MAST AND FORKS

1. Specifications ............................................................................................................. 13-2

2. Structure..................................................................................................................... 13-3
2.1 P17500................................................................................................................................................ 13-3 1
2.2 P20000................................................................................................................................................ 13-4

3. Suggestions for Removal and Installation.................................................................. 13-5

2
3.1 P17500 Mast and lift bracket assembly (simplex mast)...................................................................... 13-5
3.2 P20000 Mast and lift bracket assembly .............................................................................................. 13-6 3
3.3 Removal sequence ............................................................................................................................. 13-6
3.4 Suggestions for Removal.................................................................................................................... 13-7
4
4. Mast assembly ........................................................................................................... 13-9
4.1 Disassembling P17500 mast assembly (simplex mast)...................................................................... 13-9 5
4.1.1 Disassembly sequence ............................................................................................................................. 13-9
4.1.2 Suggestion for disassembly .................................................................................................................... 13-10
6
4.2 Disassembling P20000 mast assembly ............................................................................................ 13-11
4.2.1 Disassembly sequence ........................................................................................................................... 13-11
4.2.2 Suggestion for disassembly .................................................................................................................... 13-12 7
4.3 Inspection and Repair ....................................................................................................................... 13-12
4.4 Reassembly ...................................................................................................................................... 13-14 8
4.5 Readjust............................................................................................................................................ 13-20

5. Troubleshooting ....................................................................................................... 13-25

9
6. Service Data............................................................................................................. 13-26 10
11
12
13
14
15

13-1
MAST AND FORKS

1. Specifications

Truck model P17500 P20000

Mast type CJ type
Mast dimensions 170 22 30 mm 205 25 32 mm
Outer
(Flange inside width x (6.7 0.9 1.2 in.) (8.1 0.9 1.3 in.)
Flange thickness x 170 22 30 mm 205 25 32 mm
Lo Web thickness) Inner
(6.7 0.9 1.2 in.) (8.1 0.9 1.3 in.)
ad
in Type Ball bearing
g Main roller 170 45 mm 205 52 mm
eq Diameter x Width
(6.7 1.8 in.) (8.1 2.0 in.)
ui
p Side roller Type Lubricated needle
m Diameter x Width 58 40 mm (2.3 1.6 in.)
en
Lift-chain type EKBL-1234 EKBL-1434
t
1220 180 60 mm 1220 180 70 mm
Fork length (width x thickness)
(48.0 7.1 2.4 in.) (48.0 7.1 2.8 in.)
450 to 1660 mm 470 to 2010 mm
Fork width adjustment (outside width)
(17.7 to 65.4 in.) (18.5 to 79.1 in.)

13-2
 MAST AND FORKS

2. Structure
2.1 P17500

A
10

A 7
8 3
2

B
B 5 9

10

Section A - A Section B - B Detail of side roller 8

211982

1 Inner mast 5 Fork 9 Mast support cap

2 Outer mast 6 Lift cylinder 10 Mast strip
3 Lift chain 7 Main roller
4 Lift bracket 8 Side roller

13-3
MAST AND FORKS

2.2 P20000

7 A

A 3

B B
6 5

Section A - A Section B - B

211983

1 Inner mast 4 Lift bracket 6 Main roller, Side roller

2 Outer mast 5 Mast support bearing cap 7 Mast strip
3 Lift chain

13-4
 MAST AND FORKS

3. Suggestions for Removal and Installation

3.1 P17500 Mast and lift bracket assembly (simplex mast)

1
4
2
3

211984

13-5
MAST AND FORKS

3.2 P20000 Mast and lift bracket assembly

4 2
1
3

211985

3.3 Removal sequence

1 Fork, Lift bracket 4 Tilt cylinder pin
2 Lift cylinder low-pressure return hose 5 Mast support bearing cap, Bushing
3 Lift cylinder high-pressure hose

13-6
 MAST AND FORKS

3.4 Suggestions for Removal

1. Removing lift bracket
(1) Remove the split pins from the lift chain, and remove
the anchor nut and lock nut.

P17500 (Remove lift chains from mast.) P20000 (Remove lift chains from lift bracket.)

205567

(2) Bind the end of the lift chain with a rope, etc. Leave an
approximately 3 m (9.8 ft) long extras at the ends of the
rope.
(3) Start the engine and raise the inner mast up to a posi-
tion where the main rollers of the lift bracket come off.
(4) During this step, maintain the lift chain pulled down-
ward.
(5) Lift the inner mast until it comes to a position where
the main rollers of lift bracket can be removed, then
reverse the truck to separate the lift bracket from the 206563A
truck.
(6) Lower the inner mast and stop the engine.

2. Removing lift cylinder low-pressure return hose

(1) Start the engine and raise the mast to the highest posi-
tion. Then, stop the engine and disconnect the hose.
Remove the hose at the return connector side.
(2) Lower the mast.

3. Removing lift cylinder high-pressure hose

(1) Operate the lift lever to remove the remaining pressure
in the lift cylinder hydraulic lines, and disconnect the
high-pressure hose from the joint to the flow regulator
valve and the elbow of the lift cylinder.

211959

13-7
MAST AND FORKS

4. Removing tilt cylinder

(1) Hitch a sling to the upper cross-member at the top of
the mast, then lift with a hoist.

NOTE
For this operation be sure to use a hoist having a capacity
enough to support the mast assembly.
Weight of Each Component (Simplex Mast, raised
height: 3 m)
Model P17500 P17500
P20000
Part name 2SP 3FF
745 725 830
Outer mast
(1642 lb) (1598 lb) (1829 lb)
485
Main mast - -
(1069 lb) 211986
520 460 785
Inner mast
(1146 lb) (1014 lb) (1731 lb)
710 685 900
Lift bracket
(1565 lb) (1510 lb) (1984 lb)
310 310 360
Fork
(683 lb) (683 lb) (794 lb)
235 515 300
L/CYL, Others
(518 lb) (1135 lb) (661 lb)
2520 3180 3175
Total
(5556 lb) (7011 lb) (6999 lb)

(2) Remove the tilt socket pin to remove the tilt cylinder
from the mast.
(3) Start the engine and operate the tilt lever to retract the
tilt cylinder.

CAUTION
Do not touch any levers other than tilt lever, when
engine is in operation.

NOTE
Do not loosen the tilt socket bolt unless the tilt cylinder is
disassembled.
211962
5. Removing mast support bearing cap
(1) Put alignment marks on the caps.
(2) Remove the cap mounting bolts and separate the whole
mast assembly while lifting it up from the truck. Lay it
down flat with the lift bracket side facing upward on
level ground.

NOTE
In order to avoid any obstruction in the subsequent disas-
sembly, lay the removed mast assembly on a sufficient
space in both directions of mast sliding. (toward the top and
bottom).
206564

13-8
 MAST AND FORKS

4. Mast assembly
4.1 Disassembling P17500 mast assembly (simplex mast)

10
8
7

9 14
6

13

5 7
12
1 11

3
4

2
4

1 4
1 4
11
10 4
2
211963
4.1.1 Disassembly sequence
1 Fork, Lift bracket, Lift chain, Stopper pin, Guide bar, 8 Bolt, Shim
Stopper plate
2 Side roller, Bracket, Grease nipple, Shim 9 Mast strip, Shim
3 Main roller, Snap ring 10 Side roller, Bracket, Grease nipple, Shim
4 Rubber hose, Cover, Joint, O-ring, Down safety valve 11 Main roller, Snap ring
5 Return hose, Clamp 12 Inner mast
6 Chain wheel, Snap ring 13 Lift cylinder
7 Cylinder clamp, Bolt, Seat, Shim, Cushion, Collar 14 Outer mast

13-9
MAST AND FORKS

4.1.2 Suggestion for disassembly

Removing inner mast
(1) Lift cylinders LH and RH are shim adjusted at the cyl-
inder rod ends to prevent limping. When cylinder rod
installation bolts are removed, check how many shims
are used and which side of cylinder the shims are Shims
installed to.
(2) When the cylinder clamp bolts are removed, the lift
cylinder becomes unfixed (free). Shorten the cylinder
rods as much as possible to cross the top ends of two
cylinders.
(3) Slide the inner mast downward to remove main roller 205574
and mast strip of outer mast and main roller and side
roller of inner mast.
(4) Remove main and side rollers, then withdraw the inner
mast from the outer mast in an upward direction to sep-
arate them by sliding the shafts of main rollers of them
each other.

205575

13-10
 MAST AND FORKS

4.2 Disassembling P20000 mast assembly

12

13
17

14 8
13
16

1
7
4 15
8
10
5

16
16 10
1

6 18
2 11

4
6
11
211964
4.2.1 Disassembly sequence
1 Lift chain, Nut, Split pin 10 Lift cylinder
2 Lift bracket 11 Main roller, Side roller, Snap ring, Side roller shim, Pin
3 Stopper plate, Guide bar 12 Bolt, Nut
4 Fork, Stopper pin 13 Main roller, Side roller, Snap ring, Side roller shim, Pin
5 Main roller, Side roller, Bolt, Nut, Snap ring, Pin 14 Chain wheel support
6 Rubber hose, Cover, Joint, O-ring, Down safety valve 15 Inner mast
7 Return hose, Clamp 16 Chain wheel, Pin, Spacer, Collar, Bearing
8 Cylinder clamp, Bolt, Seat, Shim, Cushion, Collar 17 Mast strip, Shim
9 Bolt, Shim 18 Outer mast

13-11
MAST AND FORKS

4.2.2 Suggestion for disassembly

Removing inner mast
(1) Lift cylinders LH and RH are shim adjusted at the cyl-
inder rod ends to prevent limping. When cylinder rod
installation bolts are removed, check how many shims
are used and which side of cylinder the shims are Shims
installed to.
(2) When the cylinder clamp bolts are removed, the lift
cylinder become unfixed (free). Shorten the cylinder
rods as much as possible to cross the top ends of two
cylinders.
(3) Slide the inner mast downward to remove main roller 205577
and side roller of outer mast and main roller and side
roller of inner mast.
(4) Remove main and side rollers, then withdraw the inner
mast from the outer mast in an upward direction to sep-
arate them by sliding the shafts of main rollers of them
each other.

4.3 Inspection and Repair

1. Mast
(1) Check the roller for wear, binding or crack. 200711
(2) Check the rolling surface of each roller for wear, dam-
age or distortion.
(3) Check the mast member and the welded joints of cross-
beams, pins and supports for cracks.
(4) Check the mast support bushings for wear or damage.

2. Lift bracket
(1) Check the main rollers and side rollers for sticking,
205578
wear or cracks.
(2) Check the welded part of the lift bracket for cracks.
(3) Check the guide bars whether they are bent or
deformed.

Guide bar

212374

13-12
 MAST AND FORKS

3. Chain, Chain wheel support, and Chain wheel

(1) Check right and left chains for uneven length, wear,
adhesion, or distortion.
Truck model P17500 P20000
Standard 762 mm 889 mm
Length of lift chains value (30 in.) (35 in.)
(mm/20 links) Service 785 mm 915 mm
limit (31 in.) (36 in.

(2) Check the chain anchor bolt for cracks or defects on

thread.
(3) Check the chain wheel support and the chain wheel for
cracks or wear, or adhesion.

4. Mast strip
(1) Check for damage, chipping or distortion.
Truck model P17500 P20000
Standard 6 mm 9 mm
value (0.24 in.) (0.35 in.)
Thickness of mast strip
Service 4.5 mm 7 mm
limit (0.18 in.) (0.28 in.)

5. Fork
(1) Check the fork for bend, misalignment of tips, and
cracks.
Standard 5 mm (0.2 in.) or
Misaligned fork tips
value less

(2) Check the forks for wear. If it exceeds the repair or ser-
vice limit, replace.
Truck model P17500 P20000
Standard 60 mm 70 mm
value (2.36 in.) (2.76 in.) 205518
Fork thickness
53 mm 56 mm
Service limit
(2.09 in.) (2.20 in.)

13-13
MAST AND FORKS

4.4 Reassembly
To reassemble, follow the disassembly sequence in reverse and observe the following.
1. Front and rear clearance between mast and lift bracket
(1) Select and assemble the main roller in an appropriate
Inner mast Outer mast
manner in order that the clearances P and M are within
the dimensions as shown below throughout the height
M
range.
Truck model P17500 P20000
0.5 to 2.1 0.5 to 2.8
Lift bracket
Clearances between main roller mm mm
and rolling surface P, M (0.02 to (0.02 to P
0.08 in.) 0.11 in.)

Unit: mm 206567
Truck model P17500 P20000
169 mm 203 mm
S
(6.65 in.) (7.99 in.)
170 mm 205 mm
Main roller size M
(6.69 in.) (8.07 in.)
171 mm 207 mm
L
(6.73 in.) (8.15 in.)

2. Installing mast trip

Install to make the front and rear clearance between
Outer mast
outer and inner masts within the specified dimension.
(1) Withdraw the inner mast until the span of mast main Inner mast
roller comes to the dimension as shown below, and
measure the clearance between inner mast flange and
L
main roller L with thickness gauge.
0.2 to 1.0 mm
Clearance L
(0.008 to 0.0039 in.)

Mast Models Roller span 206568

4V80A, 4M80A 905 mm (35.6 in.)
4V90A 950 mm (37.4 in.)

(2) If the clearance of mast strip L is not within the speci-

fied value, adjust with the shims. Shims

200392A

13-14
 MAST AND FORKS

3. Left and right clearance between outer and inner masts

(1) Measure the dimension between left and right side roll- P17500
ers of outer mast A and assemble them so that the spec- A
ified dimension is obtained.
Truck model P17500 P20000
7680.5 mm 7540.5 mm
Dimension A
(30.20.02 in.) (29.70.02 in.)

NOTE
Measurements shall be made at the smallest inner width.
204679

P20000
A

205581

(2) Measure the dimension between left and right side roll- P17500
ers of inner mast B and assemble them so that the spec-
ified dimension is obtained. B

Truck model P17500 P20000

8960.5 mm 8900.5 mm
Dimension B
(35.30.02 in.) (35.00.02 in.)

NOTE
Measurements shall be made at the largest outer width.
204680

P20000

205582

13-15
MAST AND FORKS

(3) Withdraw the inner mast until the roller span specified
as shown below is obtained, press the inner mast in one P17500
direction of left or right, and measure the clearance K
produced at the opposite side of pressing.
Mast Models Roller span 905 mm
4V80A, 4M80A 905 mm (35.6 in.) (35.6 in.)
K
4V90A 950 mm (37.4 in.)

0.2 to 1.0 mm
Clearance K
(0.008 to 0.039 in.)
K
205762

P20000

K
950 mm
(37.4 in.)

(4) If the clearance K is not within the specified value,

adjust in accordance with the following procedure. K
205765
The adjustment of clearance K of P17500 shall be made
by adding/subtracting shims of side roller bracket.

Shims

205584
The adjustment of clearance K of P20000 shall be made
by loosening locknut of side roller bracket and by rotating
the adjusting bolt.

Adjusting
bolt

205585

13-16
 MAST AND FORKS

4. Left and right clearance of lift bracket

P17500 C
(1) Measure the dimension of side roller C and assemble
so that the specified dimension is obtained.
Truck model P17500 P20000
7240.5 mm 7040.5 mm
Dimension C
(28.50.02 in.) (27.70.02 in.)

204683

P20000 C

205588
(2) Withdraw the lift bracket until it is very close to the
stopper of inner mast, press it in one direction of left or P17500
right, and measure the clearance N produced at the
opposite side of pressing with thickness gauge.

0.2 to 1.0 mm
Clearance N
(0.008 to 0.039 in.)
N

205763

P20000

N
205766

13-17
MAST AND FORKS

The adjustment of clearance N of P17500 shall be made

by adding/subtracting shims of side roller bracket.

Shims

205590
The adjustment of clearance N of P20000 shall be made
by loosening locknut of side roller bracket and by rotating
the adjusting bolt.
Adjusting
bolts

Adjusting
bolts
5. Cylinder clamp
205591
(1) Install shims to maintain the lift cylinder in the aligned
position, then assemble.
Standard shim thickness 4 mm (0.158 in.)

Shims
205593

13-18
 MAST AND FORKS

6. Mast support
(1) Apply grease to the cap inner surface and groove.
(2) Install the mast support bush and the cap with larger cut Mast cap
surface as they are directed to the center of truck. Bushing
Note that placing blocks under the mast to make a clear-
ance between mast and ground facilitates filling grease.
Tighten mast cap bolts to the specified torque.
490 Nm
Tightening torque (49.97 kgfm)
[361.6 lbfft]
Apply grease.
Chamfered

204687B

7. Suggestion for assembling chain anchor kit

(1) Never install the center plate to the position link plate
2
should be installed. 3
1 Link plate (Mark on surface)
2 Center plate (No mark on surface)
3 Link
4 Split pin 1
4 Marking

200383

13-19
MAST AND FORKS

4.5 Readjust.
1. Adjusting chain tension
(1) Tilt the mast vertical on a flat place, lower the forks to
the ground level, and check that lift cylinders are in the Anchor bolt
most retracted position.
(2) Loosen the double nut (lower) 1 and the upper nut 2.
(3) Position the anchor bolt with the double nut (upper) 3. 2 Upper nut
(4) Lift the fork slightly from the ground and check the
tension of chain as the two chains are stretched evenly,
by pushing the midpoints between chain wheel and
3 Double nut (upper)
fixed end of chain of left and right chains alternately.
Adjust if required. 1 Double nut (lower)
In the case of adjusting tensions of chains by double nut 102709
(upper) 3, it is recommended to tilt the mast forward to
reduce chain tension for operational convenience.

102708
(5) When the adjustment of chain tension by double nut
(upper) 3 is completed, tighten the upper nut 2 to the P17500 P20000
specified torque with holding the anchor bolt with a
wrench.
(6) Tighten the double nut (lower) 1 to the specified torque
with holding double nut (upper) 3 with a wrench.
Anchor bolt
Truck model P17500 P20000
295 Nm 392 Nm
Tightening torque of
(30.1 kgfm) (39.9 kgfm)
anchor bolt nut
[217.7 lbfft] [289.29 lbfft]

207651

(7) Check that the projection of lift bracket main roller is

not more than 40% of the roller diameter, when the lift
cylinder is in the most retracted position.

(8) The mast must be checked in the vertical position, 40 % or less

when it is finally adjusted.
207652

13-20
 MAST AND FORKS

2. Adjusting front and rear and left and right clearances of

lift bracket
(1) Measure the front and rear and left and right clearances
of lift bracket, and adjust, if any of them exceeds the
specified value.
(2) Use a thickness gauge for front and rear clearance of
lift bracket.
(3) Use a dial gauge for left and light clearance of lift
bracket. Prepare a dial gauge for inner surface of inner
mast and make the spindle of dial gauge contact with
side wall of lift bracket.
Insert a bar between lift bracket and inner mast, and
press lift bracket in the left and right directions alter-
nately to measure the clearance.
(4) If the clearance of lift bracket is adjusted, disconnect
204691
the lift bracket from the mast in accordance with
removal/installation procedure, and adjust the rollers.
(5) If the fro-to-aft clearance of main roller is not within
the specified value, replace with an oversized main
roller.
(6) If left-to-right clearance of side roller is not within the
specified value, adjust the clearance in accordance with
the following procedure:
The adjustment of clearance N of P17500 shall be made
by adding/subtracting shims of side roller bracket.
Shims

205590

The adjustment of clearance N of P20000 shall be made

by loosening locknut of side roller bracket and by rotating Adjusting
the adjusting bolt. bolts

Adjusting
bolts
205591

13-21
MAST AND FORKS

3. Adjusting front and rear, left and right clearances of inner

mast
(1) Use a thickness gauge for front and rear clearances of
inner mast.
(2) For left and right clearance of inner mast, use a dial
gauge and the same procedure as that for lift bracket.
Prepare a dial gauge for outer mast and make the spin-
dle of dial gauge contact with side wall of inner mast.
Insert a bar between inner and outer masts and move
left and right to measure the clearance.
(3) Disconnect the lift bracket from mast before adjusting
the clearance of inner mast.
(4) In order to lower the inner masts lower than the outer
mast, perform the following procedure.
(a) Place jacks or equivalent under the chassis to lift the
front portion. 211987
(b) Remove the bolt at the top end of lift cylinder rod and
hoist the inner mast. Shims
(c) Remove the clamp of lift cylinders, withdraw the lift
cylinders from installation position at the lower portion
of outer mast, tilt the tips of two cylinders to the center
and secure the cylinders to the cross member of outer
mast with ropes.
(d) Slowly lower the inner masts with crane, until they are
in contact with lift cylinders.
(e) This results in main and side rollers of inner and outer
masts removed. It is recommended to remove mast
200392A
strips and shims in advance, because they come off eas-
ily.
(5) If the front and rear clearance of main roller at the
upper portion of inner mast is not within the specified
value, add shims to the mast strip for adjustment.
(6) If the front and rear clearance of main roller at the Shims
lower portion of inner mast is not within the specified
value, replace with an oversized main roller.
(7) If the left and right clearance of inner mast exceeds the
specified value, remove the side roller and add shims
for adjustment.
(8) When adjustment of lift bracket and inner mast is com-
P17500 204696
pleted, slowly lift/lower the masts and lift brackets to
check for smooth operation.

13-22
 MAST AND FORKS

Shims

P20000 205768

4. Adjusting mast tilt angle

(1) Regulate the inflation pressure for all the wheels, then
park the truck on a level floor.
(2) Fully tilt the mast backward and stop the engine.
(3) Measure the rear tilting angles of mast at both sides.
(4) If required, perform the adjustment as follows: loosen
the locknut of tilt cylinder rod, rotate the tilt cylinder
rod and adjust the cylinder strokes to achieve an identi-
cal tilt angle for both left and right sides.

NOTE
If the rear tilting angle is properly adjusted, the forward tilt 211988
angle is automatically determined by the stroke of tilt cylin-
der.

forward-backward 6 - 12 (STD)

(5) After adjustment, tighten the lock nuts to each specified

torque.
+98
785 0 Nm
+9.9
Lock nut tightening torque (80.0 0 kgfm)
+72.3
[579.3 0 lbfft]

205519
5. Stroke adjustment of left and right lift cylinders
(1) Slowly lift inner masts to check the stopping condition
of left and right piston rods at the maximum height.
(2) If a top portion of inner mast vibrates at a moment that
it stops, make a shim adjustment.
Abnormal conditionThere is a slight difference in
stop timing between left and right sides. A lift cylinder
with a longer stroke vibrates when it stops.

13-23
MAST AND FORKS

Adjusting method
(1) Once raise the mast and place a block under the inner
mast, then lower the mast until it rests on the block.

202983

(2) Remove the stop bolt at the top of lift cylinder which
stops earlier than the other, lower the piston rod to
insert shims to the upper portion of the piston rod end.
Shims
(3) Extend the piston rod, and tighten the lift cylinder stop-
per bolt. Then, remove the block placed under the inner
mast.
(4) Slowly lower the inner mast until it comes to the lower-
most position to check the piston rod for smooth opera-
tion.

205595

13-24
 MAST AND FORKS

5. Troubleshooting

Front and rear / left and right clearance adjust-

Improper clearance of main and/or side rollers
ment
Lift bracket/inner mast
does not lift/lower Roller does not rotates smoothly Lubricate or replace.
smoothly Chain operation too slow Lubricate or replace.
Improper clearance of mast strip Adjust with shims.
Large side roller clearance Adjust by adding shims.
Leaned lift bracket or Uneven chain tensions Adjust chain tension.
inner mast Uneven shim adjustment of left and right lift cylinders
Adjust with shims.
(at the maximum height)
Abnormal noise from Check and perform adjustment or replace roller
Roller does not rotates smoothly
mast bearing.
Damaged lift cylinder packing Replace.
Lift cylinder descends
Damaged lift cylinder inner surface Replace.
Whole mast shakes Worn mast support bush Retighten or replace bushing.
Deformed mast Uneven loading or overload Replace assembly.
Distortion of figer bar Repair or replace.
Unevenness of fork tip
Bent fork Repair or replace.
height
Deformed mast due to uneven loading Repair or replace.

13-25
MAST AND FORKS

6. Service Data

Truck model P17500 P20000

Misaligned fork tips Standard value 5 mm (0.197 in.) or less
Standard value 60 mm (2.36 in.) 70 mm (2.76 in.)
Fork thickness
Service limit 53 mm (2.09 in.) 56 mm (2.20 in.)

Fork and chain Standard value 762 mm (30.0 in.) 889 mm (35.0 in.)
Length of lift chains (mm/20 links)
Service limit 785 mm (30.9 in.) 915 mm (36.0 in.)
294 mm Nm 392 Nm
Tightening torque of chain anchor bolt nut Standard value (29.98 kgfm) (39.97 kgfm)
[216.97 lbfft] [289.30 lbfft]
S-size Standard value 169 mm (6.65 in.) 203 mm (7.99 in.)
Main roller outside diameter M-size Standard value 170 mm (6.69 in.) 205 mm (8.07 in.)
Roller
L-size Standard value 171 mm (6.73 in.) 207 mm (8.15 in.)
0 0
Side roller outside diameter Standard value 58 -0.1 mm (2.28 -0.0039 in.)
+0.5 +0.5
896 -1.0 mm 890 -1.0 mm
X1 Standard value +0.02 +0.04
(35.3 -0.04 in.) (35.0 -0.02 in.)
Smallest inner width of outer mast
+0.5 +1.0
896 -1.0 mm 890 -0.5 mm
X2 Standard value +0.04 +0.04
(35.3 -0.02 in.) (35.0 -0.02 in.)
7680.5 mm 7540.5 mm
Inner width of outer mast roller A Standard value
(30.20.02 in.) (29.70.02 in.)
+0.5 +0.5
724 -1.0 mm 704 -1.0 mm
Y1 Standard value +0.02 +0.02
(28.5 -0.04 in.) (27.7 -0.04 in.)
Smallest inner width of inner mast
+1.0 +1.0
Outer mast and 724 -0.5 mm 704 -0.5 mm
Y2 Standard value +0.04 +0.04
inner mast (28.5 -0.02 in.) (27.7 -0.02 in.)
8960.5 mm 8900.5 mm
Outer width of inner mast roller B Standard value
(35.30.02 in.) (35.00.02 in.)
Clearance between main roller and rolling surface P 0.5 to 2.1 mm 0.5 to 2.8 mm
Standard value
(Throughout height range) (0.02 to 0.08 in.) (0.02 to 0.11 in.)
Clearance between side roller and rolling surface K 0.2 to 1.0 mm
Standard value
(at the maximum height) (0.008 to 0.039 in.)
0.2 to 1.0 mm
Clearance between mast strip and sliding surface L Standard value
(0.008 to 0.039 in.)
905 mm 950 mm
Roller span used when clearance K is measured Standard value
(35.6 in.) (37.4 in.)
Largest outer width of lift bracket C 7240.5 mm 7040.5 mm
Standard value
(upper and center rollers) (28.50.02 in.) (27.70.02 in.)
Lift bracket and Clearance between lift bracket main roller and rolling 0.5 to 2.1 mm 0.5 to 2.8 mm
Standard value
inner mast surface M (Throughout height range) (0.02 to 0.08 in.) (0.02 to 0.11 in.)
Clearance between lift bracket side roller and rolling 0.2 to 1.0 mm
Standard value
surface N (at the maximum height) (0.008 to 0.039 in.)
490 mm
Tightening torque of mast cap mounting bolts Nm Standard value
(19.29 in.)

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 MAST AND FORKS

Inner mast Lift bracket

Y1 C

Inner mast

Outer mast

Y2

B
Mast strips
N
X1
Inner mast
Outer mast
N M

A P

Roller span:
905 mm
(35.6 in.) K
Lift bracket
X2

K
Outer mast
206570

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MAST AND FORKS

Inner mast Lift bracket

Y1 C

Inner mast

Outer mast

Y2

B
Mast strips
N
X1
Inner mast
Outer mast
N M

A P

Roller span:
950 mm
(37.4 in.) K
Lift bracket
X2

K
Outer mast
206571

13-28
 MAST AND FORKS

Truck model P17500 P20000

98 Nm (9.99 kgfcm2)
Tightening torque of connector 1 Standard value
[72.32 lbfft]
98 Nm (9.99 kgfcm2)
Lift piping Tightening torque of down safety valve 2 Standard value
[72.32 lbfft]
118 Nm (12.03 kgfcm2)
Tightening torque of hose 3 Standard value
[87.1 lbfft]

3
1
1
2

3
1 1 211965

13-29