MAST AND FORK

Description ................................................................................................................................ 11 - 1

Removal and Installation .......................................................................................................... 11 - 5

Dual-stage Panoramic Mast (Simplex Mast) ...................................................................... 11 - 5
Triple-stage Full Free Panoramic Mast (Triplex Mast) ...................................................... 11 - 8

Disassembly and Reassembly .................................................................................................... 11 -11

Dual-stage Panoramic Mast (Simplex Mast) ...................................................................... 11 -11
Dual-stage Full Free Panoramic Mast (Duplex Mast) ........................................................ 11 -15
Triple-stage Full Free Panoramic Mast (Triplex Mast) ...................................................... 11 -19

Inspection and Adjustment ........................................................................................................ 11 -23

Forks .................................................................................................................................... 11 -23
Chain Tension Adjustment .................................................................................................. 11 -24
Tightening Torque .............................................................................................................. 11 -24
Clearance Adjustment on Lift Bracket................................................................................ 11 - 27
Mast Clearance Adjustment ................................................................................................ 11 - 29
Main Roller Shim Replacement (Simplex Mast) ................................................................ 11 - 31
Mast Strip Adjustment ........................................................................................................ 11 - 35
Tilt Angle Adjustment ........................................................................................................ 11 - 35
Lift Cylinder Stroke Adjustment ........................................................................................ 11 - 36

Troubleshooting.......................................................................................................................... 11 - 37

Service Data .............................................................................................................................. 11 - 38

11
 MAST AND FORK

Description
Dual-stage Panoramic Mast (Simplex Mast)

G
1
↓ Forward ↓ Forward
A

Detail of A Detail of F
2
3

↓ Forward ↓ Forward

Detail of B, C Detail of D
D

C ↓ Forward
E

4 Detail of E Detail of G 207082

F
Unit: mm (in.)
Diam of
5 1 ton models 2, 3 ton models
main roller
S 99 (3.90) 113.8 (4.48)
M 100 (2.94) 115 (4.53)
207163
L 101 (3.98) 116 (4.54)
LL 102 (4.02) 117 (4.60)

1 Inner mast A Main roller F Main roller

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

The Panoramic mast features two lift cylinders Mast strips are fitted to the top end of outer
placed behind the mast columns, right and left, mast. These strips are for backing up the inner
to provide maximum visibility. mast when the mast is tilted backward.

11-1
MAST AND FORK

Dual-stage Full Free Panoramic Mast (Duplex Mast)

↓
Front

8
Cross section of mast Cross section of mast
upper main roller strip
7

9
1
↓
Front
3
6
Cross section of
Cross section of lift chain wheel
4 bracket upper main
2 roller

5
10 ↓
↓
Front Front

Cross section of mast Cross section of lift

lower main roller bracket side roller

207608

1 Lift chain 4 Inner mast 7 Chain wheel

2 First lift cylinder 5 Outer mast 8 Lift bracket main roller
3 Second lift cylinder 6 Lift bracket 9 Mast upper main roller
10 Mast lower main roller

In the dual-stage full free panoramic mast, the
first cylinder raises the forks without increas-
ing the overall mast height (free-lift) until the
upper edge of the backrest exceeds the top of
the mast.
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 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 1-ton and 2-/3-ton
models are the same as those in dual-stage
panoramic mast.

11-2
 MAST AND FORK

Triple-stage Full Free Panoramic Mast (Triplex Mast)

10 ↓
Front

8 Cross section of mast Cross section of

upper main roller mast strip
1

↓ ↓
11 Front Front
9

3 Cross section of lift Cross section of

bracket upper main hose pulley
4 roller

5
↓ ↓
Front Front
2
6

Cross section of Cross section of sec-

7 side roller ond chain wheel
12

↓
Front

Cross section of mast Cross section of

lower main roller first chain wheel
207609 207610

1 First lift chain 5 Inner mast 9 Second chain wheel

2 First lift cylinder 6 Middle mast
3 Second lift chain 7 Outer mast
4 Second lift cylinder 8 Lift bracket
In the triple-stage full free panoramic mast,
the free-lift height extends to the top of the
mast, and the overall mast height remains the
same until the upper edge of the backrest
exceeds the top of the mast.
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 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.
10 Lift bracket main roller
11 Mast upper main roller
12 Mast lower main roller
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 1-ton and 2-/3-ton
models are the same as those in dual-stage
panoramic mast.

11-3
MAST AND FORK

Operation of Dual-stage Full Free Panoramic Mast

Inner mast

First lift cylinder

Second lift cylinder

Free-lift
height Outer mast

Forks on the ground Maximum free lift Maximum lift 203598

Operation of Triple-stage Full Free Panoramic Mast

First lift chain

Inner mast
First lift cylinder
Middle mast

Second lift chain

Second lift cylinder

Free-lift Outer mast

height

Forks on the ground Maximum free lift Maximum lift

203600

11-4
 MAST AND FORK

Removal and Installation

Mast and lift bracket assembly
Dual-stage Panoramic Mast (Simplex Mast)

5 4
1

2
207346

Sequence

1 Nuts 4 Tilt cylinders

2 Forks, Lift bracket 5 High-pressure hose for lift cylinders
3 Tilt socket pins 6 Mast-support bearing cap and Bushing

Suggestions

1. Lift bracket removal

(1) Tilt the mast forward, and lower the inner
mast to the bottom. 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, from the
lift bracket and fork assembly.

207084

11-5
MAST AND FORK

2. Removing lift cylinder high pressure hoses

Place the mast in the bottom position, disconnect
the hoses at the flow regulator valve.

3. Removing tilt cylinders

(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.

204845

(2) Remove the tilt socket pins, and separate the

masts from the tilt cylinders.
(3) Start the engine, and pull back the tilt lever to
contract the tilt cylinder rods.
(4) Disconnect the high-pressure hose for lift
cylinders.

Tilt socket
pin

207086

4. Removing mast support bearing caps

(1) Mark the bearing caps to ensure the correct
reassembling before removing them.
(2) Remove the cap bolts and lift off the mast
assembly. Lay it down flat on a level floor.

NOTE
Marks
Lay the mast assembly on a floor large enough
to disassemble the parts.

207087

11-6
 MAST AND FORK

Installation

To install, follow the removal sequence in 5

reverse, and service as follows.
6
1. Procedure for mounting mast support bush-
ings 6 and caps 5.
(1) Apply grease to the inner surfaces of caps
and mast support bushings.
(2) Install mast support bushings 6 and caps 5,
making sure that the sides with larger Apply grease
chamfered area face toward the center of Chamfered faces
the vehicle. 203712
(3) Be sure to tighten the support tightening
bolts securely.
1.0 to 1.8 ton 2.0 to 3.5 ton
model model
Bolt tightening
torque 74 (7.5) [54] 178 (18.2) [132]
N·m (kgf·m)
[lbf·ft]

2. Adjust the chain tensions.

(Refer to the Inspection and Adjustment sec-
tion.) Anchor bolt
Tighten the nuts to the specified torque.
2Upper nut
Tightening torque
Unit: N·m (kgf·m) [lbf·ft]

Model 1.0 to 2.5 ton 2.8 to 3.5 ton 3Double nut (upper)
Item model model
1Double nut (lower)
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
102709
Double nut
(lower) 1 98 (10.0) [72.3] 147 (15.0) [108.5]

3. Air bleeding of lift cylinders

Due to internal drain type cylinder, the lift
cylinders do not require air bleeding.

4. After proper operation is confirmed, check

the oil level.

11-7
MAST AND FORK

Removal and Installation

Mast and lift bracket assembly

The following describes the procedures for removing and reinstalling the mast assemblies of dual-
stage full free panoramic mast (Duplex Mast) and triple-stage full free panoramic mast (Triplex Mast).
Note that the triple-stage full free panoramic mast (Triplex Mast) is used as an example.

Triple-stage Full Free Panoramic Mast (Triplex Mast)

2 6 5 4
207611

Sequence

1 Nut 4 High-pressure hose for lift cylinders

2 Fork, lift bracket assembly 5 Mast support cap
3 Tilt socket pin 6 Mast support bushing

Suggestions

1. Removing lift bracket assembly 2

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

207613

11-8
 MAST AND FORK

(2) Position the mast upright. Raise the inner mast

until main rollers 7 of the lift bracket become
free. Then, slowly move the vehicle in reverse
to separate from lift bracket 2.

201735

2. Separating mast and tilt cylinders

(1) Lower the inner mast. Hitch a sling to the
upper cross-member of the outer mast. For
sling attachment, install eye-bolts in the holes
on the right and left sides. Use a crane 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 con-
tract the tilt cylinder rods.
(3) Disconnect high-pressure hose 4 for lift cylin-
ders.

Tilt socket
pin

207086
3. Removing mast support caps 5
(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.

207615

11-9
MAST AND FORK

Installation
5
To install, follow the removal sequence in reverse, 6
and service as follows.

1. Procedure for installing mast support bushings

6 and caps 5
(1) Apply grease to the inner surfaces of caps and
mast support bushings. Apply grease
(2) Install mast support bushings 6 and caps 5, Chamfered faces
making sure that the sides with larger cham- 203712
fered area face toward the center of the vehi-
cle.
(3) Be sure to tighten the support tightening bolts
securely.

1.0 to 1.8 ton 2.0 to 3.5 ton

model model
Bolt tightening
torque N·m 74 (7.5) [54] 178 (18.2) [132]
(kgf·m) [lbf·ft]

2. Adjust the chain tensions.

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

Tightening torque Anchor bolt

Unit: N·m (kgf·m) [lbf·ft]
2Upper nut
Model 1.0 to 2.5 ton 2.8 to 3.5 ton
Item model model
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
Double nut 3Double nut (upper)
(lower) 1 98 (10.0) [72.3] 147 (15.0) [108.5]
1Double nut (lower)
3. Bleeding lift cylinders. 102709
In the dual-stage full free panoramic mast, only the
second lift cylinders are provided with air bleeding
valves.
The other 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.

11-10
 MAST AND FORK

Disassembly and Reassembly

Dual-stage Panoramic Mast (Simplex Mast)
Disassembly

12 10
15
3

11
10

13
9
2
16 17

8
2

6
6

6 14
1 4
5 207347

Disassembly Sequence

1 Nuts 10 Cylinder clamps, Seats, Shims, Cushion,

2 Forks, Lift bracket Collar, Bolts
3 Backrest 11 Bolt, Shims
4 Main roller, Shims 12 Mast strip, Shims
5 Main roller, Shims 13 Main roller, Shims
6 Side roller, Brackets, Shims 14 Main roller, Shims
7 Hose guard 15 Inner mast
8 Lift hose (high pressure), 16 Lift cylinders
Rubber hose, T-joint, Down safety valve 17 Outer mast
9 Snap ring, Chain wheel
Suggestions

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 bot-
tom of outer mast 17, and remove main rollers 13,
14 and mast strips 12.
11-11
MAST AND FORK

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

Inspection after disassembly

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 cross members, shafts and supports for
cracks.
(4) Check the mast support bushings for wear or 207090
other defects.

2. Lift bracket
(1) Check the main rollers and side rollers for
smooth rotation. Inspect each roller for wear
and cracks.
(2) Check the welded portions of the bracket for
cracks.
(3) Check the finger bar for bend or distortion.
A = Assembly standard
5 mm (0.2 in.)
Distortion of finger bar A
maximum
207091

11-12
 MAST AND FORK

3. Lift chains, chain wheels and chain wheel sup-

ports
(1) Measure the length of each chain to make sure
that two chains are equal in length. Also check
the chains for wear, indication of breakage,
link binding and twist.
(2) Check each chain anchor bolt for cracks or
defects on thread.
(3) Check each chain wheel support and chain
wheel for crack or wear. Check that the wheels
rotate smoothly.
Length of lift chain (per 20 links)

A = Assembly standard
B = Repair or service limit Unit: mm (in.)
1 ton 2 ton 3 ton
models models models
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 distor-
tion.
Reassembly

To reassemble, follow the reverse of disassembly

procedure, and service as follows:
1. Longitudinal clearance adjustment between
Clearance
mast and lift bracket
Rollers for mast and lift bracket are available in
three sizes (diameters) for selective use. Select the
size that will provide a longitudinal clearance of 1
mm (0.04 in.) or less. Clearance

Roller sizes
Unit: mm (in.)
Diam of 1 ton 2, 3 ton Lower roller Upper/middle roller
main roller models models 207096
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 (4.60)

11-13
MAST AND FORK

2. Cylinder clamps
Install each lift cylinder in place (in vertical posi-
tion) by fitting to the support, and see if there is
any clearance between the outer mast and cylinder.
Reduce the clearance, if any, to zero by shimming.

Shims

207093

3. Mast supports
(1) Apply grease to the inside surfaces and
grooves of the caps. Mast cap
(2) Install mast support bushings and caps placing Bushing
the chamfered faces inward.
Place wood blocks under mast to apply grease
easily.

Apply grease
Chamfered faces
203712

4. Precautions for installing chain anchor kit

Be careful not to install the center plate in the posi-
tion for link plate.
2
3

4 Stamped mark
207094

1 Link plate (stamped mark on surface)

2 Center plate (no stamped mark)
3 Link
4 Split pin

11-14
 MAST AND FORK

Disassembly and Reassembly

Dual-stage Full Free Panoramic Mast (Duplex Mast)
Disassembly

17

10

16
15 8
14

1 15
11
6
5

6 8
12
A
A
1
4 A 12
2
9 1
3
2
13 13 19

18

7 207607

Disassembly sequence

1 High-pressure hose for first cylinder, 10 Bolt, Washer, Shims

Clamp 11 Mast strip, Shims
2 Bolt, Washer, Shims 12 Main roller, Shims
3 First lift cylinder 13 Stopper cushion, Cushion plate, Shims,
4 Chain guard Bolt, Washer
5 Chain wheel support, Pin 14 Inner mast
6 Chain wheel, Snap ring 15 Second lift cylinder
7 Cylinder guard, Bolt, Washer 16 Cylinder bracket
8 High-pressure hose 17 O-ring, Plug
9 Cushion, Collar, Shims, Bolt, Washer, 18 Mast cap, Bolt, Washer
Clamp 19 Outer mast, Grease nipple

NOTE
The lift bracket disassembly procedure is
the same as for the dual-stage panoramic
mast.

11-15
MAST AND FORK

Preparation

With the lift bracket facing up, place the mast hor-
izontally on wood blocks. Place a wood block as a 3
wedge to prevent the inner and middle masts from
sliding.

Suggestions

1. Removing first lift cylinder 3.

(1) Remove retaining bolts from the first lift
cylinder.
(2) Tie wire ropes on first lift cylinder 3, and gen- 207619
tly remove the cylinder.
Use two wire ropes. Wind or tie ropes secure-
ly to prevent slipping.

2. Removing main rollers 12 and mast strips 11

(1) Remove clamp bolts from the second lift
cylinders.
12
(2) Remove bolts from the upper rod sections of
the second lift cylinders, and place the cylin- 11
ders 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.

3. Removing inner mast 14 12 207620

Using ropes, lift and remove inner mast 14, steer-
ing it clear of the roller shaft sections of outer mast
19.

Inspection after disassembly

Follow the same inspection procedure as for the

dual-stage panoramic mast. 19

14 207621

11-16
 MAST AND FORK

Reassembly

To reinstall, follow the removal sequence in 12

reverse, and service as follows.

1. Main rollers
(1) Adjust the right and left clearances by increas-
ing or decreasing the thickness of shims 12.

207622

(2) When replacing lift bracket main rollers, make

sure clearance A between each roller and mast
surface is 1 mm or less. A

207623

(3) 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.

202263

2. Installing second lift cylinders

When installing second lift cylinders 15, make
sure the cylinders are parallel to the mast to pre-
vent torsional stress on the lift cylinders when the
mast is positioned at the bottom. Adjust the instal- 9
lation positions of lift cylinder brackets 16 with 15
shims 9.

16 207632

11-17
MAST AND FORK

3. Installing first lift cylinder

The first lift cylinder must be installed parallel to
the mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 2, adjust the backward inclination so that

20 mm (0.79 in.)
clearance at section B is 0 to + 0.5 mm (0 to + 0.02
2
in.) larger than clearance at section A.

201752

4. Precaution for installation of chain anchor kit

Do not use center plate in place of link plate.
2
3

4 Stamped mark
207094

1 Link plate (stamped mark on surface)

2 Center plate (no stamped mark)
3 Link
4 Split pin

11-18
 MAST AND FORK

Disassembly and Reassembly

Triple-stage Full Free Panoramic Mast (Triplex Mast)
Disassembly
15
17

9 16
1
15
1
23 19
26
10
28
22 20

24 19
25

12 21
7
6 8
19
8 19
7

27 14
30

5 19
13 29
3
4
2
11 18 207606

Disassembly sequence

1 Hose for first lift cylinder, Clamp, Bolt, 16 Snap ring, Chain wheel
Washer 17 Snap ring, Hose pulley, Shaft,
2 Bolt, Washer Snap ring, Chain wheel
3 Shims 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose, clamp, Bolt, Washer
5 Chain guard 20 Joint, Connector, Bolt, Washer
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, Shims, Bracket
8 Nut (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

11-19
MAST AND FORK

NOTE
The lift bracket disassembly procedure is the
same as for the dual-stage panoramic mast.

Preparation

With the lift bracket facing up, place the mast hor-
izontally on wood blocks. Place a wood block as a
wedge to prevent the inner and middle masts from
sliding.

Suggestions

1. Removing first lift cylinder 4.

(1) Remove retaining bolts from the first lift 4
cylinder.
(2) Tie wire ropes on lift cylinder 4, and gently
remove the cylinder.
Use two wire ropes. Wind or tie ropes secure-
ly to prevent slipping.

207624

2. Removing inner mast and main rollers 12

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

10 207625

3. Removing inner mast

Using ropes, lift and remove the inner mast, steer-
ing it clear of the roller shaft sections of the mid-
dle mast.

12 207626

11-20
 MAST AND FORK

4. Removing main rollers 26, 27 from middle 28

mast 28 and outer mast 30
Remove the bolts that are holding second lift 24 27
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.

30

26 207627

Inspection after disassembly

Follow the same inspection procedure as for the

dual-stage panoramic mast.

Reassembly

To reinstall, follow the removal sequence in

reverse, and service as follows.

1. Main rollers
(1) Adjust the right and left clearances by increas-
ing or decreasing the thickness of shims.
Shims
Main
roller

207630

(2) When replacing lift bracket main rollers, make Outer mast
Middle mast
sure clearance A between each roller and mast Inner mast
surface is 1 mm (0.04 in.) or less.
A

Lift bracket 207629

11-21
MAST AND FORK

(3) To install main rollers on shafts, use a driving

tool. Be careful not to accidentally strike the
outer roller surface with the driving tool.

202263

2. Installing second lift cylinders 24

When installing second lift cylinders 24, make
sure the cylinders are parallel to the mast to pre-
vent torsional stress on the lift cylinders when the
mast is positioned at the bottom. Adjust the instal- 22
lation positions of lift cylinder brackets with shims
24
22.

207631

3. Installing first lift cylinders

The first lift cylinder must be installed parallel to
the mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 3, adjust the backward inclination so that
20 mm (0.79 in.)

clearance at section B is 0 to + 0.5 mm (0 to +

3
0.02 in.) larger than clearance at section A.

A 201752

4. Precautions for installation of chain anchor kit

Do not use center plate in place of link plate.
2
3
1 Link plate (stamped mark on surface)
2 Center plate (no stamped mark)
3 Link
4 Split pin

4 Stamped mark
207094

11-22
 MAST AND FORK

Inspection and Adjustment

Forks
1. Carefully inspect the forks for cracks. Special
attention should be given to the heel section A,
all weld areas and mounting brackets B.
Forks with cracks should be removed from
service. B
Magnetic particle inspection is generally pre- A
ferred due to its sensitivity and the ease of
interpreting the results.

101628

2. Check the difference in height of one fork tip

to the other when mounted on the fork carrier.
A difference in fork tip height can result in
uneven support of the load and cause problems
when loaded.
The maximum allowable difference in fork tip C
elevation C is 5 mm (0.20 in.) for pallet forks.
Replace one or both forks when the difference
in fork tip height exceeds the maximum allow-
able difference. 101629

3. Check the fork blade D. The fork should be

withdrawn from service if the thickness is
reduced to less than the allowable thickness.
Fork blade length may also be reduced by
wear, especially on tapered forks and platens.
Withdraw the forks from service when the D
blade length is no longer adequate for the load
size.
Unit: mm (in.)
101630
Tolerant thickness Standard Limit
GP/DP15K 40 (1.6) 31 (1.2)
GP/DP18K 40 (1.6) 33 (1.3)
GP/DP20K 45 (1.8) 38 (1.5)
GP/DP25K 45 (1.8) 40 (1.6)
GP/DP30K 45 (1.8) 39 (1.53)
GP/DP35K 50 (2.0) 45 (1.8)

11-23
MAST AND FORK

Chain Tension Adjustment

Simplex Mast
NOTE
Follow the same chain tightening procedure Anchor bolt
for all masts except for the Simplex Mast
chains on the lift bracket side.
➁ Upper nut
! WARNING
Turn the engine/main key to the (OFF)
position before making the inspection or
adjustment of lift chains, anchor bolts and
nuts. Place blocks below the forks when ➂ Double nut (upper)
they are lifted.
➀ Double nut (lower)
1. Inspection of Chain Tension 102709
(1) On a level ground, place the mast vertical and
lower the forks to the ground. Check the lift
cylinders are fully retracted.
(2) Raise the forks approx. 100 mm (3.9 in.) from
the ground.
(3) Turn the key to (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 the right and left chains for
even tightness.
2. Adjustment of right and left chain balance 102708
(1) Displace the blocks below the forks.
Turn the key to I (ON) position.
(2) Lower the forks to the ground and tilt forward
until the tips contact with ground. The chains
are slackened to facilitate the adjustment.
(3) Turn the key to (OFF) position.
(4) Loose the double nut (lower) ➀and then upper nut ➁.
(5) Turn the double nut (upper) ➂ to adjust the
chain tension.
(6) Turn the key to I (ON) position, and place the
mast vertical again.
40% or less
(7) Repeat the procedure 1. (2) through (5) to con- 207634
firm the chain tension.
3. Tightening of nuts after the adjustment Tightening Torque
(1) Hold the anchor bolt at two flats with a wrench Unit: N·m (kgf·m) [lbf·ft]
so as not to twist the chain, then tighten the Model 1, 2 ton 3 ton
upper nut ➁ to the specified torque. Item models models
(2) Hold the double nut (upper) ➂ with a wrench
and tighten the double nut (lower) ➀ to the 57 84
specified torque. Upper nut 2 (5.8) (8.6)
[42.0] [62.2]
4. When the lift cylinders are fully extended or 98 147
retracted, check the protrusion of each lift Double nut (10) (15.0)
(lower) 1 [72.3] [108.5]
bracket main roller to be 40 % of the roller
diameter or less.
11-24
 MAST AND FORK

Dual-stage full free panoramic mast

(Duplex Mast)

! WARNING
Turn the engine/main 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) On a level ground, place the mast vertical and
lower the forks to the ground. Check the lift
cylinders are fully retracted.
(2) Raise the forks approx. 100 mm (3.9 in.) from
the ground.
(3) Turn the key to (OFF) position.
(4) Place blocks approx. 90 mm (3.5 in.) high
below the forks.
(5) Push the chains at the middle point between 207633
the chain wheel and chain fixed end on the lift
bracket. Check the right and left chains for
even tighteness.

2. Adjustment of right and left chain balance

(1) Displace the blocks below the forks.
Turn the key to I (ON) position.
(2) Lower the forks to the ground and tilt forward
until the tips contact with ground.
The chains are slackened to facilitate the
adjustment.
(3) Turn the key to (OFF) position.
(4) Fix anchor bolts on the lift bracket.
(5) Turn the double nut (upper) ➂ on the lift 102708
cylinder to adjust the chain tension.
(6) Turn the key to I (ON) position, and place the
mast vertical again.
(7) Repeat the procedure 1. (2) through (5) to
confirm the chain tension.

3. Tightening of nuts after the adjustment

(1) Hold the anchor bolt on the lift cylinder at two
flats with a wrench so as not to twist the chain,
then tighten the upper nut ➁ to the specified
torque.
(2) Hold the double nut (upper) ➂ with a wrench
and tighten the double nut (lower) ➀ to the 40% or less
specified torque.
207818
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.
11-25
MAST AND FORK

Triple-stage full free panoramic mast

(Triplex Mast)

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

1. Inspection of Chain Tension

(1) On a level ground, place the mast vertical and
lower the forks to the ground. Check the lift
cylinders are fully retracted.
(2) Raise the forks approx. 100 mm (3.9 in.) from the
ground.
(3) Turn the key to (OFF) position.
207635
(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 the right and left chains for
even tightness. Adjust the primary and
secondary chains, totally four chains.
2. Adjustment of right and left chain balance
(1) Displace the blocks below the forks.
Turn the key to I (ON) position.
(2) Lower the forks to the ground and tilt forward
until the tips contact with ground.
The chains are slackened to facilitate the
adjustment.
(3) Turn the key to (OFF) position.
(4) Fix anchor bolts on the lift bracket (primary
chains) and under the inner masts (secondary
chains).
(5) Turn the double nut (upper) ➂ on the lift
cylinder to adjust the chain tension. 102708
When the secondary chains are replaced,
adjust their tension relatively tight to reduce
the risk of the interference with piping pulleys.
(6) Turn the key to I (ON) position, and place the
mast vertical again.
(7) Repeat the procedure 1. (2) through (5) to
confirm the chain tension.
3. Tightening of nuts after the adjustment
(1) Hold the anchor bolt on the lift cylinder at two flats
with a wrench so as not to twist the chain, then
tighten the upper nut ➁ to the specified torque.
(2) Hold the double nut (upper) ➂ with a wrench
and tighten the double nut (lower) ➀ to the
specified torque.
4. When the lift cylinders are fully extended or
retracted, check the protrusion of each lift 40% or less
bracket main roller to be 40 % of the roller 207819
diameter or less.
11-26
 MAST AND FORK

Clearance Adjustment on Lift Bracket

NOTE
The adjustment procedure for the lift bracket
is the same for the Simplex Mast, Duplex
Mast and Triplex Mast.

1. Longitudinal clearance adjustment on lift

bracket main rollers F
(1) Raise the forks a little from the floor.
(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.
0.1 to 1.0 mm
Clearance F
(0.004 to 0.039 in.) F 207095

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

oversize rollers. F
Roller sizes
Unit: mm (in.)
Diam. of 1 ton 2, 3 ton
main roller models models
S 99 (3.90) 113.8 (4.48) F
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57) Lower roller Upper/middle roller
LL 102 (4.02) 117 (4.60) 207096

(4) Lift bracket main rollers (upper and center rollers)

The upper rollers should be the same in size or
1-rank larger than the center rollers.
2. Lateral clearance adjustment on lift bracket
main rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its con-
tact point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and
push the lift bracket to one side with a bar. Set
the indicator to zero. 203818
(4) Insert a bar between the inner mast and lift
bracket on the indicator side, and push the lift 1 1
bracket to the opposite side. G1
(5) Read the indicator. 2 2
0.1 to 0.5 mm
Clearance G1
(0.004 to 0.020 in.)

(6) Adjust clearance G1 between the center main

roller and weld plate 2 at the maximum lift
position by increasing or decreasing the thick-
ness of the shim. 202276
Do not install a shim at upper main rolller 1.
11-27
MAST AND FORK

For the lift bracket upper main roller or center

main roller, to extend 0.5 mm (0.02 in.) , insert Inner mast
a 0.5 mm (0.02 in.) shim (a) on the inside and
remove the 0.5 mm (0.02 in.) shim (b) from
Shims (b)
the lower stopper, then tighten the bolts.
>

>
Shims (a)

207156

(7) Lower the lift bracket slightly from the top,

then adjust clearance G2 between the side
roller and mast by increasing or decreasing the G2
thickness of the shims. • •

Side roller
Side roller

202277

Adjust the side roller clearance by adding

shims between the roller bracket and lift
bracket.

Shims
Roller

Bracket
207098

(8) With the lift bracket at the top, adjust clear-

ance G3 with shims.

G3
207158

11-28
 MAST AND FORK

Mast Clearance Adjustment

NOTE
Adjust mast clearances at the locations indi-
cated below.
1. Simplex Mast and Duplex Mast: Main
rollers between the outer mast and inner Shims
mast
2. Triplex Mast: Main rollers between the
outer mast and middle mast, and main
rollers between the middle mast and inner 207157
mast.

1. Longitudinal clearance adjustment on mast

main rollers
(1) Tilt the mast fully backward.
(2) Using feeler gauges, measure the clearance H H
between the inner mast lower roller and outer
mast.
0.1 to 1.0 mm
Clearance H
(0.004 to 0.039 in.)

(3) If the clearance H is out of the specification,

207099
use oversize rollers.
Roller sizes
Unit: mm (in.)
Diam. of 1 ton 2, 3 ton
main roller models models
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 (4.60)

2. Lateral clearance adjustment 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.
J
204886

11-29
MAST AND FORK

(4) Insert a bar between the outer and inner masts

on the indicator side, and push the inner mast
to the opposite side.
(5) Read the indicator.
0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)

J
207101

(6) If the clearance J is out of specification, adjust

by shims.

NOTE
Refer to Main Roller Shim Replacement.
Shims

207102

3. Lateral clearance adjustment 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.
K
(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 the inner mast to the opposite side. 204889
(5) Read the indicator.
0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.) K

207103

11-30
 MAST AND FORK

(6) If the clearance K is out of specification,

adjust it by shims.

NOTE
Refer to Main Roller Shim Replacement.

Shims

207104

Main Roller Shim Replacement (Simplex Mast)

1. Remove the lift bracket from the mast.

NOTE
Refer to REMOVAL AND INSTALLATION,
1. Lift bracket removal.

2. Lower the inner mast below the outer mast as

follows:
(1) Raise the front end of the truck, and support
that end with block or the like.
(2) Remove the upper set bolts from the lift cylin-
ders, and lift the inner mast with a hoist.
Remove the hose guard.
(3) Remove the clamps from the lift cylinders.
Pull the bottom ends of the cylinders from the
outer mast, tilt the cylinders to the center of
the mast, and tie them to the crossmember of
outer mast with rope.
(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 202961
and shims in advance because they are apt to
come off under this condition.

11-31
MAST AND FORK

Procedure for replacing main roller shims

[Dual-stage full free panoramic mast (Duplex
Mast)]

1. Separate the lift bracket from the mast.

NOTE
Refer to "Separating lift bracket" in the
Hydraulic System section.

2. Removing first lift cylinder

(1) Tie a wire rope on the first lift cylinder, and
suspend it with a crane. Wind the rope secure-
ly to prevent slipping.
(2) Remove lift cylinder connecting bolts and
mounting bolts, and gently remove the first lift
cylinder.

NOTE
Subsequent removal procedure is the same as 207619
the removal procedure for the Simplex Mast
(see "Procedure for replacing main roller
shims").

3. Position the inner mast lower than the outer

mast by following operations.
(1) Lift the front side of the vehicle with a rigid
rack or other equipment.
(2) Remove set bolts from the upper sections of
the lift cylinders, then lift the inner mast.
(3) 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. 202961
(4) Lower the inner mast until it contacts the lift
cylinders.
(5) In this condition, main rollers can be removed
from the inner mast and outer mast. Since the
mast strips and shims can fall off, remove
these parts first.

11-32
 MAST AND FORK

Procedure for replacing main roller shims

[Triple-stage full free panoramic mast (Triplex
Mast)]

1. Separate the lift bracket from the mast.

NOTE
Refer to "Separating lift bracket" section in
the Hydraulic System section.

2. Removing first lift cylinder

(1) Tie a wire rope on the first lift cylinder, and
suspend it with a crane. Wind the rope secure-
ly to prevent slipping.
(2) Remove lift cylinder connecting bolts and
mounting bolts, and gently remove the first lift
cylinder.

3. Position the inner mast lower than the middle

mast by following operations. 207616
(1) Lift the front side of the vehicle with a rigid
rack or other equipment.
(2) Tie wire ropes to the upper cross-member of
the inner mast, and suspend with a crane.
(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.
(5) Lower the inner mast until main rollers can be
removed.
(6) Place wood blocks under the inner mast for 207639
support.
(7) In this condition, main rollers can be removed
from the inner mast and outer mast. Since the
mast strips and shims can fall off, remove
these parts first.

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

11-33
MAST AND FORK

4. Position the middle mast lower than the outer

mast by following operations.
(1) Lift the inner mast to the height of the middle
mast, then place wood blocks for support.
(2) Tie wire ropes to both middle mast and inner
mast, and suspend with a crane.
(3) Remove set bolts from the upper sections of
the middle mast lift cylinders, then lift the
middle mast and inner mast.
(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) In this condition, main rollers can be removed
from the inner mast and outer mast. Since the
mast strips and shims can fall off, remove
these parts first.

207640

11-34
 MAST AND FORK

Mast Strip Adjustment

1. Check the clearance L with the clearance

between the outer mast rollers and inner mast L
set to zero (0) in maximum lift position.
0.l to 0.5 mm
Clearance L
(0.004 to 0.020 in.)

200391

2. If the clearance L is out of specification, adjust

it by shims. Shims

NOTE
Refer to Main Roller Shim Replacement.

3. After adjusting the all clearance, move the

mast and lift bracket slowly to make sure that
they move smoothly through their full stroke.

200392

Tilt Angle Adjustment

1. Adjust the tire pressure correctly and park the

truck on a level floor.
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 Bolt
turning the rod. Adjust cylinder so that there is
no difference in stroke tilt angle between the
cylinders, left and right. 207105

NOTE
It is not necessary to adjust the forward tilt angle
if the backward tilt angle is properly adjusted.

Forward - backward tilt angle 6° -10° (standard)

11-35
MAST AND FORK

5. After adjusting the tilt angle, tighten the sock-

et bolts to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 127 to 152
for tilt cylinder (13 to 15.5)
socket bolt [94 to 112]

Lift Cylinder Stroke 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 rolls 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 rolling of the rod with a longer 204698
cylinder stroke.

3. Adjusting method
(1) Raise the inner mast, place blocks under the
left and right sides of the inner mast, and
lower the mast until its rests on the blocks.
(2) Remove the set bolt at the top of lift cylinder
which stopped first, retract the piston rod, and
insert shims at the top of piston rod end.
(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 202983
ensure the piston rods move smoothly and that
the left and right lift cylinders come to the end
of stroke simultaneously.

Bleeding lift cylinders

Set bolt
When air and oil remaining inside the air Shims
chamber of the rod and inside the rod chamber
between the tubes are compressed, they open
the check valve and flow out of the cylinder.
Therefore, there is no need to bleed the lift
cylinders.

200365

11-36
 MAST AND FORK

Troubleshooting
Complaints Possible causes Remedies
Lift bracket and inner mast a) Clearance between lift rollers and side rollers Readjust clearance,
will not move smoothly incorrect see page 11-38
b) Rollers binding on their shafts Relubricate of replace.
c) Lift chains strained in movement Relubricate of replace.
d) Mast strip clearance incorrect Shim adjust.
0.1 to 0.5mm
(0.004 to 0.020 in.)
Lift bracket or inner mast a) Too much clearance on side rollers Readjust by means of
binds shims.
0.1 to 0.5mm
(0.004 to 0.020 in.)
b) Lift chains unequally tensioned Readjust, see page 11-24
c) Shim adjustments unequally made on between Readjust, see page 11-36
left and right lift cylinders (at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts Relubricate of replace.
Load descends (drift) a) Lift cylinder packing damaged Replace.
b) Sliding (inside) surface of lift cylinder tube Replace.
damaged
Retighten or replace,
Whole mast shakes Mast-support bushing or metal worn
see page 11-39
Mast is distorted Off-center loading or overload Replace mast assembly.
Fork tips differ in height a) Finger bar bent Repair or replace.
b) Forks bent Repair or replace.
c) Un-even loading Repair or replace.

Low oil temperature Increase oil temperature

Second lift cylinders
operate while first lift
cylinder is moving.
[Triple-stage full free
panoramic mast]
to 40-50 °C.
Insufficient clearances between lift Readjust rollers.
bracket rollers and sliding surfaces
Clogged pipe Inspect and clean hydraulic
lines.

Insufficient air bleeding Bleed air completely.

Lift bracket is spongy

when it stops in lift- Insufficient air bleeding Bleed air completely.
ing operation.

11-37
MAST AND FORK

Service Data
Simplex Mast A: Assembly standard B: Repair or service limit
Duplex Mast Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
Difference in height between fork tips A 5 (0.20)
GP/DP30K:
125 × 45 ± 0.8
100 × 40 ± 0.8 100 × 45 ± 0.8 (4.92 × 1.8 ± 0.03)
A (3.9 × 1.6 ± 0.03) (3.9 × 1.8 ± 0.03) GP/DP35K:
Forks and chains

125 × 50 ± 0.8
(4.92 × 2.0 ± 0.03)
Thickness of forks (width × thickness)
GP/DP30K:
GP/DP15K: GP/DP20K: 125 × 39
100 × 31 (3.9 × 1.2) 100 × 38 (3.9 × 1.5) (4.92 × 1.53)
B GP/DP18K: GP/DP25K: GP/DP35K:
100 × 33 (3.9 × 1.3) 100 × 40 (3.9 × 1.6) 125 × 45
(4.92 × 1.8)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 100 (3.94) 115 (4.53)
Rollers

Diameter of main roller L A 101 (3.98) 116 (4.57)

LL A 102 (4.02) 117 (4.60)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
(inside to inside) A A 523 (20.59) 575 (22.64)
Distance between middle mast main rollers
(outside to outside) B A 581 (22.87) 639 (25.16)
Distance between lift bracket main rollers
(outside to outside) C1 A 396 (15.60) 437 (17.22)
Distance between lift bracket main rollers
(outside to outside) C2 A 396 (15.60) 437 (17.22)
Distance between lift bracket main rollers
(outside to outside) D A 401 (15.80) 439 (17.30)
Distance between lift bracket side rollers
(outside to outside) E A 406 (16.00) 446 (17.57)
Mast and lift bracket

Longitudinal clearance of lift bracket middle

rollers (with forks slightly lifted) F A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of lift bracket middle
main rollers (fully raised) G1 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket side rollers
(fully raised) G2 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket lower main
rollers (fully raised) G3 A 0.1 to 0.5 (0.004 to 0.020)
Longitudinal clearance of mast main rollers
(in the whole lift range) H A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of middle mast, inner mast
main rollers (fully raised) J A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of outer mast, middle mast
main rollers (fully raised) K A 0.1 to 0.5 (0.004 to 0.020)
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)
Distance between middle mast main roller M A 433 475
(17.06) (18.72)
Distance between inner mast main roller N A 491 539
(19.35) (21.24)
11-38
 MAST AND FORK

Simplex Mast A = Assembly standard

Duplex Mast Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K

F
L
G1

G3

G2
B
F
Inner mast
Lift bracket
A C1
K

H E

J C2

D
Outer mast

207106
Mast support bolts A 74 (7.5) [54] 178 (18.2) [132]
Tightening torque
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
N·m(kgf·m)[lbf·ft] A
Double nut (lower) 1 98 (10) [72.3] 147 (15.0) [108.5]
Distortion of finger bar A 5 (0.2)

Anchor bolt

2 Upper nut

3 Double nut (upper)

1 Double nut (lower)

102709

11-39
MAST AND FORK

Triplex Mast A: Assembly standard B: Repair or service limit

Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
Difference in height between fork tips A 5 (0.20)
GP/DP30K:
125 × 45 ± 0.8
100 × 40 ± 0.8 100 × 45 ± 0.8 (4.92 × 1.8 ± 0.03)
A (3.9 × 1.6 ± 0.03) (3.9 × 1.8 ± 0.03) GP/DP35K:
Forks and chains

125 × 50 ± 0.8
(4.92 × 2.0± 0.03)
Thickness of forks (width × thickness)
GP/DP30K:
GP/DP15K: GP/DP20K: 125 × 39
100 × 31 (3.9 × 1.2) 100 × 38 (3.9 × 1.5) (4.92 × 1.53)
B GP/DP18K: GP/DP25K: GP/DP35K:
100 × 33 (3.9 × 1.3) 100 × 40 (3.9 × 1.6) 125 × 45
(4.92 × 1.8)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 100 (3.94) 115 (4.53)
Rollers

Diameter of main roller

L A 101 (3.98) 116 (4.57)
LL A 102 (4.02) 117 (4.60)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
(inside to inside) A A 523 (20.59) 575 (22.64)
Distance between inner mast main rollers
(outside to outside) B A 581 (22.87) 639 (25.16)
Distance between lift bracket main rollers
(outside to outside) C1 A 485 (19.09) 535 (21.06)
Distance between lift bracket main rollers
(outside to outside) C2 A 487 (19.17) 537 (21.14)
Distance between lift bracket main rollers
(outside to outside) D A 491 (19.33) 539 (21.22)
Distance between lift bracket side rollers
(outside to outside) E A 496 (19.53) 546 (21.50)
Mast and lift bracket

Longitudinal clearance of lift bracket middle

rollers (with forks slightly lifted) F A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of lift bracket middle
main rollers (fully raised) G1 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket side rollers
(fully raised) G2 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket lower main
rollers (fully raised) G3 A 0.1 to 0.5 (0.004 to 0.020)
Longitudinal clearance of mast main rollers
(in the whole lift range) H A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of middle and inner mast
main rollers (fully raised) J A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of outer and middle mast
main rollers (fully raised) K A 0.1 to 0.5 (0.004 to 0.020)
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)
Distance between middle mast main rollers M A 433 (17.06) 475 (18.72)
Distance between inner mast main rollers N A 491 (19.35) 539 (21.24)
11-40
 MAST AND FORK

Triplex Mast A = Assembly standard

Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
F
L
G1

G3
Middle mast
G2
F B
N Lift bracket
Inner mast

K C1

Outer mast E
A
H M J C2
Middle mast K

207644
Mast support bolts A 74 (7.5) [54] 178 (18.2) [132]
Tightening torque
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
N·m (kgf·m) [lbf·ft] A
Double nut (lower) 1 98 (10) [72.3] 147 (15.0) [108.5]
Distortion of finger bar A 5 (0.2)

Anchor bolt

2 Upper nut

3 Double nut (upper)

1 Double nut (lower)

102709

11-41