stroke as required.
See 12-28 "Inspecting and Adjusting Right and Left Lift
Cylinder Stroke".
12-16
1.14 Connecting Chains
Assemble chains on the lift bracket as shown.
Installing chain on lift bracket

Install the chain as shown in the illustration.
5
4
2
1)
3
1
502161
1. Lift bracket 4. Split pin
2. Center plate (without engraved 5. Link
mark) 1) Engraved mark
3. Link plate
R CAUTION
DO NOT use a center plate without a mark on the outer side.
Installing chain to outer mast side

(1) Secure the anchor bolt with a wrench to prevent the 1
chain from twisting, and tighten the upper nut to the
specified torque.
(2) Secure the double nut (upper) with a wrench and 3
tighten the double nut (lower) to the specified torque.
4
2 5 609749
1. Anchor bolt 4. Double nut (upper)
2. Split pin 5. Double nut (lower)
3. Upper nut

Upper nut 385±38.5 N·m
(39.3±3.93 kgf·m)
Double nut (lower) [283.96±28.40 lbf·ft]
12-17
1.15 Installing Hydraulic Lines
General precautions
- Use care not to allow abrasive dust or dirt to enter the hydraulic system during installation.
- When assembling elbow connector 3 (straight thread O-ring connector), follow the instructions in the "Installation using
straight thread and O-ring" on the following page.
2)
3)
1
1)
1
3
1
2
1)
3
609591
1) Lift cylinder 3) Return hose
2) Return connector

118 ±11.8 N·m
1 Nut (12.0±1.20 kgf·m)
[87.03±8.703]
107.8 ± 9.8 N·m
2 Connector (10.99± 1.00 kgf·m)
[79.509± 7.228 lbf·ft]
98.1 N·m (10.00 kgf·m)
3 Connector
[72.355 lbf·ft]
12-18
Installation using straight thread and O-ring

(1) Apply grease or hydraulic oil on O-ring and O-ring seat
on the housing side. 1 1)
2
(2) Turn locknut so that it moves up against the body of the
fitting. Move the backup washer and O-ring up against
the locknut.
4
(3) Tighten the fitting by hand. Once the O-ring is placed in 3
the correct position of housing and the backup washer 5
comes in contact with the surface of housing, turn it
back to adjust the mounting direction. Never loosen 6
the body fitting more than one turn.
(4) Tighten the locknut to the specified torque. 502164
1. End of fitting body 5. O-ring
(for hose connection) 6. Portion threaded into the
2. Fitting body housing
3. Locknut 1) Shape varies by fitting type
4. Backup washer
12-19
1.16 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift
Truck
The mast rollers and strips can only be removed or installed

when the inner mast is positioned lower than the outer
mast. This can be achieved as follows:
(1) Disconnect the lift bracket assembly from the mast.
(2) Lift the front side of the forklift truck by 15 to 20 cm (0.6
to 0.8 in.) and place wood blocks underneath. Keep the
front side of the forklift truck off the ground in
preparation to lower the inner mast with a hoist.
609592
(3) Remove the set bolts located on the top of the lift
cylinders. Attach a sling on the inner mast, and raise the
inner mast with a hoist to separate the lift cylinder
piston rods from the inner mast. 1
(4) Remove the lift cylinder clamp bolts, and separate the
lift cylinders from the outer mast. Pull out the lift 4
cylinders from the mounting seats at the bottom of the
outer mast. Tilt the cylinder tops inward until they rest
on the outer mast cross member. Using a rope, fix the 3 2
cylinders onto the cross member.
3
5
609593
1. Lift cylinder set bolt 4. Cylinder bracket
2. Clamp bolt 5. Lift cylinder
3. Parts for cylinder clamp
(5) Using the hoist, slowly lower the inner mast until the
inner mast contacts the lift cylinders. 2
(6) The main rollers of the inner and outer masts can now
be removed. Before attempting to remove the main 1
rollers, remove the mast strips and shims first as they
tend to drop easily.
(7) Adjust shim thickness for main rollers and mast strips as
required. 4
Note: To assemble, follow the disassembly sequence in
reverse. 3
609594
1. Mast strip 3. Main roller
2. Shim 4. Shim
1.17 Inspection and Adjustment
This section covers the inspection/adjustment which does

not involve removal or disassembly. Conduct this inspection
and adjustment whenever a defect is suspected.
12-20
1.18 Inspecting Forks
1) 2)
90 mm (2 in.) 3)
5) 4)
609750
1) Outside jaws 100% 4) Replace fork wit 10% wear

2) Inside jaws 90% 5) Fork OK
3) New forkarm shank cross section =10%
Fork calipers perform two tasks at once.

They measure the thickness of the fork arm shank and then automatically indicate what a 10% wear factor would be when the
calipers are applied to the blade cross section.
Note: Not for use on full tapered forks.
Forks are often mistreated and forgotten. As insubstantial as - Forks are often used to open rail car doors and break
they seem, neglecting forks could make them dangerous. loads out or away from other loads. They are also used
Forks carry larger loads than almost any lifting device but to pick up capacity loads not seated against the fork
there are no mandatory requirements for maintenance or shank and to pick up off-balanced loads far from the
inspection. side of the forklift truck. The fork tips are sometimes
You can find thousands of extra parts for forklift trucks in inserted under other forklift trucks to lift them during
some fleet repair shops, but you’ll seldom see spare forks. maintenance operations.
Even when all the forklift trucks in the fleet are the same, - Forklift trucks may collide with building columns and
fleet maintenance managers rarely order spare forks. Forks walls, and though the forks show no discernible bend,
last a long time if treated properly, but they can be they may be damaged beyond safety.
deceiving by looking as good from most viewing angles - Any time excessive heat is applied to any part of a fork–
when they are worn as when they are new. during repair, for instance–hidden damage may occur.
It is true that most forks are customized to the forklift truck The fork itself is a concern but so are the hooks that secure
by model and capacity: they are big and heavy and thought them to the lift carriage.
of as indestructible. But forks can be abused or ruined in the
course of daily work. Designed to take a beating
Forks for counterbalanced and straddle forklift trucks are
Here are some examples of ways that forks can be damaged:
not just bent bars of steel. The manufacturing process is
- Forks can be overloaded either by picking up a load too careful and precise with many checks and inspections
far out on the forks, or simply by picking up loads critical to their safety. Some factors essential to fork
heavier than the forklift truck rating. manufacture include the steel, the bend and thickness of
- Maintenance shops may bend forks back into shape, the heel, the welding of the hooks that hold them on the
weld on them, or drill holes through them. Forklift truck carriage, and the heat treatment of the finished product.
users can add attachments to the forklift truck that
stress the forks. Drum clamps and portable booms can
be supported on the forks–but what is contained in the
drum or on the boom hook makes the safety difference.
12-21
1.19 Inspecting and Adjusting Chain Tension
R CAUTION
Be sure to turn the key switch to the OFF position before
inspecting or adjusting lift chains, anchor bolts, and nuts in
order to prevent serious injury or death caused by a sudden
movement of the mast and the lift bracket. Also be sure to
place wood blocks under the forks in order to prevent
serious injury or death caused by a sudden movement of
the forks when they are raised.
Inspecting chain tension

(1) Place the mast vertical on a hard and level surface, then
lower the forks to the ground. Make sure that the lift
cylinders are fully retracted.
(2) Raise the forks approximately 10 cm (0.4 in.) off the
ground.
(3) Turn the key switch to the OFF position.
(4) Place wood blocks with the height of approximately 9
cm (0.4 in.) under forks.
(5) Push both chains at the midpoint between the chain
wheel and the fixed chain end on the lift bracket.
502172
Make sure the tension in the right and left chains are
the same.
If uneven, adjust the chain tension.
Adjusting right and left chain balance

(1) Remove the wood blocks under the forks. Start the 1
engine.
(2) Lower the forks to the ground. Tilt the mast forward to
allow slack in the chain. 3
(3) Stop the engine.
(4) Loosen the double nut (lower). Then loosen the upper
nut.
(5) Adjust chain tension by turning the double nut (upper). 4
(6) Start the engine and place the mast in a vertical
position. 2 5 609749
(7) Repeat Steps 2 through 5 of "Inspecting chain tension" 1. Anchor bolt 4. Double nut (upper)
to check chain tension and adjust as needed. 2. Split pin 5. Double nut (lower)
3. Upper nut

Upper nut 385±38.5 N·m
(39.3±3.93 kgf·m)
12-22
R CAUTION
After adjustment, move the lift bracket up and down several
times. With the mast being tilted backward and fully 2
retracted, check the position of the lift bracket lower roller.
The protrusion of each lower roller must not exceed 40% of 1
the roller diameter from the bottom of inner mast. If it
exceeds 40%, elongation of chains is suspected.
1)
502174
1. Lift bracket 1) 40% or less of roller diameter
lower roller
2. Inner mast
Tightening nuts after adjustment

(1) Hold the anchor bolt with a wrench to prevent the
chain from twisting, and secure the bolt. Then tighten
the upper nut.
(2) Hold the double nut (upper) with a wrench, and tighten
the double nut (lower) to the specified torque.
1.20 Measuring Chain Elongation
(1) Pull the chains taut by applying a load close to the

maximum load evenly on both forks.
(2) Measure 20 links of chain length. If limit is exceeded,
replace the chain with a new one. 1)
2)
505791
1) Link 2) 20 links
Item Standard Limit

Chain length 635 mm 654 mm
(20 links) (25.00 in.) (25.75 in.)
12-23
1.21 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
Measuring back-to-front clearance on lift bracket

main rollers 1 1)
(1) Slightly raise the forks off the ground.
(2) Insert a claw bar between the upper part of the lift
bracket and the inner mast, push the inner mast to
either side. Measure the clearance between the main
roller and the inner mast on the opposite side with a
feeler gauge.
(3) If the clearance deviates from the specified value,
replace with an oversize roller.
For replacement, see 12-11 "Assembly Sequence of Lift 1)
Bracket Roller". 506077
1. Main rollers 1) Clearance
Item Standard
1)
rolling face and inner mast (0.039 in.) or less
Measuring right-to-left clearance on lift bracket main

rollers and side rollers
R CAUTION
Place wood blocks under the lift bracket to prevent it from falling.
(1) Raise the lift bracket to the inner mast uppermost

position.
(2) Set a dial indicator on the inner mast with its contact
point rested on the side of the lift bracket.
(3) 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.
(4) Insert a claw bar between the inner mast and lift
bracket on the dial indicator side, and push the lift
bracket to the opposite side.
502177
(5) Lower the lift bracket slightly from the top so that the
side roller comes in contact with the inner mast.
Measure the clearance between the side roller and
inner mast. Adjust shim thickness as required.
For adjustment, see 12-11 "Assembly Sequence of Lift 1)
Bracket Roller".
1
506078
1. Side roller 1) Clearance
Item Standard
1)
12-24
1.22 Adjusting Mast Roller Clearance
Measuring back-to-front clearance on mast main

rollers
(1) Tilt the mast fully backward.
(2) Using a thickness gauge, measure the clearance
1)
between inner mast lower roller and outer mast's
rolling contact face.
replace with oversize roller. For replacement, see 12-14
"Installing Outer/Inner Mast Rollers".
502181
Item Standard
1)
Measuring right-to-left clearance on inner mast main

rollers
(1) Raise the mast to the maximum height.
R CAUTION
Place wood blocks under the inner mast to prevent it from falling.
(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the inner mast.
(3) Using a claw bar, push the inner mast roller against the
outer mast's rolling surface. Then go over to the
opposite side of the mast and set the dial indicator to
zero.
(4) Insert a claw bar between the outer mast and the inner
mast on the dial indicator side, and push the inner mast
to the opposite side.
1) 502182
(5) Measure the clearance between outer mast and inner

mast main roller.
(6) If clearance deviates from the specified value, adjust
the shim thickness.
For adjustment, see 12-14 "Installing Outer/Inner Mast
Rollers".
1)
502183
Item Standard
Clearance between main roller 0.2 to 1.0 mm
1)
side face and mast (0.008 to 0.039 in.)
12-25
Measuring right-to-left clearance on outer mast main

rollers
(2) Set a dial indicator on the outer mast with its contact
point rested on the inner mast.
(3) Using a claw bar, push the outer main roller against the
inner mast's rolling surface. Then go over to the
1)
opposite side of the mast and set the dial indicator to
zero.
(4) Insert a claw bar between the outer mast and the inner
mast on the dial indicator side, and push the inner mast
to the opposite side. 502184

mast main roller. 1)
the shim thickness.
For shim adjustment, see 12-14 "Installing Outer/Inner
Mast Rollers".
502185
Item Standard
1)
12-26
1.23 Mast Strip Clearance Inspection and Adjustment
(1) Measure the clearance with the clearance between

outer mast rollers and inner mast rolling face adjusted 1)
to 0 mm (0.00 in.) at the maximum height
(2) If mast strip clearance deviates from the specified value,
adjust shim thickness.
For adjustment, see 12-15 "Installing Mast Strips".
502186
Item Standard
Clearance between mast and 0.2 to 1.0 mm
1)
mast strip (0.008 to 0.039 in.)
(3) After all clearances are adjusted, move the mast and lift
bracket slowly, and check whether the full stroke
movement is smooth.
1.24 Adjusting Mast Tilt Angle
(1) Adjust tire air pressure, and park the forklift truck on a
hard and level surface.
(2) Tilt the mast fully backward, and turn OFF the engine.
(3) Measure the backward tilt angle of the right and left of
the mast.
(4) Adjust the cylinder stroke by loosening the tilt cylinder
socket bolt, and then turn the tilt cylinder rod so that
the backward tilt angle of the mast on each side is the
same.
Note: Once the backward tilt angle has been properly
adjusted, there is no need for forward tilt adjustment
as it is determined by the tilt cylinder stroke. 609595
Slowly tilt the mast backwards, and adjust the rod so
that both cylinders simultaneously move into their
stroke end positions.
Forward tilt Backward tilt

Item
angle angle
Standard tilt angle 6 degrees 12 degrees
(5) After adjustment, tighten the tilt cylinder socket bolts

to the specified torque.

262 ± 13 N·m
Tilt cylinder socket bolt (26.72 ± 1.33 kgf·m)
[193.24 ± 9.59 lbf·ft]
12-27
1.25 Inspecting and Adjusting Right and Left Lift Cylinder Stroke
Inspection
(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, adjust
shim thickness.
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 cylinder stroke.
502188
Adjustment
(1) 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.
(2) 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 lever to
the lowering direction to release the hydraulic oil
from the cylinders.
501408
(3) Extend the piston rod, and tighten the lift cylinder set
bolt. Remove the wood blocks under the inner mast. 1
(4) Make sure that the piston rods move smoothly
throughout the stroke by slowly lowering the inner
mast to the bottom. Also make sure that the left and 2
right lift cylinders come to the end of the stroke
simultaneously at the maximum height of the inner 4
mast.
3
502189
1. Set bolt 3. Cylinder bracket
12-28
1.26 Troubleshooting
Condition Possible cause Action

Incorrect clearance between lift rollers and side Adjust forward/backward and
rollers right/left clearances
Lift bracket and inner mast do
not move smoothly Lubricate side rollers and replace other
Defective roller rotation
rollers
Incorrect clearance on mast strip Adjust with shims
Excessive clearance on side roller Adjust by adding shim(s)
Uneven tension between chains on right and left
Lift bracket or inner mast is Adjust chain tension
side
tilted
Uneven shim adjustments between left and right
Adjust by adding or removing shims
lift cylinders (at the maximum height)
Adjust or replace rollers after
Mast makes noise Defective roller rotation
inspection
Drift (natural descent) of lift Damaged lift cylinder packing Replace

cylinders Flaws on sliding (inside) surface of lift cylinder tube Replace
Whole mast shakes Worn mast support bushing Retighten or replace bushing
Deformed mast Off-center load or overload Replace mast assembly
Distortion of finger bar
Difference in height of forktips Distortion of forks Repair or replace
Uneven loading
12-29
1.27 Service Data
4 6
4
7
4 5
5
2
3
1
506080
Note: The mast is slightly wider at the lower side than at the upper side.
Thus, always measure the clearance at the upper side of the mast.
Item Specification
Standard 635 mm (25.00 in.)
Limit 654 mm (25.75 in.)
S Standard 149 mm (5.87 in.)
Main roller outside diameter M Standard 150 mm (5.91 in.)
L Standard 151 mm (5.94 in.)
Side roller external diameter Standard 58 mm (2.28 in.)
1 Width of outer mast Standard 850 mm (33.46 in.)
Simplex
Mast 2 Width of inner mast Standard 692 mm (27.24 in.)
size (reference)
3 Width of lift bracket Standard 564 mm (22.20 in.)
12-30
Item Specification
Clearance between main
4 Standard 1.0 mm (0.039 in.) or less
roller rolling face and mast
Mast 5 Standard 0.2 to 1.0 mm (0.008 to 0.039 in.)
roller side face and mast
Clearance between mast and
6 Standard 0.2 to 1.0 mm (0.008 to 0.039 in.)
mast strip
4 roller rolling face and inner Standard 1.0 mm (0.039 in.) or less
Lift mast
bracket
Clearance between side roller
rolling face and inner mast
Distortion of finger bar Standard 5 mm (0.20 in.) or less
490 ± 49 N·m
Mast support bolt Tightening torque
(49.97±5.0 kgf·m) [361.41±36.14 lbf·ft]
261 ± 13 N·m
Tilt cylinder socket bolt Tightening torque
(26.61 ± 1.33 kgf·m) [192.50 ± 9.59 lbf·ft]
Lift chain nut Tightening torque 385 ±38.5 N·m

(39.3 ±3.93 kgf·m) [283.96 ±28.40 lbf·ft]
12-31
2. Triplex Mast
2.1 Mast System
The following table shows a combination of forklift truck and mast models.
Truck classifications Mast

FD70N 4M70Dcc
Note: cc represents maximum lift height. Example: 40 = 4000 mm (157.48 in.) lift height
Mast type and code
Code Mast
M Triplex mast
Mast serial number location
609576
How to read mast model code
4 M 70 D 40
5
4
3
2
1 609597
1. Major change (2, 3, 4,...... 9) 4. Order of the minor change (A, B, C,..... Z)
2. Indicates mast type 5. Maximum lifting height (40: 4000 mm [157.48 in.])
3. Applicable truck class (7.0 ton class in this example)
12-32
2.2 Structure and Functions
11 14 13
1 7
2
3
12
6
7
5
10
4
8
10
9
17 16 15
13 11 12 15 16 17
11
14 10
4) 5)
1) 2) 3)
506115
1. Outer mast 13. Outer mast main roller

2. Middle mast 14. Middle mast upper roller
3. Inner mast 15. Lift bracket lower roller
4. Lift bracket 16. Inner mast main roller
5. First lift cylinder 17. Middle mast lower roller
6. Second lift cylinder 1) Detail of outer mast main rollers and middle mast
7. Lift chain (first and second) upper rollers
8. Backrest 2) Detail of lift bracket upper rollers
9. Forks 3) Detail of lift bracket, middle mast lower rollers and
inner mast main rollers
10. Side roller
4) Detail of side roller
11. Mast strip
5) Detail of mast strip
12. Lift bracket upper roller
Note: For hydraulic lines, see 12-50 "Installing Hydraulic

Lines".
12-33
The triplex mast features both triple mast mechanism and The first lift cylinder has an internal drainage system. The
full-free mast mechanism. second lift cylinder is equipped with cushion mechanism
and has an external drainage system, thus, has return hose.
The mast assembly consists of inner mast, middle mast,
outer mast, lift bracket, first lift cylinder and second lift For mast operation, see "Mast Operation" below.
cylinder.
The first lift cylinder raises the forks. The second cylinder
extends the three-stage mast and raises the forks.
Mast operation
The first cylinder extends to raise the forks to the maximum
free-lift height.
When the first lift cylinder rod is fully extended, the second
lift cylinder takes over the role to raise the middle mast, and
also raise the forks, inner mast, and first lift cylinder as a unit
using the second lift chain.
The mast lowering mechanism is the reverse of lifting. See
"11. HYDRAULIC SYSTEM".
Free lift
Free lift height means the maximum elevation of the forks
with the mast in a vertical position and its height
unchanged.
5
1
6
4
4) 7
1) 2) 3) 502219
1. First lift cylinder 1) Forks on the ground
2. Second lift cylinder 2) Maximum free lift
3. First lift chain 3) Maximum lift
4. Second lift chain 4) Free lift height
5. Inner mast
6. Middle mast
7. Outer mast
12-34
2.3 Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the forklift truck, see 12-52 "Removing and Installing Mast Rollers
and Strips Without Removing Mast From Forklift Truck".
10
5
1 6
4
3 8
2 3 9
2 506116
1. Chain guard, Bolt 6. High-pressure hose
2. Split pin 7. Lift cylinder return hose
3. Double nut 8. Tilt socket pin
4. Upper nut 9. Mast support cap, Bushing
5. Load backrest extension, Lift bracket, Forks 10. Inner mast, Middle mast, Outer mast, First lift cylinder,
Second lift cylinder
2.4 Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly

(1) Tilt the mast forward and lower the inner mast to the
bottom so that the lift chain is slack. Then remove split
pin 1, double nuts 2, and upper nut 3 from the lift
chains.
(2) Tilt the mast backward to the vertical position and lift
the inner mast until the lift bracket becomes free. Then,
slowly move the forklift truck away from the lift bracket.
Note: Before overhauling the mast assembly, be sure to
3
measure the clearance between the mast and the 2
rollers. This helps to improve work efficiency by 1
609752
understanding which roller is to be replaced or the
necessity of shim adjustment. (See 12-58 "Adjusting 1. Split pin 3. Upper nut
Mast Roller Clearance"). 2. Double nuts
R CAUTION
Place wood blocks under the lift bracket to prevent it from falling down before the lift bracket is removed from the forklift truck.
12-35
Disconnecting lift cylinder return hose

1)
(1) Turn the engine OFF and disconnect hose at the hose
clamp on the return connector side (arrow in the 2
illustration).
2)
(2) Lower the mast.
1 3)
609580
1. Return hose 1) To right lift cylinder
2. Return connector 2) To left lift cylinder
3) To tank
Disconnecting lift cylinder high-pressure hoses

Lower the mast to the bottom, and then disconnect hose at
the location indicated by the arrow.
506083
Separating tilt cylinders

(1) Attach a sling to the rings on the crossmember at the
top of the outer mast, then lift the outer mast with a
hoist.
506084
R CAUTION
When removing and installing the mast assembly with a hoist, be sure to use a hoist with enough lift capacity.
(2) Place wooden blocks under the tilt cylinder mounting

section and remove the tilt socket pins, and separate 2
the mast from the tilt cylinders.
(3) Start the engine, and pull back on the tilt lever to retract
the tilt cylinder rods.
609583
1. Tilt socket pin 2. Tilt cylinder rod
12-36
R CAUTION
- Do not touch any levers except the tilt lever while the engine is running.
- Never loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps

(1) Make a matchmark on each cap.
(2) Remove cap mounting bolts from the mast and
disconnect the mast assembly from the forklift truck by
hoisting. Lay the mast assembly horizontally on a hard
and level surface with the lift bracket side facing up.
Note: Lay the mast assembly in a space large enough for
disassembly work.
1) 1)
506085
1) Matchmark
12-37
2.5 Suggestions for Installing Mast and Lift Bracket Assembly
To install, follow the removal sequence in reverse and also

follow the instructions below:
Mast support
(1) Apply a thick coat of grease on the inner surface of the
caps and the mast support bushings.
(2) Install the mast supports in the same direction as they
were removed. (The larger chamfered side of the
bushing shall face the center of the forklift truck body).
(3) For greasing, place wood blocks under the mast so that
the mast is off the ground.
(4) Tighten the mast support bolts to the specified torque.
1
2
3)
1)
2)
609584
1. Bushing 1) Bushing internal view
2. Cap 2) Cap internal view
3) Chamfer

Mast support bolt 490 ± 49 N·m
(49.97 ± 5.0 kgf·m)
[361.41 ± 36.14 lbf·ft]
Adjusting chain tension

For chain tension adjustment, see 12-55 "Inspecting and
Adjusting Chain Tension".
Bleeding lift cylinders
Move the lift bracket up and down several times to bleed air
trapped in the piston end of the lift cylinder. After the
proper operation of the forklift truck is confirmed, check the
oil level in the hydraulic tank.
12-38
2.6 Disassembly Sequence of Mast and Lift Bracket
B
C 24
9 6 6
1 1
15
B 22
19
10 1
1
18
16
5 A 7 21
3 20 1
A
12
3 8 16
4 18 17
23 14
4 11
13
2 25
2
506086
1. First lift cylinder hose, Clamp, Bolt 14. Lift chain (for second lift cylinder)
2. First lift cylinder, Shims 15. Chain wheel, Collar,
3. Chain wheel support, Chain guard Chain wheel pin
4. Snapring, Chain wheel 16. Hose
5. Hook 17. Joint, Connector
6. Spring, Shaft, Hook, Hook 18. Cylinder clamps, Seats, Shims, Cushion,
bracket Collar, Clamp bolt
7. Snapring, Pulley, Bolt 19. Set bolt, Washer, Shim
8. Nut (for second lift cylinder chain) 20. Second lift cylinder
9. Mast strip, Shims 21. Mast strip, Shims
10. Main roller, Shims 22. Main roller, Shims
11. Main roller, Shims 23. Main roller, Shims
12. Inner mast 24. Middle mast
13. Nut 25. Outer mast, Grease nipple
Note: The lift bracket disassembly procedure is the same as
that of the simplex mast.
2.7 Preparation for Disassembling Mast and Lift Bracket
Lay the mast assembly horizontally on wood blocks with the

lift bracket side facing up.
Place a wood block so that it stops the inner and middle
masts from falling down.
Before disassembly, measure and record all clearances
between each of the rollers and the lift bracket and between
the main rollers and the mast. Recorded measurements will
be helpful when replacing rollers or selecting shims to
adjust clearances.
See 12-58 "Adjusting Mast Roller Clearance".
12-39
2.8 Suggestions for Disassembling Mast and Lift Bracket
Removing first lift cylinders

(1) Remove the first lift cylinder mounting bolt.
(2) Attach two slings securely to the first lift cylinder, and
gently lift the cylinder.
502226
Removing main rollers from inner and middle masts

and removing mast strips from middle mast
Lower inner mast until main rollers can be removed.
Remove the middle mast rollers and mast strips.
502227
Removing inner mast

Using a sling, slightly lift the inner mast to clear the middle
mast roller shafts, and separate the inner mast from the
middle mast.
502228
Removing main rollers from middle and outer masts

and removing mast strips from outer mast
Remove the set bolts from the top of the second lift cylinder
rods. Then place the cylinders on the outer mast. Lower
middle mast until main rollers can be removed. Then
remove main rollers and mast strips from the outer mast.
502229
12-40
2.9 Inspecting Mast and Lift Bracket
Mast
(1) Check each roller for binding, wear, and cracks.
(2) Check each roller on rolling surface for pitting or other
defects.
(3) Make sure that rollers rotate smoothly on the rolling
face.
(4) Check welded joints of mast member, crossmembers,
shafts, supports, and tilt brackets for cracks.
(5) Check the mast support bushings for wear or other
defects.
502230
Lift bracket
(1) Check the main rollers and side rollers for binding,
wear, and cracks.
(2) Check welded areas of lift bracket for cracks.
(3) Check the finger bar for bend or distortion.
1
506112
1. Straightedge
Item Standard
Distortion of finger bar 5 mm (0.20 in.) or less
Lift chains, chain wheels, and chain wheel supports

(1) Measure the length of each chain to make sure that the
two chains are equal in length. Also check the chains for
wear, indication of breakage, and link binding and
twisting.
(2) Check each chain anchor bolt for cracks or thread
damage.
(3) Check the chain wheel support and the chain wheel for
cracks, wear, and binding.
(4) Measure chain length. To check for elongation, see 12-
56 "Measuring Chain Elongation".
Item Standard Limit

(20 links) (25.00 in.) (25.75 in.)
Mast strip
Check for damage, scoring, or distortion.
Item Standard Limit

4 mm 2.5 mm
Thickness of mast strip
(0.16 in.) (0.098 in.)
12-41
2.10 Assembly Sequence of Lift Bracket Roller
1 2 5
8 4
1)
1
5)
5
8
9
4 1
2 3)
5 6 7
4
2) 1
4)
9
5
1 8 3)
3 8
4 3
506117
1. Lift bracket 1) Clearance between upper roller rolling face
2. Lift bracket upper roller and inner mast
3. Lift bracket lower roller 2) Clearance between lower roller rolling face
and inner mast
4. Side roller
3) Clearance between side roller rolling face
5. Inner mast and inner mast
6. Middle mast 4) No shim required
7. Outer mast 5) Minimum clearance
8. Grease nipple
9. Shim (a)
12-42
2.11 Adjusting Lift Bracket Clearance
The lift bracket has 2 main roller bearings and 2 side rollers
on one side as shown in the illustration.
The clearances are necessary so that the lift bracket can
move up and down smoothly along the inner mast.
Clearance between main roller rolling face and inner

mast
Clearance between roller circumference and inner mast
thrust face (back-to-front play).
Clearance 1) and 2) is used for determining the proper size
of the rollers.
Select a roller of correct diameter so that the clearance
meets the specified value. Check that the rollers rotate
smoothly when installed.
Item Standard
Clearance between main roller 1.0 mm (0.039 in.)
rolling face and inner mast or less
Clearance between side roller rolling face and inner

mast
The clearance between the side roller surface and the inner
mast side roller thrust surface is created when the opposite
side of the clearance between the side roller surface and the
inner mast side roller thrust surface is adjusted to 0 mm
(0.00 in.) with the side rollers being placed at the top of the
inner mast.
Adjust the number of shims (a) so that the clearance meets
the specified value.
Item Standard
Clearance between side roller rolling 0.2 to 1.0 mm
face and inner mast (0.008 to 0.039 in.)
Selecting roller of correct outer diameter

Measure the clearance between the upper and lower rollers'
rolling faces and the mast. If the measured clearances do
not meet the standard shown in the table, replace the roller
with a roller of the correct diameter.
Clearance Between Lift Bracket Roller and Inner Mast".
Make sure that the rollers rotate smoothly when installed.
Item Standard
S 149 mm (5.87 in.)
Roller size
diameter)
L 151 mm (5.94 in.)
12-43
Installing rollers
To install main rollers on shafts, use a driving tool, and be
careful not to strike the outer roller surface. The side of the
roller with larger chamfering must face toward the outside.
Make sure the rollers rotate smoothly when installed.
506114
Adjusting clearance between side roller rolling face

and inner mast
2) 4
Measure the clearance between side roller rolling face and 2
inner mast. If the measured clearance does not meet the 3
standard, adjust the clearance as follows: 1
Clearance Between Lift Bracket Roller and Inner Mast". 4
(1) If the clearance is too large, increase shim thickness (a) 1)
as required. Shim (a) is available in two thicknesses: 0.5
and 1 mm (0.020 and 0.04 in.) 506075
1. Side roller 1) Clearance between side roller
2. Inner mast rolling face and inner mast
3. Lift bracket 2) Shim (a)
4. Roller mounting bolt
12-44
2.12 Installing Outer/Middle/Inner Mast Rollers
Mast rollers are identical in shape and size with lift bracket
lower rollers.
2) 2)
Clearance between main roller side face and inner
mast
1) 1)
Clearance between roller side face and inner mast thrust
face (right and left clearance): 6
- Use clearance 2) to determine if the thickness of the
shim of the bearing seat is correct.
- Lift the forks to maximum lift height, and measure the
clearance 2) between roller side face and mast when
3 4 4
the other side of the clearance of the roller side face 2 1
and mast is 0 mm. 2) 2)
- Adjust the clearance 2) with shim (b) to the specified
value. 1) 1)
4 4
5
506088
1. Outer mast 6. Mast upper side
2. Middle mast 7. Mast lower side
3. Inner mast 1) Clearance between main roller
4. Shim (b) rolling face and mast
5. Lift bracket 2) Clearance between main roller
side face and mast
Item Standard
1)
2)
Measuring clearance between main roller rolling face

and mast
If measured clearance does not meet the specified value,
replace the roller with a roller of the correct diameter in the
table below.
Clearance".
Item Standard
S 149 mm (5.87 in.)
Roller size
diameter)
L 151 mm (5.94 in.)
12-45
Installing rollers
Installation of mast rollers is exactly the same as the lift
bracket rollers. See 12-42 "Assembly Sequence of Lift
Bracket Roller".
Measuring the clearance between main roller rolling

face and mast
If measured clearance is larger than the specified value,
adjust the clearance by increasing the number of shims (b)
under the roller seats.
Clearance".
(1) If the clearance is too large, add shim (b).
(2) Shims (b) are available in two thicknesses: 0.5 and 1 mm
(0.020 and 0.04 in.).
2.13 Installing Mast Strips
Adjusting clearance between mast and mast strip

5
Measure the clearance by inserting a feeler gauge between
4 3
mast and mast strip. Adjust the number of shims (c) so that 1)
the clearance is within the range of 0.2 to 1.0 mm (0.008 to 5
0.039 in.).
1
1
5
4 3 2 506089
1. Mast strip 4. Outer mast
2. Inner mast 5. Shim (c)
3. Middle mast 1) Clearance between mast and
mast strip
Item Standard
Clearance between mast 0.2 to 1.0 mm
1)
and mast strip (0.008 to 0.039 in.)
(1) If the clearance is too large, increase the number of

shims (c) as required.
(2) After shim adjustment, slowly move the lift bracket up
and down to check for smooth movement.
12-46
2.14 Installing Second Lift Cylinder
(1) Install the cylinder brackets on the second lift cylinders.

(2) Install the second lift cylinders between the outer and
inner masts.
1
(3) Install each second lift cylinder on the mounting hole of
the outer mast by aligning the cylinder end with the
spring pin.
506090
1. Spring pin
(4) Install the lift cylinder rods on the middle mast as

shown in the illustration on the right. Do not forget to 3
install shims if they were installed. Normally shims are
not installed.
Note: Be sure to tighten the set bolt securely on the cylinder 2
rod.
4
502159
1. Cylinder bracket 3. Set bolt
2. Middle mast 4. Shim
(5) With cylinder rods fully retracted, measure the

clearance by placing the cylinders vertically.
Adjust shim thickness (d) so that the clearance between
cylinder bracket and seat is 1.6 mm (0.063 in.) or less.
2 1
If the clearance is too large, increase shim thickness (d).
If the clearance is 3.2 mm (0.126 in.) or more, be sure to
insert a 3.2 mm (0.126 in.) thick seat in the shim pack.
1
1)
506091
1. Seat 1) Clearance between cylinder
2. Shim (d) bracket and seat
Item Standard
Clearance between cylinder 1.6 mm (0.063 in.)
1)
bracket and seat or less
(6) After assembly, check both lift cylinders for smooth

stroke movement, and adjust the stroke as required.
See 12-63 "Inspecting and Adjusting Right and Left
Second Lift Cylinder Stroke".
12-47
2.15 Installing First Lift Cylinder
(1) With the mast positioned vertically and fully lowered,

temporarily install the first lift cylinder to the inner mast
with the original shims and mounting bolts.
(2) Position the first lift cylinder vertically and measure the 3
clearance between the cylinder brackets and the
cylinder mounts on the inner mast. If there is clearance,
remove the clearance by adding shims (e).
- To check whether both sides of the cylinder (right-to-
left) are vertical against each other, measure to check 2
if the cylinder is parallel to the side face of the inner
mast. The parallel difference at the top and the 1
bottom should be plus or minus 1.0 mm (0.039 in.) 502209
- To check whether both sides of the cylinder (front-to-
back) are vertical against each other, visually check if 1. First lift cylinder 3. Mounting bolt
2. Shim (e)
the cylinder is parallel to the front face of the inner
mast. The cylinder should not be inclined forward, not
even slightly. The cylinder slightly inclined backward
is acceptable.
- Thickness of each adjusting shim is 1.0 mm (0.039 in.).
(3) After shim adjustment, tighten the mounting bolts.
12-48
2.16 Connecting Chains
Assemble each chain on the lift bracket.

After assembly is completed, maintain clearance between
chains with locknuts in order to allow for chain tension.
609753

Single nut 385±38.5 N·m
(39.3±3.93 kgf·m)
2
5
7
1 1
3
2
3 3 2
4
609754
1. Double nut 6. Middle mast chain wheel
2. Single nut 7. Outer mast
3. Split pin
4. Inner mast
5. First lift cylinder
12-49
2.17 Installing Hydraulic Lines
General precautions
- Use care not to allow abrasive dust or dirt to enter the hydraulic system during installation.
- Apply hydraulic oil on O-rings before installation.
- When assembling an elbow connector 6 (straight thread O-ring connector), follow the instructions in the "Installation
using straight thread and O-ring" on the following page.
6 7
5 9
8 11
10
2) 12
1
2) 1) 13
3 4 2 3)
506092
1) First lift cylinder 3) Down safety valve
2) Second lift cylinder
12-50

118 ± 11.8 N·m
1 Nut (12.0 ± 1.20 kgf·m)
[87.03 ± 8.703 lbf·ft]
98.1 N·m (10.00 kgf·m)
2 Connector
[72.355 lbf·ft]
98.1 N·m (10.00 kgf·m)
3 Connector
[72.355 lbf·ft]
107.8 ± 9.8 N·m
4 Connector (10.99 ± 1.00 kgf·m)
[79.509 ± 7.228 lbf·ft]
118 ± 11.8 N·m
5 Nut (12.0 ± 1.20 kgf·m)
[87.03 ± 8.703 lbf·ft]
98.1 N·m (10.00 kgf·m)
6 Connector
[72.355 lbf·ft]
58.8 N·m (6.00 kgf·m)
7 Connector
[43.369 lbf·ft]
58.8 ±5.88 N·m
8 Nut (6.00 ±0.600 kgf·m)
[43.369 ± 4.3369 lbf·ft]
58.8 ±5.88 N·m
9 Nut (6.00 ±0.600 kgf·m)
[43.369 ± 4.3369 lbf·ft]
58.8 N·m (6.00 kgf·m)
10 Connector
[43.369 lbf·ft]
98.1 N·m (10.00 kgf·m)
11 Connector
[72.355 lbf·ft]
118 ± 11.8 N·m
12 Nut (12.0 ± 1.20 kgf·m)
[87.03 ± 8.703 lbf·ft]
98.1 N·m (10.00 kgf·m)
13 Connector
[72.355 lbf·ft]
Installation using straight thread and O-ring

(1) Apply grease or hydraulic oil on O-ring and O-ring seat
on the housing side. 1 1)
2
(2) Turn locknut so that it moves up against the body of the
fitting. Move the backup washer and O-ring up against
the locknut.
4
(3) Tighten the fitting by hand. Once the O-ring is placed in 3
the correct position on the housing and the backup 5
washer comes in contact with the surface of the
housing, turn it back to adjust the mounting direction. 6
Never loosen the body fitting more than one turn.
(4) Tighten the locknut to the specified torque. 502164
1. End of fitting body 5. O-ring
(for hose connection) 6. Portion threaded into the
2. Fitting body housing
3. Locknut 1) Shape varies by fitting type
4. Backup washer
12-51
2.18 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift
Truck
Preparation
(1) Disconnect the lift bracket assembly from the mast.
(2) Disconnect the pipes from the first and the second lift
cylinders.
Removing first lift cylinders
(1) Attach a sling to the first lift cylinder, and suspend it
with a hoist. Attach the sling securely to the first lift
cylinder to prevent the cylinder from slipping.
(2) Remove the mounting bolts and slowly remove the first
lift cylinder using a hoist.
506093
Removing inner mast main rollers and middle mast

upper main rollers
(1) Lift the front side of the forklift truck by 15 to 20 cm (0.6
to 0.8 in.) and place wood blocks underneath. Keep the
front side of the forklift truck off the ground in
preparation to lower the inner mast with a hoist.
609592
(2) Attach a sling to the crossmember of the inner mast

and suspend the inner mast with a hoist.
(3) Remove the chain guard from the second lift chain
wheel.
(4) Disconnect the second lift chain from the outer mast,
and place the chain in front of the inner mast.
(5) Lower the inner mast so that the mast rollers can be
removed.
(6) Support the inner mast with wood blocks.
506094
12-52
(7) The main rollers of the inner mast and upper main
rollers of middle mast can now be removed. Before
attempting to remove rollers, remove the mast strips
and shims from the middle mast as they tend to drop
easily. 1
(8) Adjust shim thickness for main rollers and mast strips as
required. 2
3
502239
1. Outer mast 3. Inner mast
2. Middle mast
Removing outer mast main rollers and middle mast

lower rollers
(1) Lift the inner mast crossmember to the level of middle
mast crossmember, and support the inner mast with
wood blocks.
(2) Lift the middle and the inner masts.
(3) Remove the set bolts from the top of the second lift
cylinder, and lift the middle and the inner masts.
506095
(4) Remove the cylinder clamp bolts from the second lift
cylinder, and secure the cylinder to the outer mast cross
member.
(5) Lower the middle and the inner masts until the outer 1
mast main rollers can be removed.
(6) Support the middle and inner masts by placing wood
blocks underneath. 2
(7) Now the main rollers of the outer mast and the lower
rollers of the middle mast can be removed. Mast strips
and shims of the outer mast should be removed at this
stage also because they tend to drop easily. 3
(8) Adjust shim thickness for main rollers and mast strips as 502241
required.
1. Outer mast 3. Inner mast
2. Middle mast
Note: To install, follow the removal sequence in reverse.
12-53
2.19 Inspection and Adjustment
This section covers the inspection/adjustment that does not

involve removal or disassembly. Conduct this inspection
and adjustment whenever a defect is suspected.
2.20 Inspecting Forks
1) 2)
90 mm (2 in.) 3)
5) 4)
609750
1) Outside jaws 100% 4) Replace fork wit 10% wear

2) Inside jaws 90% 5) Fork OK
3) New forkarm shank cross section =10%
Forks are often mistreated and forgotten. As insubstantial as - Forks are often used to open rail car doors and break
they seem, neglecting forks could make them dangerous. loads out or away from other loads. They are also used
Forks carry larger loads than almost any lifting device but to pick up capacity loads not seated against the fork
there are no mandatory requirements for maintenance or shank and to pick up off-balanced loads far from the
inspection. side of the forklift truck. The fork tips are sometimes
You can find thousands of extra parts for forklift trucks in inserted under other forklift trucks to lift them during
some fleet repair shops, but you’ll seldom see spare forks. maintenance operations.
Even when all the forklift trucks in the fleet are the same, - Forklift trucks may collide with building columns and
fleet maintenance managers rarely order spare forks. Forks walls, and though the forks show no discernible bend,
last a long time if treated properly, but they can be they may be damaged beyond safety.
deceiving by looking as good from most viewing angles - Any time excessive heat is applied to any part of a fork–
when they are worn as when they are new. during repair, for instance–hidden damage may occur.
It’s true that most forks are customized to the forklift truck The fork itself is a concern but so are the hooks that secure
by model and capacity: they are big and heavy and thought them to the lift carriage.
of as indestructible. But forks can be abused or ruined in the
course of daily work. Designed to take a beating
Forks for counterbalanced and straddle forklift trucks are
Here are some examples of ways that forks can be damaged:
not just bent bars of steel. The manufacturing process is
- Forks can be overloaded either by picking up a load too careful and precise with many checks and inspections
far out on the forks, or simply by picking up loads critical to their safety. Some factors essential to fork
heavier than the forklift truck rating. manufacture include the steel, the bend and thickness of
- Maintenance shops may bend forks back into shape, the heel, the welding of the hooks that hold them on the
weld on them, or drill holes through them. Forklift truck carriage, and the heat treatment of the finished product.
users can add attachments to the forklift truck that
stress the forks. Drum clamps and portable booms can
be supported on the forks–but what is contained in the
drum or on the boom hook makes the safety difference.
12-54
2.21 Inspecting and Adjusting Chain Tension
R CAUTION
Be sure to turn the key switch to the OFF position before
inspecting or adjusting lift chains, anchor bolts, and nuts in
order to prevent serious injury or death caused by a sudden
movement of the mast and the lift bracket. Also be sure to
place wood blocks under the forks in order to prevent
serious injury or death caused by a sudden movement of
the forks when they are raised.
(1) Place the mast vertical on a hard and level surface, then
lower the forks to the ground. Make sure that the lift
cylinders are fully retracted.
(2) Raise the forks approximately 10 cm (0.4 in.) off the
ground.
(3) Turn the key switch to the OFF position.
(4) Place wood blocks with the height of approximately 9
cm (0.4 in.) under forks.
(5) To inspect the tension of the first lift chain, push the
chains alternately right and left at the middle point
between chain wheel and lift bracket chain fixed
portion. 609753
To inspect the tension of the second lift chain, push the
chains alternately right and left at the middle point
between chain wheel and inner mast chain fixed
portion.
The tension of right and left chains should be even.
When uneven, adjust the tension of chain.
Adjusting right and left chain balance

(1) Remove the wood blocks under the forks. Start the 1
engine.
(2) Lower the forks to the ground. Tilt the mast forward to
allow slack in the chain.
(3) Stop the engine.
(4) Loosen the double nut (lower).
(5) Adjust chain tension by turning the double nut (upper).
(6) Start the engine and place the mast in a vertical 3
position.
(7) Repeat Steps 2 through 5 of "Inspecting chain tension" 2 4 609755
to check chain tension and adjust as needed. 1. Anchor bolt 3. Double nut (upper)
2. Split pin 4. Double nut (lower)
385±38.5 N·m
Double nut (lower) (39.3±3.93 kgf·m)
[283.96±28.40 lbf·ft]
12-55
R CAUTION
After adjustment, move the lift bracket up and down several
times. With the mast being tilted backward and fully 2
retracted, check the position of the lift bracket lower roller.
The protrusion of each lower roller must not exceed 40% of
the roller diameter from the bottom of inner mast. If it
exceeds 40%, elongation of chains is suspected.
1 1)
609757
1. Lift bracket 1) 40% or less of roller diameter
lower roller
2. Inner mast
Tightening nuts after adjustment

For first lift chain
(1) Hold the anchor bolt with a wrench to prevent the
chain from twisting, and secure the bolt. Then tighten
the upper nut.
(2) Hold the double nut (upper) with a wrench, and tighten
the double nut (lower) to the specified torque.
For second lift chain
Hold the double nut (upper) with a wrench, and tighten the
double nut (lower) to the specified torque.
2.22 Measuring Chain Elongation
(1) Pull the chains taut by applying a load close to the

maximum load evenly on both forks.
Measure 20 links of chain length. If limit is exceeded, replace
the chain with a new one. 1)
2)
505791
1) Link 2) 20 links
Item Standard Limit

(20 links) (25.00 in.) (25.75 in.)
12-56
2.23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
Measuring back-to-front clearance on lift bracket

main rollers 1 1)
(1) Slightly raise the forks off the ground.
(2) Insert a claw bar between the upper part of the lift
bracket and the inner mast, push the inner mast to
either side. Measure the clearance between the main
roller and the inner mast on the opposite side with a
feeler gauge.
replace with oversize roller.
For replacement, see 12-42 "Assembly Sequence of Lift 1)
Bracket Roller". 506077
1. Main rollers 1) Clearance
Item Standard
1.0 mm
1) roller rolling face and inner
(0.039 in.) or less
mast
Measuring right-to-left clearance on lift bracket main

rollers and side rollers
R CAUTION
Place wood blocks under the lift bracket to prevent it from falling.
(1) Raise the lift bracket to the inner mast uppermost

position.
(2) Set a dial indicator on the inner mast with its contact
point rested on the side of the lift bracket.
(3) 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.
(4) Insert a claw bar between the inner mast and lift
bracket on the dial indicator side, and push the lift
bracket to the opposite side.
502177
(5) Lower the lift bracket slightly from the top so that the
side roller comes in contact with the inner mast.
Measure the clearance between side roller and inner
mast. Adjust shim thickness as required.
For adjustment, see 12-42 "Assembly Sequence of Lift 1)
Bracket Roller".
1
506078
1. Side roller 1) Clearance
Item Standard
1)
12-57
2.24 Adjusting Mast Roller Clearance
Measuring back-to-front clearance on mast main

rollers
(1) Tilt the mast fully backward. 1)
(2) Measure the clearance between the inner and middle
mast lower roller and the mast rolling surface.
replace with oversize roller. For replacement, see 12-45
"Installing Outer/Middle/Inner Mast Rollers".
502243
Item Standard
1)
rolling face and mast (0.039 in.) or less
Measuring right-to-left clearance on inner mast main

rollers
R CAUTION
Place wood blocks under the inner mast to prevent it from falling.
(2) Set a dial indicator on the inside of the middle mast

with its contact point rested on the inner mast.
(3) Push the inner mast main roller against the middle mast
rolling surface with a claw bar from the opposite side of
the dial indicator, and set the dial indicator to zero.
(4) Insert a claw bar between the middle mast with dial
indicator and the inner mast, and push the middle mast
1) 502182

mast main roller.
the shim thickness.
For shim adjustment, see 12-45 "Installing Outer/
Middle/Inner Mast Rollers".
1) 502245
Item Standard
1)
12-58
Measuring right-to-left clearance on middle mast

upper main rollers
R CAUTION
Place wood blocks under the middle mast to prevent it from falling.
(2) Set a dial indicator on the middle mast with its contact
point rested on the inner mast.
(3) Push the inner mast main roller against the middle mast
rolling surface with a claw bar from the opposite side of
the dial indicator, and set the dial indicator to zero.
(4) Insert a claw bar between the middle mast with dial
indicator and the inner mast, and push the middle mast
to the opposite side. 1)
502184
(5) Measure the clearance between the middle mast upper

main roller and the inner mast.
the shim thickness.
1)
502244
Item Standard
1)
12-59
Measuring right-to-left clearance on middle mast

lower main rollers
R CAUTION
Place wood blocks under the middle mast to prevent it from falling.

(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the middle mast.
(3) From opposite side of dial indicator, push the middle
mast main roller against the outer mast's rolling surface
with a claw bar, and set the dial indicator to zero.
(4) Insert a claw bar between the outer mast with the dial
indicator and middle mast, and push the middle mast
1) 502182
(5) Measure the clearance between the middle mast lower

main roller and the inner mast.
the shim thickness.
1) 502245
Item Standard
1)
12-60
Measuring right-to-left clearance on outer mast main

rollers
R CAUTION
Place wood blocks under the outer mast to prevent it from falling.

(2) Set a dial indicator on the outer mast with its contact
point rested on the middle mast.
(3) From the opposite side of dial indicator, push the outer
mast main roller against the middle mast rolling surface
with a claw bar, and set the dial indicator to zero.
(4) Insert a claw bar between the outer mast with the dial 1)
indicator and middle mast, and push the middle mast
502184

mast main roller. 1)
the shim thickness.
503983
Item Standard
1)
12-61
2.25 Inspecting and Adjusting Mast Strip Clearance
(1) Measure the clearance with the clearance between

outer mast rollers and inner mast rolling face adjusted 1)
to 0 mm (0.00 in.) at the maximum height.
Measure the clearance between the outer mast main
roller and the middle mast rolling surface in a similar
manner.
(2) If mast strip clearance deviates from the specified value,
adjust shim thickness.
For adjustment, see 12-46 "Installing Mast Strips".
502186
Item Standard
Clearance between mast and 0.2 to 1.0 mm
1)
mast strip (0.008 to 0.039 in.)
(3) After all clearances are adjusted, move the mast and lift
bracket slowly, and check whether the full stroke
movement is smooth.
2.26 Adjusting Mast Tilt Angle
(1) Adjust tire air pressure, and park the forklift truck on a
hard and level surface.
(2) Tilt the mast fully backward, and turn OFF the engine.
(3) Measure the backward tilt angle of the right and left of
the mast.
(4) Adjust the cylinder stroke by loosening the tilt cylinder
socket bolt, and then turn the tilt cylinder rod so that
the backward tilt angle of the mast on each side is the
same.
Note: Once the backward tilt angle has been properly
adjusted, there is no need for forward tilt adjustment
as it is determined by the tilt cylinder stroke. 609595
Slowly tilt the mast backwards, and adjust the rod so
that both cylinders simultaneously move into their
stroke end positions.
Forward tilt Backward tilt

Item
angle angle
Standard tilt angle 6 degrees
(5) After adjustment, tighten the tilt cylinder socket bolts

to the specified torque.

262 ± 13 N·m
Tilt cylinder socket bolt (26.72 ± 1.33 kgf·m)
[193.24 ± 9.59 lbf·ft]
12-62
2.27 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke
Inspection
(1) Slowly raise the inner mast, and observe how the piston
rods, left and right, stop at the moment the middle
mast reaches its maximum height.
(2) If the top of the middle 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 second lift cylinder
stroke.
502216
Adjustment
(1) Raise the middle mast, place wood blocks under the
right and left sides of the middle mast, and lower the
mast until it rests on the wood blocks.
(2) Remove the set bolt at the top of second 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 lever to
the lowering direction to release the hydraulic oil
from the second lift cylinders.
501408
(3) Raise the piston rod, and tighten the second lift cylinder
set bolt. Remove the wood blocks under the middle 1
mast.
(4) Check that the piston rods move smoothly throughout
the stroke by slowly lowering the middle mast to the 2
bottom. Also check that the left and right lift cylinders
come to the end of the stroke simultaneously at the 4
maximum lift position of the middle mast.
3
502189
1. Set bolt 3. Cylinder bracket
12-63
2.28 Troubleshooting
Condition Possible cause Action

Incorrect clearance between lift rollers and side Adjust forward/backward and
rollers right/left clearances
Lift bracket and inner mast do
not move smoothly Lubricate side rollers and replace other
Defective roller rotation
rollers
Incorrect clearance on mast strip Adjust with shims
Excessive clearance on side roller Adjust by adding shim(s)
Uneven tension between chains on right and left
Lift bracket or inner mast is Adjust chain tension
side
tilted
Uneven shim adjustments between left and right
Adjust by adding or removing shims
lift cylinders (at the maximum height)
Adjust or replace rollers after
Mast makes noise Defective roller rotation
inspection
Drift (natural descent) of lift Damaged lift cylinder packing Replace

cylinders Flaws on sliding (inside) surface of lift cylinder tube Replace
Whole mast shakes Worn mast support bushing Retighten or replace bushing
Deformed mast Off-center load or overload Replace mast assembly
Distortion of finger bar
Difference in height of fork tips Distortion of forks Repair or replace
Uneven loading
12-64
2.29 Service Data
7
5
5 6
6 3
5 6
6
2
4
609756
Note: The mast is slightly wider at the lower side than at the upper side.
Thus, always measure the clearance at the upper side of the mast.
Item Specification
Standard 635 mm (25.00 in.)
Limit 654 mm (25.75 in.)
S Standard 149 mm (5.87 in.)
Main roller outside diameter M Standard 150 mm (5.91 in.)
L Standard 151 mm (5.94 in.)
Side roller external diameter Standard 58 mm (2.28 in.)
12-65
Item Specification
1 Width of outer mast Standard 850 mm (33.46 in.)
Triplex mast 2 Width of outer mast Standard 722 mm (28.43 in.)
dimensions
(reference) 3 Width of inner mast Standard 594 mm (23.39 in.)
4 Width of lift bracket Standard 466 mm (18.35 in.)
Clearance between main roller
rolling face and mast
Mast 6 Standard 0.1 to 0.5 mm (0.0039 to 0.020 in.)
side face and mast
Clearance between mast and
mast strip
Lift rolling face and inner mast
bracket Clearance between side roller
rolling face and inner mast
Distortion of finger bar Standard 5 mm (0.20 in.) or less
490 ± 49 N·m
Mast support bolt Tightening torque
(49.97±5.0 kgf·m) [361.41±36.14 lbf·ft]
261 ± 13 N·m
Tilt cylinder socket bolt Tightening torque
(26.61 ± 1.33 kgf·m) [192.50 ± 9.59 lbf·ft]
Lift chain nut Tightening torque 385 ±38.5 N·m

(39.3 ±3.93 kgf·m) [283.96 ±28.40 lbf·ft]
Item Value
Thickness Standard 70 mm (2.76 in.)
Fork size
Width Standard 150 mm (5.91 in.)
12-66

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CHAPTER 12 MAST AND FORKS

Chapter 12 MAST AND FORKS

Truck classifications Mast

Mast serial number location

How to read mast model code

Note: For hydraulic lines, see 12-18 "Installing Hydraulic

1.4 Suggestions for Removing Mast and Lift Bracket Assembly

Removing lift bracket assembly

Disconnecting lift cylinder return hose

Disconnecting lift cylinder high-pressure hoses

Separating tilt cylinders

(2) Place wood blocks under the tilt cylinder mounting

Removing mast support caps

To install follow the removal sequence in reverse and also

Item Tightening torque

Adjusting chain tension

Bleeding lift cylinders

Bar type lift bracket

1.7 Suggestions for Disassembling Mast and Lift Bracket

Removing mast strips and main rollers

Removing inner mast

Lift chains, chain wheels, and chain wheel supports

Item Standard Limit

Item Standard Limit

See "11. HYDRAULIC SYSTEM".

Clearance between main roller rolling face and inner

Clearance between side roller rolling face and inner

Selecting roller of correct outer diameter

Item Specified value

Adjusting clearance between side roller rolling face

Measuring clearance between main roller rolling face

Item Specified value

Measuring the clearance between main roller rolling

1.12 Installing Mast Strips

Adjusting clearance between mast and mast strip

(1) If the clearance is too large, increase the number of

(1) Install cylinder brackets on lift cylinders.

(4) Install lift cylinder rods on inner mast as shown in the

(5) Measure the clearance by placing the cylinders

(6) After assembly, check both lift cylinders for smooth

Assemble chains on the lift bracket as shown.

Installing chain on lift bracket

Installing chain to outer mast side

Item Tightening torque

Item Tightening torque

Installation using straight thread and O-ring

The mast rollers and strips can only be removed or installed

1.17 Inspection and Adjustment

This section covers the inspection/adjustment which does

1) Outside jaws 100% 4) Replace fork wit 10% wear

Fork calipers perform two tasks at once.

Inspecting chain tension

Adjusting right and left chain balance

Item Tightening torque

Tightening nuts after adjustment

1.20 Measuring Chain Elongation

(1) Pull the chains taut by applying a load close to the

Item Standard Limit