MAST AND FORKS

Mast Systems ..........................................................................................13 – 1

Structure ...................................................................................................13 – 2
Simplex Mast (5A15C to 5A33B) ...............................................................13 – 2
Duplex Mast (5B15C to 5B33C) ................................................................13 – 3
Triplex Mast (5C15C to 5C33C) .................................................................13 – 4
Operation of Duplex Mast ..........................................................................13 – 5
Operation of Triplex Mast ...........................................................................13 – 5
Removal and Installation .....................................................................13 – 6
Mast and Lift Bracket Assembly ................................................................13 – 6
Simplex Mast .........................................................................................13 – 6
Duplex Mast and Triplex Mast ................................................................13 – 9
Disassembly and Reassembly ........................................................... 13 – 12
Disassembly .............................................................................................. 13 – 12
Simplex Mast ......................................................................................... 13 – 12
Duplex Mast ........................................................................................... 13 – 14
Triplex Mast ............................................................................................ 13 – 16
Inspection after Disassembly (All Mast Models) ................................... 13 – 18
1. Mast ................................................................................................... 13 – 18
2. Lift bracket ......................................................................................... 13 – 18
3. Lift chains, chain wheels and chain wheel supports ........................... 13 – 18
4. Mast strips ......................................................................................... 13 – 18
Reassembly ............................................................................................. 13 – 19
1. Installing lift bracket rollers (all mast models) ..................................... 13 – 19
2. Installing mast rollers (all mast models) ............................................. 13 – 22
3. Installing mast strip (all mast models) ................................................ 13 – 23
13
4. Installing second lift cylinders (all mast models) ................................. 13 – 23
5. Installing first lift cylinder (duplex mast and triplex mast models) ....... 13 – 24
6. Installing chain on lift bracket (simplex mast model) ........................... 13 – 24
7. Installing hydraulic lines ..................................................................... 13 – 24
 Removal/installation of mast rollers and mast strips without removing
mast from truck ....................................................................................... 13 – 28
Simplex Mast ......................................................................................... 13 – 28
Duplex Mast ........................................................................................... 13 – 29
Triplex Mast ............................................................................................ 13 – 30
Inspections and Adjustment .............................................................. 13 – 32
Forks ........................................................................................................13 – 32
Chain Tension Inspection and Adjstment ................................................... 13 – 33
Simplex Mast ......................................................................................... 13 – 33
Duplex Mast and Triplex Mast ................................................................ 13 – 34
Chain, Chain Wheel Support and Chain Wheel .......................................... 13 – 34
Checking Clearance between Lift Bracket Roller and Inner Mast .............. 13 – 35
Checking Clearance for Mast Roller .......................................................... 13 – 36
Mast Strip Clearance, Inspection and Adjustment ..................................... 13 – 38
Tilt Angle Adjustment ................................................................................ 13 – 38
Lift Cylinder Stroke Inspection and Adjustment ......................................... 13 – 39
Troubleshooting ..................................................................................... 13 – 40
Service Data ............................................................................................. 13 – 41
 MAST AND FORKS

Mast Systems

This manual applies to the following truck models (names).

Mast Types
Simplex Mast Duplex Mast Triplex Mast
Truck Model
FGC15N, FGC18N 5A15C 5B15C 5C15C
FGC20CN 5A20C 5B20C 5C20C
FGC20N, FGC20N HO
5A25C 5B25C 5C25C
FGC25N, FGC25N HO
FGC28N, FGC30N 5A30C 5B30C 5C30C
FGC33N 5A33C 5B33C 5C33C

NOTE : Maximum fork lift height (33: 3300 mm)

Mast Type Code Stamping Position Mast Types

Code Mast Type

A Simplex mast

B Duplex mast

C Triplex mast

209115A

Explanation of Mast Type Code

Example: 5 A 15 C 33

Maximum fork lift height (33: 3300 mm)

Revision code (A ª B ª C ··· Z)
Representative model (not allowable load)
Mast type
Major revision record (2 to 9)

13-1
MAST AND FORKS

Structure

Simplex Mast (5A15C to 5A33C)

Lift bracket
Inner mast Outer mast Inner mast

Side roller

Detail of A Detail of D

Inner mast Inner mast

Detail F
Detail E Outer mast
Lift bracket
Lift bracket

Detail of B Detail of E and F

Inner mast
Lift bracket Outer mast
Mast strip

207760

Shims

Detail of C Detail of G
209116

1 Inner mast A: Main roller E: Main roller

2 Outer mast B: Main roller F: Main roller
3 Lift chain C: Main roller G: Mast strip
4 Lift bracket D: Side roller
5 Mast-support bearing cap

The simplex mast features two lift cylinders placed Roller Sizes
behind the mast columns, right and left, to provide
Diam. of
excellent visibility. 1 ton class 2, 3 ton classes
main roller
Mast strips are fitted to the top end of outer mast. S 99 mm (3.90 in.) 113.8 mm (4.48 in.)
These strips are for backing up the inner mast when the M 100 mm (3.94 in.) 115 mm (4.53 in.)
mast is tilted backward. L 101 mm (3.98 in.) 116 mm (4.57 in.)
LL 102 mm (4.02 in.) 117 mm (4.61 in.)

13-2
 MAST AND FORKS

Duplex Mast (5B15C to 5B33C)

207608

1 Lift chain 5 Outer mast 8 Lift bracket main roller

2 First lift cylinder 6 Lift bracket 9 Mast upper main roller
3 Second lift cylinder 7 Chain wheel 10 Mast lower main roller
4 Inner mast

The duplex mast provides a free lift amount until the
top of lift bracket reaches the mast height.
The mast assembly consists of the inner mast, outer
mast, lift bracket, first lift cylinder and second lift
cylinders.
The first lift cylinder raises the lift bracket, while the
second lift cylinders operate the inner mast and lift
bracket.
For lifting operation, oil is first sent to the first lift
cylinder which raises the forks until the cylinder rod
reaches its stroke end.
When the first lift cylinder rod extends fully, the second
lift cylinders raise the assembly consisting of the lift
bracket, first lift cylinder and inner mast.
The shoulder sections of the mast main rollers contact
the mast rails. The rollers are installed perpendicular to
the sliding surfaces.
The main rollers used in the duplex mast models are the
same as those used in the simplex mast models.

13-3
MAST AND FORKS

Triplex Mast (5C15C to 5C33C)

207609 207610

1 First lift chain 5 Inner mast 9 Second chain wheel

2 First lift cylinder 6 Middle mast 10 Lift bracket main roller
3 Second lift chain 7 Outer mast 11 Mast upper main roller
4 Second lift cylinder 8 Lift bracket 12 Mast lower main roller

The triplex mast provides a free lift amount until the
top of lift bracket reaches the mast height.
The mast assembly consists of the inner mast, middle
mast, outer mast, lift bracket, first lift cylinder and
second lift cylinders.
The first lift cylinder raises the lift bracket, while the
second lift cylinder operates the three-stage telescopic
mechanism and lift bracket. Two pairs of lift chains are
installed. The cylinders and lift chains are designed for
smooth and effective operation.
For lifting operation, oil is first sent to the first lift
cylinder which raises the forks until the cylinder rod
reaches its stroke end.
When the first lift cylinder rod extends fully, the second
lift cylinders raise the assembly consisting of the lift
bracket, first lift cylinder, inner mast and middle mast.
The shoulder sections of the mast main rollers contact
the mast rails. The rollers are installed perpendicular to
the sliding surfaces.
The main rollers used in the triplex mast models are the
same as those used in the simplex mast models.

13-4
 MAST AND FORKS

Operation of Duplex Mast

203598

Operation of Triplex Mast

203600

13-5
MAST AND FORKS

Removal and Installation

Mast and Lift Bracket Assembly NOTICE: Refer to page 13-28 for the mast roller
replacement procedure without removing the
Simplex Mast
mast from the truck.
Removal

210717

Sequence
1 Nuts, Spring 4 Tilt socket pin, Tilt cylinder
2 Fork, Lift bracket 5 Mast-support bearing cap, Bushing
3 High-pressure hose for lift cylinder

Suggestions for Removal

1. Removing lift bracket assembly

(1) Tilt the mast forward, and lower the inner mast all the
way. Slacken the lift chains, and remove the nuts from
the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away, leaving the lift bracket and fork assembly
standing on the floor.

! WARNING 210718

Do not shut off the function of the mast interlock

system by means of “GSE” service tool.

13-6
 MAST AND FORKS

2. Disconnecting high-pressure hoses for lift cylinder

With the mast in the lowest position, disconnect the hoses
at the flow regulator valve.

3. Separating mast and tilt cylinder

(1) Hitch a sling to the mast. Using two eye-bolts and a
sling as shown and support the mast with a hoist.

! CAUTION
Be sure to use a hoist having a capacity enough
to support the mast assembly.

Weight of components
Unit: kg (lb)
207393A
Truck Model FGC20N
FGC15N FGC20N HO FGC28N
FGC20CN FGC33N
FGC18N FGC25N FGC30N
Item FGC25NHO

Gross
535 570 690 805 860
(simplex
(1180) (1260) (1530) (1780) (1900)
3.3 m mast)

(2) Place wood blocks under the tilt cylinder mounting

section and remove the tilt socket pins, and separate the
mast from the tilt cylinders.
(3) Start the engine and pull back the tilt lever to retract
the tilt cylinder rods.

! CAUTION
When the engine is running, do not touch any 209373
lever other than the tilt lever.

4. Removing mast support bearing caps

(1) Mark caps to ensure correct reassembly.
(2) Remove the cap bolts and lift off the mast assembly,
laying it down flat on a level floor.

NOTE Marks

Lay the mast assembly on a floor large enough for

disassembly.
200372

13-7
MAST AND FORKS

Installation
To install, follow the removal sequence in reverse, and
service as follows.
1. Procedure for mounting mast support bushings and
Inner Inner cap
caps. bushing
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) 1, 2 ton classes:
When installing caps, make sure the wider chamfered
side faces toward the center of the chassis.
3 ton class: Bushing

Chamfering is the same both in the right and left sides.

1, 2 ton classes
Be sure to reassemble in the same position as it was. Cap
(3) When applying grease, place wood blocks under the
mast. By doing so, it is easily greased.

3 ton class 209731

2. Adjust the chain tensions.

(Refer to the “Inspection and Adjustment” section.)
Anchor bolt
(1) Tighten the nuts to the specified torque.

Truck Model
1, 2 ton classes 3 ton class
Item
98 N·m 147 N·m
Double nut (lower) ù (10 kgf·m) (15.0 kgf·m)
[72.3 lbf·ft] [108.5 lbf·ft] ➀
210719
(2) Make sure that the chain tension is correct with the
mast in vertical (0°) position.

3. Air bleeding of lift cylinders

Start the engine. Raise and lower the lift bracket over full
stroke several times to bleed the cylinder.

4. After proper operation is confirmed, check the oil

level.

13-8
 MAST AND FORKS

Mast and Lift Bracket Assembly

The following describes the procedures for removing and reinstalling the mast assemblies of Duplex Mast and
Triplex Mast. Note that the Triplex Mast is used as an example.

Duplex Mast and Triplex Mast NOTICE: Refer to page 13-29 or 13-30 for the mast
roller replacement procedure without
Removal removing the mast from the truck.

This illustration shows the Triplex Mast.

210720

Sequence
1 Nuts, Spring 4 Tilt socket pin, Tilt cylinder
2 Fork, Lift bracket assembly 5 Mast support bearing cap, Bushing
3 High-pressure hose for lift cylinder

Suggestions for Removal

1. Removing lift bracket assembly

(1) Lower lift bracket assembly 2, and place wood
blocks under the assembly. Tilt the mast forward,
lower the inner mast to the bottom, then remove
nuts and spring 1 from the anchor bolts of the first
lift chains.
1

210721

13-9
MAST AND FORKS

(2) Position the mast upright. Raise the inner mast until
main rollers 6 of the lift bracket become free. Then,
slowly move the vehicle in reverse to separate from lift
bracket 2.

! WARNING 6

Do not shut off the function of the mast interlock 2

system by means of “GSE” service tool.

210722

2. Disconnecting high-pressure hoses for lift cylinder

Place the mast in the fully lowered position, then disconnect
the hoses at the flow regulator valve.

3. Separating mast and tilt cylinders

(1) Lower the inner mast. Hitch a sling to the upper
crossmember of the outer mast. For sling attachment,
install eye-bolts in the holes on the right and left sides.
Use a hoist and lift.

! CAUTION
Be sure to use a hoist having a capacity enough
to support the mast assembly.
207614

(2) Place wood blocks under the tilt cylinder mounting

sections, and remove pins.
(3) Start the engine, and pull back the tilt lever to retract
the tilt cylinder rods.

! CAUTION
When the engine is running, do not touch any
lever other than the tilt lever.

209373

4. Removing mast support caps

(1) Mark caps 5 to ensure the caps are reinstalled in
original positions during reassembly.
(2) Remove cap mounting bolts. Dismount the mast
assembly from vehicle in the suspended condition.
With the lift bracket side facing up, place the mast
assembly horizontally on wooden blocks on the level
ground.
207615A

13-10
 MAST AND FORKS

Installation
To install, follow the removal sequence in reverse, and
service as follows.
1. Procedure for installing mast support bushings and
Inner Inner cap
caps. bushing
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) 1, 2 ton classes:
When installing caps, make sure the wider chamfered
side faces toward the center of the chassis.
3 ton class: Bushing

Chamfering is the same both in the right and left sides.

1, 2 ton classes
Be sure to reassemble in the same position as it was. Cap
(3) When applying grease, place wood blocks under the
mast. By doing so, it is easily greased.

2. Adjust the chain tensions.

(Refer to the “Inspection and Adjustment” section.)
(1) Tighten the nuts to the specified torque.

Truck Model
1, 2 ton classes 3 ton class
Item
98 N·m 147 N·m 3 ton class 209731
Double nut (lower) ù (10 kgf·m) (15.0 kgf·m)
[72.3 lbf·ft] [108.5 lbf·ft]

(2) Make sure that the chain tension is correct with the Anchor bolt
mast in vertical (0°) position.

3. Bleeding lift cylinders.

Whenever the oil supply line is disconnected from the
lift cylinders and reconnected, raise and lower the lift
bracket a few times to bleed all air out of the piping ➀
210719
and the areas below pistons in the cylinders.
In the duplex mast, only the second lift cylinders are
provided with air bleeding screws.
The first lift cylinder does not require air bleeding
since it is an internal drain type cylinder.

4. After proper operation is confirmed, check the oil

level.

13-11
MAST AND FORKS

Disassembly and Reassembly

Simplex Mast
Disassembly

210723

Sequence
1 Nuts, Spring 8 Lift hose (high pressure), 12 Mast strip, Shims
2 Fork, Lift bracket Rubber hose, T-joint, Down 13 Main roller, Shims
3 Backrest safety valve 14 Main roller, Shims
4 Main roller, Shims 9 Snap ring, Chain wheel 15 Inner mast
5 Main roller, Shims 10 Cylinder clamps, Seats, 16 Lift cylinder
6 Side roller, Brackets, Shims Shims, Cushion, Collar, Bolt 17 Outer mast
7 Hose guard 11 Bolt, Shims

Suggestions for Disassembly NOTE

1. Removing mast strips and main rollers
Remove bolts 10, 11 to free lift cylinder 16. Displace
the tops of the two lift cylinders from inner mast 15.
Slide inner mast 15 toward the bottom of outer mast
17, and remove main rollers 13, 14 and mast strips 12.
Before disassembling the mast and fork assembly,
measure and record all clearances between each lift
bracket and roller and between each mast and
roller. Recorded measurements will be helpful
when replacing rollers or selecting shims to adjust
clearances. Refer to pages 13-35 through 13-38.

13-12
 MAST AND FORKS

2. Inner mast removal

After removing the main rollers, hitch a sling to the inner
mast crossmember and slide the inner mast to the upper side
of the outer mast to clear the outer mast roller shafts. Hitch
a sling to the inner mast again and remove it from the outer
mast.

207089

13-13
MAST AND FORKS

Duplex Mast
Disassembly

14
1
8
15 16

13

14
1
1

First
cylinder

18

17

210724

Sequence
1 High-pressure hose for first cylinder, Clamp 10 Bolt, Washer, Shims
2 Bolt, Washer, Shims 11 Mast strip, Shims
3 First lift cylinder 12 Main roller, Shims
4 Chain guard 13 Inner mast
5 Chain wheel support, Pin 14 Second lift cylinder
6 Chain wheel, Snap ring 15 Cylinder bracket
7 Hose guard, Bolt, Washer 16 O-ring, Plug
8 High-pressure hose 17 Mast support cap, Bolt, Washer
9 Cushion, Collar, Shims, Bolt, Washer, Clamp 18 Outer mast, Grease nipple

NOTE
The lift bracket disassembly procedure is the same as
for the simplex mast.

13-14
 MAST AND FORKS

Start by:
With the lift bracket side facing up, place the mast
horizontally on wood blocks. Place a wood block as a
wedge to prevent the inner mast from sliding.
Before disassembling the mast and fork assembly, measure
and record all clearances between each lift bracket and
roller and between each mast and roller. Recorded
measurements will be helpful when replacing rollers or
selecting shims to adjust clearances. Refer to pages 13-35
through 13-38.

Suggestions for Disassembly

1. Removing first lift cylinder 3

(1) Remove retaining bolts from the first lift cylinder. 3

(2) Hitch slings on first lift cylinder 3, and gently remove

the cylinder.
Use two slings. Wind or tie slings securely to prevent
slipping.

207619

2. Removing main rollers 12 and mast strips 11

(1) Remove clamp bolts from the second lift cylinders.
11 12
(2) Remove bolts from the upper rod sections of the
second lift cylinders, and place the cylinders on the
outer mast.
(3) Check the number of shims and the shim thickness at
the rod end sections.
(4) Move the inner mast down, then remove main rollers
12, mast strips and shims 11. 12
207620

3. Removing inner mast 14

18
Using slings, lift and remove inner mast 14, steering it
clear of the roller shaft sections of outer mast 18.

14 207621

13-15
MAST AND FORKS

Triplex Mast
Disassembly

210725

Sequence
1 Hose for first lift cylinder, Clamp, Bolt, Washer 17 Snap ring, Hose pulley, Shaft, Snap ring,
2 Bolt, Washer Chain wheel
3 Shims 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose
5 Chain guard 20 Hose, T-joint, Down safety valve
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, Shims, Bracket
8 Nut, Spring (chain for second lift cylinder) 23 Bolt, Washer, Shims
9 Mast strip, Shims 24 Second lift cylinder
10 Main roller, Shims 25 Mast strip, Shims
11 Main roller, Shims 26 Main roller, Shims
12 Inner mast 27 Main roller, Shims
13 Nuts 28 Middle mast
14 Lift chain (for second lift cylinder) 29 Cap, Bolt, Washer
15 Chain guard, Bolt, Washer 30 Outer mast, Grease nipple
16 Snap ring, Chain wheel

13-16
 MAST AND FORKS

NOTE
The lift bracket disassembly procedure is the same as
for the simplex mast.

Start by:
With the lift bracket side facing up, place the mast
horizontally on wood blocks. Place a wood block as a
wedge to prevent the inner and middle masts from sliding.
Before disassembling the mast and fork assembly, measure
and record all clearances between each lift bracket and roller
and between each mast and roller. Recorded measurements
will be helpful when replacing rollers or selecting shims to
adjust clearances. Refer to pages 13-35 through 13-38.

Suggestions for Disassembly

1. Removing first lift cylinder 4

4
(1) Remove retaining bolts from the first lift cylinder.
(2) Hitch slings on lift cylinder 4, and gently remove the
cylinder.
Use two slings. Wind or tie slings securely to prevent
slipping.

207624

2. Removing main rollers and mast strips 12

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

11

207625
10

3. Removing inner mast

Using slings, lift and remove the inner mast 12,
steering it clear of the roller shaft sections of the
middle mast.

12 207626

13-17
MAST AND FORKS

4. Removing main rollers 26, 27 from middle mast 28

28
and outer mast 30
24
Remove the bolts that are holding second lift cylinders 24.
Place the cylinder rod ends on the outer mast. Lower
middle mast 28 until main rollers 26, 27 can be removed.
Then, remove the main rollers. 27

30

26 207627

Inspection after Disassembly (All Mast Models)

1. Mast
(1) Check each roller for wear, binding or other defects.
(2) Check each roller on rolling surface for pitting or other
defects.
(3) Check the mast member and the welded joints of
crossmembers, shafts and supports for cracks.
(4) Check the mast support bushings for wear or other
defects. 207090

2. Lift bracket
(1) Check the main rollers and side rollers for smooth
rotation. Inspect each roller for wear an cracks.
(2) Check the welded portions of the bracket for cracks.
(3) Check the finger bar for bend or distortion.

A: Standard value
Unit: mm (in.)
Distortion of finger bar A 5 (0.19) or less 207091

3. Lift chains, chain wheels and chain wheel supports Length of lift chain (per 20 links)
(1) Measure the length of each chain to make sure that two A: Standard value B: Repair or service limit
chains are equal in length. Also check the chains for Unit: mm (in.)
wear, indication of breakage, link binding and twist. FGC20CN
(2) Check each chain anchor bolt for cracks or defects on FGC20N FGC28N
FGC15N
FGC20N HO FGC30N
thread. FGC18N FGC25N FGC33N
(3) Check each chain wheel support and chain wheel for FGC25N HO
crack or wear. Check that the wheels rotate smoothly. A 318 (12.52) 381 (15.00) 508 (20.00)
B 327 (12.87) 392 (15.43) 523 (20.59)
4. Mast strips
Check the mast strips for damage, wear or distortion.

13-18
 MAST AND FORKS

Reassembly
Follow the disassembly sequence in reverse. Be careful with the following suggestions.

Suggestions for Reassembly

1. Installing lift bracket rollers (all mast models)

F 2 F 3

2 1 1
1
No shim Shim (a)

Thrust
plate
6
G

1 mm (0.04 in.) Shim (b)

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

4
Lower roller Side roller
209122

Sequence
1 Lift bracket F: Clearance between roller circumference and
2 Lift bracket upper roller inner mast thrust surface (back-to-front play)
3 Lift bracket middle roller G: Clearance between roller side surface and
4 Lift bracket lower roller inner mast thrust surface (right-to-left play)
5 Side roller G1: Clearance between side roller circumference
6 Inner mast and inner mast side roller thrust surface

The lift bracket has three main roller bearings at one
side and a side roller at both sides as shown.
Clearances F, G and G1 must be maintained between
these rollers and thrust surface of the inner mast.
• Clearance F is used for determining the proper size
of the rollers.
• Clearance G is used for determining the correct
amount of shims at the bearing seat.
Shims (a), (b) and (c) are used in the rollers for
clearance adjustment.
Clearance G 0.1 to 0.5 mm (0.004 to 0.020 in.)

Clearance F 1.0 mm (0.039 in.) or less • Clearance G1 is used for determining the correct
amount of shims (shim (d)) under the seat of roller
bracket.

Clearance G1 0.1 to 0.5 mm (0.004 to 0.020 in.)

13-19
MAST AND FORKS

(1) Selecting main rollers of the appropriate diameter Roller Sizes

• As for upper roller 2, middle roller 3 and lower roller 4, Unit: mm (in.)
take measurements of clearance F. Based on the value, Diam. of 1 ton class 2, 3 ton classes
select rollers of the appropriate size from the table. main roller
• Rollers should rotate smoothly when installed. S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.61)

(2) Measuring and adjusting right-to-left clearance G at lift

bracket middle and lower rollers Lift bracket middle roller
Inner mast
Note: It is not necessary to adjust the lift bracket upper
Lift bracket
roller with shims.
• Measurement Roller
stopper
Move lift bracket to the top of the inner mast and press the Shim (a)
bracket to either the leftmost or rightmost position. Take
measurements of clearance G between the side surface of Shim (b) Thrust
roller and inner mast. plate

• Adjusting middle roller

G
If clearance G is excessive, a proper amount of shims 0.1 to 0.5 mm
should be added at location (a) and the same amount of (0.004 to
0.0020 in.)
shims should be added at location (b), theoretically.
However, shims for location (a) are available in two sizes: 209123
0.5 mm (0.020 in.) and 1.0 mm (0.04 in.). Shims for
location (b) are available in only one size: 1.0 mm (0.04
in.). Lift bracket lower roller
When a 0.5 mm (0.020 in.) thick shim is added at location Inner mast
Lift bracket
(a), it is not necessary to add the shim at location (b) [the G
0.5 mm (0.020 in.) difference can be ignored]. 0.1 to 0.5 mm
(0.004 to
NOTICE: At the time of shipment from the factory, a 1 0.020 in.)
Shim (c)
mm (0.04 in.) thick shim is installed at location
(a) and a 2 mm (0.08 in.) thick shim is installed
at location (b).
• Adjusting lower roller
If clearance G is too large, an appropriate amount of shims
should be added at location (c).
209138
NOTICE: At the time of shipment from the factory, a 1
mm (0.04 in.) thick shim is installed at location
(c).

(3) Installation
To install main rollers on shafts, use a driving tool. Be
careful not to accidentally strike the outer roller surface
with the driving tool.
The side of the roller with larger chamfered area must
face toward the outside.
Make sure the rollers rotate smoothly when installed. 202263

13-20
 MAST AND FORKS

(4) Measuring and adjusting clearance G1 between side

Lift bracket
roller and inner mast Inner mast
• Measurement Shim (d)

Move side roller to the upper end of the inner mast and
press the lift bracket to either the leftmost or rightmost Roller Side roller
mounting bolt
position. Take measurement of clearance G1 between
the roller circumference and inner mast. G1

• Adjustment
If measurement of clearance G1 is excessive, add a Lift bracket

proper amount of shims (d) under the seat of the roller

bracket. 209124
NOTICE: At the time of shipment from the factory, a 1
mm (0.04 in.) thick shim is installed at
position (d).

13-21
MAST AND FORKS

2. Installing mast rollers (all mast models)

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

(Mast top) F F
F 1.0 mm
1.0 mm Shim (g) (0.04 in.) or less
(Mast top) (0.04 in.) or less Shim (h)

Shim (e)

Inner mast Middle

Inner mast Outer mast Outer mast
mast G G
G 0.1 to 0.5 mm
0.1 to 0.5 mm (0.004 to 0.020 in.)
Mast bracket (0.004 to 0.020 in.) F
F
lower roller 1.0 mm
1.0 mm
(0.04 in.) or less Shim (i) (0.04 in.) or less
Shim (f) Shim (j)
(Mast bottom) (Mast bottom)

Lift bracket Lift bracket

Mast rollers for Simplex and Mast rollers for Triplex mast
Duplex masts 209375 209376

The mast rollers are completely identical with those of Roller Sizes
the lift bracket rollers in both the shape and size. The
Diam. of
same standard values apply to the roller-to-mast 1 ton class 2, 3 ton classes
main roller
clearances of both rollers.
S 99 mm (3.90 in.) 113.8 mm (4.48 in.)
Clearance F 1 mm (0.04 in.) or less M 100 mm (3.94 in.) 115 mm (4.53 in.)
L 101 mm (3.98 in.) 116 mm (4.57 in.)
Clearance G 0.1 to 0.5 mm (0.004 to 0.020 in.)
LL 102 mm (4.02 in.) 117 mm (4.61 in.)
(1) Measure the clearance F between the mast and the • The mast rollers are fitted in the same manner as the
rolling surface of each roller. If the measurement F lift bracket rollers.
is not within the standard value range, replace the
roller with the one of an appropriate diameter
selected from the table on the right.
NOTICE: Refer to the “Inspection and Adjustment”
section in this chapter for the clearance
measuring method.

13-22
 MAST AND FORKS

(2) Measure the clearance G between the mast and the side Shim thickness
surface of each roller. If the measurement G exceeds Location
the standard value range, increase the number of the 1 ton class 2, 3 ton classes
shims (e) to (j) appropriately to adjust the clearance to Shim (e) 2 mm (0.08 in.) 1 mm (0.04 in.)
specification. Shim (f) 2 mm (0.08 in.) 1 mm (0.04 in.)
NOTICE: With standard new trucks, the shims (e) to
Shim (g) 1 mm (0.04 in.) 1 mm (0.04 in.)
(j) installed are of the thicknesses shown in
the table on the right. Shim (h) 2 mm (0.08 in.) 1 mm (0.04 in.)
Shim (i) 2 mm (0.08 in.) 1 mm (0.04 in.)

3. Installing mast strip (all mast models) Shim (j) 2 mm (0.08 in.) 1 mm (0.04 in.)

(1) Measurement
Make a gap between the mast strip and inner mast. Simplex mast Shim (k)
Insert a thickness gauge in the gap to measure the 0.1 to 0.5 mm
clearance G2. (0.004 to 0.020 in.)
G2
Outer mast
Clearance G2 0.1 to 0.5 mm (0.004 to 0.020 in.)
Mast strip
(2) Adjustment
If the clearance G2 is excessive, add a proper amount
of shims under the mast strip (shim (k)). Usually, a 1.0
mm (0.04 in.) thick shim is used.
Shim (k)

209377 Inner mast

4. Installing second lift cylinders (all mast models)
(1) Install the cylinder bracket on the lift cylinder.
Simplex mast
(2) Install the lift cylinder between the outer and inner
masts.
(3) Attach the upper part of the cylinder rod in position on Inner mast
the inner mast. If the shim (l) has been removed during
disassembly, install the shim (l). Usually, the shim (l) Shim (l)
is not used.
(4) With the cylinder rod fully retracted and in a
perpendicular position, take measurement of the Cylinder bracket
clearance H.

Clearance H 1.6 mm (0.063 in.) or less 209127

If the lift cylinder is not vertical, fill the gap with shims
(m). Shims are not used usually. Simplex mast
Available as service parts are 1.6 mm (0.063 in.) thick
shims.
If the clearance is larger than 3.2 mm (0.126 in.), use a
3.2 mm (0.126 in.) thick seat (Parts No. 94110-09701) Shim (m)
rather than two pieces of 1.6 mm (0.063 in.) thick
shim.
(5) After reassembling, perform an operation test to check
if the stroke of the left and right cylinders is the same. H
207003A
For the check procedure, refer to page 13-39.

13-23
MAST AND FORKS

5. Installing first lift cylinder (duplex mast and triplex

mast models) Shim
Adjust the position of the first lift cylinder with shims so First lift cylinder
that the first lift cylinder becomes vertical when it is
installed and placed at the lowered position.
Mounting bolt
• Usually, a 2.0 mm (0.08 in.) thick shim is used. (2 and 3 ton
Mounting bolt class trucks)
• The thickness of each shims is 1.0 mm (0.04 in.). (1 ton class
trucks)
• Forward inclination is undesirable. It should be rather
inclined rearward.
Tighten the mounting bolt after completing necessary 209126
adjustment using shims.

6. Installing chain on lift bracket (simplex mast model)

Upper chain anchor kit
Connect each chain to the lift bracket using the upper chain Chain
anchor kit assembled as shown in the illustration. The link 3 1
plate 3 (with a stamped mark) should be on the side
opposite to the link 1. 4

Stamped
mark 2

Joint

Lower chain anchor kit

209378

1 Link
2 Center plate (without mark)
3 Link plate (with a stamped mark)
7. Installing hydraulic lines 4 Split pin

General precautions
• Use care not to let abrasive dust or dirt to enter the
hydraulic system.
• Apply a thin coat of oil to O-rings before installation.
• Tighten to the specified torque whenever shown.
• Fitting C (fitting with straight threads and O-ring)
shown in the illustration has each backup washer and
locknut. Use the procedure shown below to install it
properly.

13-24
 MAST AND FORKS

(1) Hydraulic lines in simplex mast models

A Tightening torques
Unit: N·m (kgf·m) [lbf·ft]
Part to be Tightening Truck
tightened torque model
Second
cylinder 58.8±5.9
Nut A (6±0.6)
A [43.4±4.3] 1 to 3 ton
B classes
49±4.9
Nut B (5±0.5)
[36.1±3.6]
39.2±3.9
1, 2 ton
(4.0±0.4)
classes
C [28.9±2.9]
B Nut C
58.8±5.9
(6±0.6) 3 ton class
[43.4±4.3]
39.2±3.9
1, 2 ton
D (4.0±0.4)
classes
[28.9±2.9]
Nut D
58.8±5.9
(6±0.6) 3 ton class
[43.4±4.3]
Second
cylinder

209466

Installation of a fitting with straight thread and O-ring

seal
1. Turn locknut 3 to move it as close to fitting body 2 as
possible. Place washer 4 and O-ring seal 5 against the
locknut.
2. Screw the fitting into the mating component until
washer 4 comes in contact with the surface of the
component and O-ring seal 5 seats correctly.
3. Turn the fitting in the tightening direction as necessary
to bring it to a position appropriate for connection.
4. Tighten locknut 3 to the specified torque. Elbow body assembly
1 End of fitting body 4 Backup washer
(connects to hose) 5 O-ring seal
2 Fitting body 6 End of fitting body
3 Locknut (connects to part)

13-25
MAST AND FORKS

(2) Hydraulic lines in duplex mast models

Tightening torques
Unit: N·m (kgf·m) [lbf·ft]
Part to be Tightening Truck
F tightened torque model
58.8±5.9
E
Nut A (6±0.6)
[43.4±4.3] 1 to 3 ton
49±4.9 classes
Nut B (5±0.5)
[36.1±3.6]
A 39.2±3.9
1, 2 ton
(4.0±0.4)
classes
[28.9±2.9]
Second Nut C
58.8±5.9
cylinder
(6±0.6) 3 ton class
A Second [43.4±4.3]
B cylinder
E 39.2±3.9
1, 2 ton
(4.0±0.4)
classes
[28.9±2.9]
Nut D
58.8±5.9
B (6±0.6) 3 ton class
[43.4±4.3]
C
58.8±5.9
Nut E (6±0.6)
E [43.4±4.3]
D 58.8±5.9
1 to 3 ton
Nut F (6±0.6)
classes
[43.4±4.3]
58.8±5.9
G Nut G (6±0.6)
First cylinder [43.4±4.3]

209467

NOTE

When installing fittings C and F , follow the

procedure under “Installation of a fitting with straight
thread and O-ring seal” on page 13-25.

13-26
 MAST AND FORKS

(3) Hydraulic lines in triplex mast models

Tightening torques
Unit: N·m (kgf·m) [lbf·ft]
Part to be Tightening Truck
tightened torque model
58.8±5.9
Nut A (6±0.6)
[43.4±4.3] 1 to 3 ton
49±4.9 classes
Nut B (5±0.5)
[36.1±3.6]
39.2± 3.9
1, 2 ton
(4.0±0.4)
classes
[28.9±2.9]
Nut C
58.8±5.9
(6±0.6) 3 ton class
[43.4±4.3]
39.2±3.9
E 1, 2 ton
(4.0±0.4)
classes
[28.9±2.9]
Nut D
58.8±5.9
A (6±0.6) 3 ton class
[43.4±4.3]
E
58.8±5.9
F Nut E (6±0.6)
[43.4±4.3] 1 to 3 ton
First cylinder classes
58.8±5.9
Nut F (6±0.6)
[43.4±4.3]
Second cylinder
A

C
B

Second cylinder
B

209468

NOTE

When installing fittings C , follow the procedure

under “Installation of a fitting with straight thread and
O-ring seal” on page 13-25.

13-27
MAST AND FORKS

Removal/Installation of Mast Rollers and Mast Strips without Removing Mast from
Truck
Simplex mast Upper set bolt
The mast rollers and mast strips can be removed/installed
when the inner mast is lowered until it is below the outer
mast. Follow the steps described below.

Cylinder
1. Separate the lift bracket from the mast. bracket

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 13-6. Lift cylinder
Shim

2. Position the inner mast lower than the outer mast as

follows:
(1) Raise the front end of the truck, and support that end Cylinder
clamp
with block or the like. parts
(2) Remove the upper set bolts from the lift cylinders, and Shim Mast roller

lift the inner mast with a hoist. Remove the hose

guard. Cylinder
(3) Remove the clamps from the lift cylinders. Pull out the clamp
parts
bottom ends of the cylinders from the outer mast, tilt
Mast strip
the cylinders to the center of the mast, and tie them to
the cross-member of outer mast with rope.
209381
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition.

3. Perform clearance adjustment of the removed rollers

using shims, replacement of rollers, and/or clearance
adjustment of the mast strips as necessary. Lift the inner mast
with a hoist
• To reassemble the mast, follow the removal sequence in
reverse.

202961

13-28
 MAST AND FORKS

Duplex mast
1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 13-6.

2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a crane. Wind the sling securely to prevent from
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.

NOTE
The rest of the procedure is the same as the procedure
for simplex mast models.

209132
3. Position the inner mast lower than the outer mast as
follows:
(1) Raise the front end of the truck, and support that end
with block or the like.
Lift the inner mast
(2) Remove the upper set bolts from the lift cylinders, and with a hoist
lift the inner mast with a hoist. Remove the hose
guard.
(3) Remove the clamps from the lift cylinders. Pull out the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
the cross-member of outer mast with rope. 202961
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition.
4. Perform clearance adjustment of the removed rollers
using shims, replacement of rollers, and/or clearance
adjustment of the mast strips as necessary.
• To reassemble the mast, follow the removal sequence in
reverse.

13-29
MAST AND FORKS

Triplex mast
1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 13-6.

2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and suspend it
with a hoist. Wind the sling securely to prevent from
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.

207616

3. Position the inner mast lower than the middle mast as

follows:
(1) Raise the front end of the truck, and support that end
with block or the like.
(2) Hitch slings to the upper cross-member of the inner
mast, and suspend with a hoist.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
and place them in front of the inner mast. 207639

(5) Lower the inner mast until main rollers can be

removed.
(6) Place wood blocks under the inner mast for support.
(7) Now the main rollers can be removed from the inner
and middle masts. Remove the mast strips and shims
in advance because they are apt to come off under this
condition.

NOTE
In this condition, second lift cylinders cannot be
dismounted.

13-30
 MAST AND FORKS

4. Position the middle mast lower than the outer mast as

follows:
(1) Lift the inner mast to the height of the middle mast,
then place wood blocks for support.
(2) Hitch slings to both middle mast and inner mast, and
suspend with a hoist.
(3) Remove set bolts from the upper sections of the middle
mast lift cylinders, then lift the middle mast and inner
mast.
207640
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the lower outer
mast section. Tilt the cylinders by moving the top
sections towards the center of the vehicle, then secure
the cylinders to the cross-member of the outer mast
with a rope.
(5) Lower the middle mast and inner mast until main
rollers can be removed.
(6) Place wood blocks under the middle mast and inner
mast for support.
(7) Now the main rollers can be removed from the middle
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition.
5. Perform clearance adjustment of the removed rollers
using shims, replacement of rollers, and/or clearance
adjustment of the mast strips as necessary.
• To reassemble the mast, follow the removal sequence in
reverse.

13-31
MAST AND FORKS

Inspection and Adjustment

The inspection and adjustment in this chapter can be done

without dismounting or disassembling. Conduct inspection
whenever a defect is suspected.

Forks (all mast models)

Fork calipers perform two tasks at once.

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

NEW FORK ARM

SHANK CROSS
50 mm / 2 in. SECTION = 100%
Figure 1

Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR

Not for use on full taperd forks. 210995

Forks are often mistreated and forgotten. As
insubstantial as they seem, neglecting forks could make
them dangerous.
Forks carry larger loads than almost any lifting device
but there are no mandatory requirements for
maintenance or inspection.
You can find thousands of extra parts for lift trucks in
some fleet repair shops, but you’ll seldom see spare
forks. Even when all the trucks on the fleet are the
same, fleet maintenance managers rarely order spare
forks. Forks last a long time if treated properly, but
they can be deceiving by looking as good from most
viewing angles when they are worn as when they are
new.
It’s true that most forks are customized to the truck by
model and capacity: they are big and heavy and thought
of as indestructible. But forks can be abused or ruined
in the course of daily work.
Here are some examples of ways that forks can be damaged:
• Forks can be overloaded either by picking up a load
too far out on the forks, or simply by picking up
loads heavier than the truck rating.
• Maintenance shops may bend forks back into shape,
weld on them, or drill holes through them. Lift truck
users can add atachments to the truck that stress the
forks. Drum clamps and portable booms can be
supported on the forks–but what is contained in the
13-32
drum or on the boom hook makes the safety
difference.
• Forks are often used to open rail car doors and break
loads out or away from other loads. They are also
used to pick up capacity loads not seated against the
fork shank and to pick up off-balanced loads far
from the side of the truck. The fork tips are
sometimes inserted under other fork trucks to lift
them during maintenance operations.
• Lift turcks may collide with building columns and
walls, and though the forks show no discernible
bend, they may be damaged beyond safety.
• Any time excessive heat is applied to any part of a
fork–during repair, for instance–hidden damage may
occur.
The fork itself is a concern but so are the hooks that
secure them to the lift carriage.
DESIGNED TO TAKE A BEATING
Forks for counterbalanced and straddle lift trucks are
not just bent bars of steel. The manufacturing process
is careful and precise with many checks and inspections
critical to their safety. Some factors essential to fork
manufacture include the steel, the bend and thickness of
the heel, the welding of the hooks that hold them on the
carriage, and the heat treatment of the finished product.
 MAST AND FORKS

Chain Tension Inspection and Adjustment

Simplex Mast

! WARNING
Turn the key to the OFF position before making
the inspection or adjustment of lift chains, anchor
bolts and nuts. Place blocks below the forks when
they are lifted.

1. Inspection of chain tension

(1) Place the mast vertical on a level ground, then lower
102708
the forks to the ground. Check that the lift cylinders
are fully retracted.
(2) Raise the forks approx. 100 mm (4.0 in.) from the
ground. Anchor bolt

(3) Turn the key to the OFF position.

(4) Place blocks approx. 90 mm (3.5 in.) high below the
forks.
(5) Push the chains at the middle point between the chain
wheel and chain fixed end on the lift bracket. Check ➁
the right and left chains for even tightness. ➀
210719A

2. Adjustment of right and left chain balance

Tightening torque
(1) Remove the blocks below the forks.
Turn the key to ON position. Truck Model
1, 2 ton classes 3 ton class
(2) Lower the forks to the ground and tilt forward until the Item
tips come in contact with the ground.
98 N·m 147 N·m
Double nut
The chains are now slack to facilitate the adjustment. (10 kgf·m) (15.0 kgf·m)
(lower) ù
[72.3 lbf·ft] [108.5 lbf·ft]
(3) Turn the key to the OFF position.
(4) Loosen double nut (lower) ù .
(5) Turn double nut (upper) û to adjust the chain tension.
(6) Turn the key to the ON position, and place the mast
vertical again.
(7) Repeat (2) through (5) of procedure 1, to check the
chain tension.
Inner mast
Lift bracket
3. Tightening of nuts after adjustment lower roller
Hold the double nut (upper) û with a wrench and tighten
double nut (lower) ù to the specified torque.
4. When the lift cylinders are fully extended or retracted,
check the protrusion of each lift bracket main roller to
be 40% of the roller diameter or less. 40% or less

207652

13-33
MAST AND FORKS

Duplex Mast and Triplex Mast

Duplex mast Triplex mast

Turn nuts for

adjustment

Turn nuts for

adjustment

Turn nuts for

adjustment

210726

The inspection and adjustment procedures are completely the same as those for simplex mast models. Follow the
procedures in the previous page to perform inspection or adjustment as necessary.

Chain, Chain Wheel Support and Chain Wheel

(1) Check the right and left chains for uneven length, wear,
adhesion or torsion.
Lift the forks high enough to put their full weight on
the carriage and chains.
Check to be sure the lift chains have equal tension.
20 links
(2) Check the chain anchor bolt for cracks or damaged
thread.
(3) Check the chain wheel support and the chain wheel for
cracks, wear or adhesion. 201768

(4) Replace chain or chain anchor bolt. If new parts are

installed, refer to “Installing chain on lift bracket” on
Length of lift chain (per 20 links)
page 13-24.
A: Standard value B: Repair or service limit
Unit: mm (in.)
NOTE
FGC20CN
To lubricate lift chains, molybdenum disulfide oil FGC20N FGC28N
(spray type) is recommended since it is easy to use and FGC15N FGC20N HO FGC30N
provides long lubrication. FGC18N FGC25N FGC33N
Super chain guard oil: 9101M-00150 FGC25N HO
A 318 (12.52) 381 (15.00) 508 (20.00)
B 327 (12.87) 392 (15.43) 523 (20.59)

13-34
 MAST AND FORKS

Checking Clearance between Lift Bracket Roller and Inner Mast

NOTE
The check procedure for the lift bracket is the same for
the Simplex mast, Duplex mast and Triplex mast.

1. Back-to-front clearance check on lift bracket main

F
rollers
(1) Raise the forks a little from the ground.
(2) Insert a bar between the upper part of lift bracket and
the inner mast, and push the inner mast to one side.
Using feeler gauges, measure the clearance F between
the main roller and inner mast on the opposite side.

Clearance F 1.0 mm (0.039 in) or less

F 207095

(3) If clearance F is out of specification, use oversize

rollers. Remove lift bracket from mast and replace
rollers with proper sized rollers. For roller replacement
procedure, refer to “Installing lift bracket rollers” on
pages 13-19 and 13-20.

2. Right-to-left clearance check on lift bracket main

rollers and side rollers
(1) Raise the mast to the top.
203818
(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 push the ➀ ➀
lift bracket to one side with a bar. Set the indicator to G
zero.
(4) Insert a bar between the inner mast and lift bracket on ➁ ➁
the indicator side, and push the lift bracket to the
opposite side.
(5) Read the indicator.
This reading is the clearance G between middle roller
202276
and thrust plate 2.
ù Upper roller û Thrust plate
Clearance G 0.1 to 0.5 mm (0.004 to 0.020 in.)

(6) If clearance G is out of specification, it is necessary to

add shims to the seat of the roller to adjust to correct
clearance. Remove lift bracket from mast and adjust
the thickness of the shims for the rollers. For
adjustment and installation procedures, refer to
“Installing lift bracket rollers” on page 13-20.

13-35
MAST AND FORKS

(7) Lower the lift bracket sligtly from the top, then check
clearance G1 between the side roller.
G1
Clearance G1 0.1 to 0.5 mm (0.004 to 0.020 in.)

If clearance G1 is out of specification, it is necessary

to add shims to the seat of the roller bracket to adjust to Side roller Side roller
correct clearance. Remove lift bracket from mast and
adjust the shim thickness. For adjustment and
installation procedures, refer to “Installing lift bracket
202277
rollers” on page 13-21.
(8) With the lift bracket at the top, check clearance G.

Clearance G 0.1 to 0.5 mm (0.004 to 0.020 in.)

If clearance G is out of specification, it is necessary to

add shims to the seat of the roller to adjust to correct
clearance. Remove lift bracket from mast and adjust
the shim thickness for the rollers. For adjustment and Lower roller
installation procedures, refer to “Installing lift bracket
rollers” on page 13-20.
G 207158

Checking Clearance for Mast Roller

NOTE
The following instructions concerning the mast roller F
clearance check pertains to the Simplex and Duplex
masts. These instructions, however, are essentially
applicable also to the Triplex mast. See the “Installing
mast rollers” section on page 13-22 for detail of the
clearances between the mast and rollers.

1. Back-to-front clearance inspection on mast main

207099
rollers
(1) Tilt the mast fully backward.
(2) Using feeler gauges, measure the clearance F between
the inner mast lower roller and outer mast.

Clearance F 1.0 mm (0.039 in.) or less

(3) If the clearance F is out of the specification, use

oversize rollers.
For mast roller replacement and installation
procedures, refer to “Installing mast rollers” on page
13-22. For mast roller removal procedure, refer to
“Removing mast rollers” on page 13-29 to 13-31.
13-36
 MAST AND FORKS

2. Right-to-left clearance inspection on inner mast main

rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the inner mast.
(3) Go over to the opposite side of the mast, and push the
inner mast against the outer mast. Set the indicator to
zero.
(4) Insert a bar between the outer and inner masts on the
indicator side, and push the inner mast to the opposite G 204886
side.
(5) Read the indicator.
This reading is the clearance G between inner mast
roller and outer mast.

Clearance G 0.1 to 0.5 mm (0.004 to 0.020 in.)

(6) If the clearance G is out of specification, it is necessary

to add shims to the seat of the roller to adjust to correct
clearance. For adjustment and installation procedures, G
refer to “Installing mast rollers” on page 13-22. For
207101
mast roller removal procedure, refer to “Removing
mast rollers” on page 13-29 to 13-31.

3. Right-to-left clearance check on outer mast main

rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the outer mast with its contact
point rested on the inner mast.
(3) Go over to the opposite side of the mast, and push the
outer mast against the inner mast with a bar. Set the
indicator to zero.
(4) Insert a bar between the outer and inner mast, and push 204889
the inner mast to the opposite side.
(5) Read the indicator.
This reading is the clearance G between outer mast G
roller and inner mast.

Clearance G 0.1 to 0.5 mm (0.004 to 0.020 in.)

(6) If the clearance G is out of specification, adjust it by

shims.
It is necessary to add or remove shims at the seat of the
roller to adjust to correct clearance. For adjustment
and installation procedures, refer to “Installing mast 207103
rollers” on page 13-22. For mast roller removal
procedure, refer to “Removing mast rollers” on page
13-29 to 13-31.
13-37
MAST AND FORKS

Mast Strip Clearance, Inspection and Adjustment

1. Check the clearance G2 with the clearance between the
outer mast rollers and inner mast set to zero (0) in G2
maximum lift position.

Clearance G2 0.1 to 0.5 mm (0.004 to 0.020 in.)

2. If clearance G2 is out of specification, remove upper

mast roller (refer to “Removing mast rollers”).
Remove mast strip and adjust the clearance. For
adjustment procedure, refer to “Measuring and 200391
adjusting clearance G2 between mast strip and inner
mast” on page 13-23.
3. After adjusting the all clearance, move the mast and
lift bracket slowly to make sure that they move
smoothly through their full stroke.

Tilt Angle Adjustment

1. Park the truck on a level ground.
2. Tilt the mast fully backward and stop the engine.
3. Measure the backward tilt angle of the mast at both
sides.
4. To adjust the tilt angle, loosen the bolt of tilt cylinder
socket, and adjust the rod length by turning the rod.
Adjust cylinder so that there is no difference in stroke
tilt angle between the cylinders, right and left.
209383
NOTE
It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.

5. After adjusting the tilt angle, tighten the socket bolts to

the specified torque.

157 to 182 N·m

Tightening torque for tilt
(16 to 18.6 kgf·m)
cylinder socket bolt
[116 to 134 lbf·ft]

Standard tilt angles

F: Forward B: Backward
Truck Models 1 ton class 2 ton class 3 ton class

Mast Models F B F B F B
Simplex 5° 10° 5° 9° 5° 6°
Duplex 5° 10° 5° 9° 5° 6°
Triplex 5° 6° 5° 6° 5° 6°
13-38
 MAST AND FORKS

Lift Cylinder Stroke Inspection and Adjustment

1. Slowly raise the inner mast, and observe how the
piston rods, left and right, stop at the moment the inner
mast reaches its maximum height.
2. If the top of the inner mast jolts at that moment, make a
shim adjustment. Abnormal condition can be detected
by a little time lag in stopping between the piston rods,
left and right, and shaking of the rod with a longer
cylinder stroke.

204698

3. Adjusting method
(1) Raise the inner mast, place blocks under the right and
left sides of the inner mast, and lower the mast until its
rests on the blocks.

202983

(2) Remove the set bolt at the top of lift cylinder which
showed earlier stroke end, retract the piston rod, and Shim
insert shims at the top of piston rod end. Inner mast
(3) Extend the piston rod, and tighten the cylinder set bolt.
Remove the blocks from under the inner mast.
(4) Slowly lower the inner mast to the bottom to ensure the
piston rods move smoothly and that the left and right Cylinder bracket
lift cylinders come to the end of stroke simultaneously.

209127A

13-39
MAST AND FORKS
Troubleshooting
Lift bracket, inner mast and
middle mast do not rise or
lower smoothly.
Lift bracket or inner mast is out
of square.
Abnormal noise is generated by
mast.
Lift cylinder drift is too large.
Entire mast shake
Mast is deformed in shape.
Uneven fork end heights
Second lift cylinders move when
first lift cylinder operates
(only in Duplex and Triplex
masts).
Lift bracket is spongy when it
stops in lifting operation.
Faulty rotation of side roller Replace rollers.
Faulty rotation of main rollers Replace rollers.
Improper mast strip clearance Adjust with shims.
Improper main roller or side roller Adjust front-to-back and
clearance right-to-left clearances.
Uneven chain tension between right and Adjust chain tension.
left chains
Excessive side roller clearance Adjust by adding shims.
Uneven adjustment of shims between Adjust by removing shims.
right and left lift cylinders
(at maximum lift position)
Faulty rotation of side roller Replace rollers.
Faulty rotation of main rollers Replace rollers.
Defective hose pulley bearing Replace.
(Triplex mast only)
Damaged gaskets in lift cylinders Replace.
Internal leak of control valve Replace.
Worn mast support bushings and caps Retighten, or replace bushings
and caps.
Uneven cargo load or overload Replace assembly.
Bent finger bars Repair or replace.
Bent forks Replace.
Mast deformation due to uneven cargo Repair or replace.
load
Low oil temperature Increase oil temperature by
raising and lowering lift
bracket.
No clearance for lift bracket roller Readjust rollers.
surfaces
Clogged pipes Inspect and clean hydraulic line.
Improper air bleeding Bleed hydraulic system.
Air is present under each lift cylinder Bleed hydraulic system.
piston due to poor air bleeding.
13-40
 MAST AND FORKS

Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model FGC20N
FGC15N FGC20N HO FGC28N
FGC20CN FGC33N
FGC18N FGC25N FGC30N
Item FGC25N HO

Gap of fork end heights A 5 (0.20) or less

318 381 508
Forks and A
(12.52) (15.00) (20.00)
chains Chain extension (mm (in.)/20 links)
327 392 523
B
(12.87) (15.43) (20.59)
S A 99 (3.90) 113.8 (4.48)

Main roller external diameter M A 100 (3.94) 115 (4.53)

Rollers (for lift bracket and mast) L A 101 (3.98) 116 (4.57)
LL A 102 (4.02) 117 (4.60)
Side roller external diameter A 42 (1.65)
Width of outer mast B A 610 (24.02) 670 (26.38)
Simplex mast and
Width of inner mast B2 A 516 (20.07) 568 (22.36)
duplex mast
Width of lift bracket C A 408 (16.06) 458 (18.03)
Dimensions
(for Width of outer mast B A 610 (24.02) 670 (26.38)
reference)
Width of middle mast B1 A 516 (20.31) 568 (22.36)
Triplex mast
Width of inner mast B2 A 426 (16.77) 468 (18.43)
Width of lift bracket C A 318 (12.52) 358 (14.09)
Clearance between main roller
A 1 (0.04) or less
circumference and mast thrust surface F
Clearance between main roller side
Mast A 0.1 to 0.5 (0.004 to 0.020)
surface and mast thrust surface G
Clearance between inside mast and mast
A 0.1 to 0.5 (0.004 to 0.020)
strip G2
Clearance between upper, middle and
Clearance lower roller circumference and inner A 1 (0.04) or less
mast thrust surface F
Clearance between middle roller side
Lift A 0.1 to 0.5 (0.004 to 0.020)
surface and inner mast thrust plate G
bracket
Clearance between lower roller side
A 0.1 to 0.5 (0.004 to 0.020)
surface and inner mast thrust surface G
Clearance between side roller
A 0.1 to 0.5 (0.004 to 0.020)
circumference and inner mast surface G1
Distortion of finger bar A 5 (0.19) or less

13-41
MAST AND FORKS

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model FGC20N
FGC15N FGC20N HO FGC28N
FGC20CN FGC33N
FGC18N FGC25N FGC30N
Item FGC25N HO

The mast width is prone to be narrower at the top than at

the bottom. It is recommended to always measure the
clearance at the top.

G
G2
F

G
G

G1

G
F
G1 G

F G
B2
G

G G
B2 B1
C
Lift bracket

B B

Simplex mast, Triplex mast

Duplex mast 208742

Tightening torque for double nut (lower) ù

A 98 (10) [72.3] 147 (15.0) [108.5]
N·m (kgf·m) [lbf·ft]

Anchor bolt

➀ 210719

13-42