MAST AND FORKS

Structure ...................................................................................................11 – 1
Simplex Mast (4V40A, 4V45A, 4V50A) .....................................................11 – 1
Duplex Mast (4F40A, 4F45A, 4F50A) .......................................................11 – 2
Triplex Mast (4M40A, 4M45A, 4M50A) ......................................................11 – 3
Removal and Installation ......................................................................11 – 5
Mast and Lift Bracket Assembly ................................................................11 – 5
Disassembly and Reassembly ............................................................ 11 – 11
Simplex Mast ............................................................................................ 11 – 11
Duplex Mast .............................................................................................. 11 – 13
Triplex Mast .............................................................................................. 11 – 15
Inspection and Adjustment ................................................................. 11 – 26
Forks ........................................................................................................ 11 – 26
Chain Tension Inspection and Adjustment ................................................ 11 – 27
Simplex Mast ......................................................................................... 11 – 27
Duplex Mast and Triplex Mast ................................................................ 11 – 28
Chain, Chain Wheel Support and Chain Wheel ..................................... 11 – 28
Checking Clearance between Lift Bracket Roller and Inner Mast .......... 11 – 29
Checking Clearance for Mast Roller ...................................................... 11 – 31
Mast Strip Clearance, Inspection and Adjustment ..................................... 11 – 37
Tilt Angle Adjustment ................................................................................ 11 – 37
Lift Cylinder Stroke Inspection and Adjustment ......................................... 11 – 38
11
Troubleshooting ...................................................................................... 11 – 39
Service Data ............................................................................................ 11 – 40
 MAST AND FORKS

Structure

Simplex Mast (4V40A, 4V45A, 4V50A)

D D 9

1 15

2 4

6 16

C C 10

14

B B 10
11
3
11
7
A
A 13

13 12 208720

208721

1 Outer mast 7 Fork 12 Main roller (inner mast lower)

2 Inner mast 8 Mast strip 13 Main roller (lift bracket lower)
3 Lift bracket 9 Main roller (mast upper) 14 Side roller
4 Lift cylinder 10 Main roller (lift bracket upper) 15 Chain wheel
5 Lift chain 11 Main roller (lift bracket middle) 16 Tilt cylinder
6 Backrest

11-1
MAST AND FORKS

Duplex Mast (4F40A, 4F45A, 4F50A)

208722

208721A

1 Outer mast 7 Backrest 12 Main roller (lift bracket upper)

2 Inner mast 8 Fork 13 Main roller (outer mast upper)
3 Lift bracket 9 Chain wheel 14 Main roller (lift bracket middle)
4 First lift cylinder 10 Side roller 15 Main roller (lift bracket lower)
5 Second lift cylinder 11 Mast strip 16 Main roller (inner mast lower)
6 Lift chain

11-2
 MAST AND FORKS

Triplex Mast (4M40A, 4M45A, 4M50A)

208724

208725

1 Outer mast 8 Backrest 14 Main roller (outer mast upper)

2 Middle mast 9 Fork 15 Main roller (middle mast upper)
3 Inner mast 10 Chain wheel 16 Main roller (lift bracket middle)
4 Lift bracket 11 Side roller 17 Main roller (lift bracket lower)
5 First lift cylinder 12 Mast strip 18 Main roller (middle mast lower)
6 Second lift cylinder 13 Main roller (lift bracket upper) 19 Main roller (inner mast lower)
7 Lift chain

11-3
MAST AND FORKS

Operation of Duplex Mast

203598

Operation of Triplex Mast

203600

11-4
 MAST AND FORKS

Removal and Installation

Mast and Lift Bracket Assembly

Simplex Mast Removal

208726

Sequence
1 Nuts 5 High-pressure hose for lift cylinder
2 Fork, Lift bracket, Backrest 6 Mast support bearing cap, Bolt, Washer
3 Tilt socket pin, Bolt, Washer, Spacer 7 Bushing
4 Tilt cylinder

Suggestions for Removal

1. Removing lift bracket 2

(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 FORKS

2. Separating mast and tilt cylinders 4

(1) Hitch a sling to the upper cross-member of the outer
and inner masts, then lift with a hoist.

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

206939

(2) Place wood blocks under the tilt cylinder mounting

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

207086A

3. Disconnecting high-pressure hoses for lift cylinder

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

4. Removing mast support bearing caps 6

(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
Lay the mast assembly on a floor large enough to
disassemble the parts.
207087A

11-6
 MAST AND FORKS

Weight of main parts [Simplex mast, lifting height 3.0

m (9.8 ft)]
Unit: kg (lbs)
Mast Models
Item 4V40A 4V45A 4V50A

Outer mast 340 380 380

(749.6) (837.7) (837.7)
Inner mast 220 260 260
(485.0) (573.2) (573.2)
Lift bracket 260 265 310
(incl. backrest) (573.2) (584.2) (683.4)
Fork (two), standard 180 180 260
(396.8) (396.8) (573.2)
Lift cylinder (two) 80 90 90
(176.4) (198.4) (198.4)
Total (incl. other parts) 1080 1190 1320
(2381.0) (2623.5) (2910.1)

Installation
To install, follow the removal sequence in reverse, and
service as follows.
1. Procedure for mounting mast support bushings 7 and
caps 6
(1) Apply grease to the inner surfaces of caps and
mast support bushings.
(2) Install mast support bushings 7 and caps 6,
making sure that the sides with larger chamfered
area face toward the center of the truck.
203712
(3) Be sure to tighten the support tightening bolts
securely.
Unit: N·m (kgf·m) [lbf·ft]
Mast Models
4V40A thru 4V50A
Item

Bolt tightening torque 290 (29.6) [214]

2. Adjust the chain tensions. (Refer to the “Chain Tension

Adjustment” on page 11-27.)

3. Air bleeding of lift cylinders

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

4. After proper operation is confirmed, check the oil level.

11-7
MAST AND FORKS

Mast and Lift Bracket Assembly

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

208727

Sequence
1 Nuts 5 High-pressure hose for lift cylinders
2 Fork, Lift bracket, Backrest 6 Mast support bearing cap, Bolt, Washer
3 Tilt socket pin, Bolt, Washer, Spacer 7 Mast support bushing
4 Tilt cylinder

Suggestions for Removal

1. Removing lift bracket 2

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

207613

11-8
 MAST AND FORKS

(2) Tilt the mast back to the vertical position. Raise the
inner mast until main rollers 8 of the lift bracket
become free. Then, back the truck away, from the 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, middle
and inner masts, then lift with a hoist.

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

207796

(2) Place wood blocks under the tilt cylinder mounting

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

3. Disconnecting high-pressure hose for lift cylinder

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

207086A

4. Removing mast support caps 6

(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.

207615

11-9
MAST AND FORKS

Installation
To install, follow the removal sequence in reverse, and
service as follows.
1. Procedure for installing mast support bushings 7 and
caps 6
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings 7 and caps 6, making sure
that the sides with larger chamfered area face toward
the center of the vehicle. 203712
(3) Be sure to tighten the support tightening bolts securely.

Unit: N·m (kgf·m) [lbf·ft]

Mast Models 4F40A thru 4F50A (Duplex),
Item 4M40A thru 4M50A (Triplex)

Bolt tightening torque 290 (29.6) [214]

2. Adjust the chain tensions. (Refer to the “Chain Tension

Adjustment” on page 11-27.) Tighten the nuts to the
specified torque.

3. Bleeding lift 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.
In the triplex mast, start the engine, raise and lower the lift
bracket with several strokes to bleed the cylinder.

4. After proper operation is confirmed, check the oil level.

11-10
 MAST AND FORKS

Disassembly and Reassembly

Simplex Mast
Disassembly

12 10
15
3 11

9 13 10
2
17
16
5

8 7

6
14
1 4 208728

Sequence
1 Nuts 10 Cylinder clamps, Seats, Shims, Cushion,
2 Forks, Lift bracket Collar, Bolts
3 Backrest 11 Bolt, Shims
4 Main roller, Roller stopper, Bolt, Shim 12 Mast strip, Shims
(lift bracket middle roller) 13 Main roller, Roller stopper, Bolt, Shim
5 Main roller, Snap ring (lift bracket upper roller) (outer mast roller)
6 Side roller, Side roller bracket, Shim 14 Main roller, Roller stopper, Bolt, Shim
(mounted on lift bracket) (inner mast roller)
7 Lift hose (high pressure), Rubber hose, T-joint, 15 Inner mast
Down safety valve 16 Lift cylinders
8 Lift chain 17 Outer mast
9 Snap ring, Chain wheel

Start by: Suggestions for Disassembly

Before disassembling the mast and fork assembly,
1. Removing mast strips and main rollers
measure and record all clearances between each lift
bracket and roller and between each mast and roller. Remove bolts 10, 11 to free lift cylinder 16. Displace
Recorded measurements will be helpful when the tops of the two lift cylinders from inner mast 15.
replacing rollers or selecting shims to adjust Slide inner mast 15 toward the bottom of outer mast
clearances. Refer to pages 11-28 through 11-32. 17, and remove main rollers 13, 14 and mast strips 12.
11-11
MAST AND FORKS

2. Inner mast removal

After removing the main rollers, hitch a sling to the inner
mast cross-member 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.

206944

11-12
 MAST AND FORKS

Duplex Mast
Disassembly

207807A

Sequence
1 Hose clamp, Bolt, Washer 12 Mast strip, Shims
2 High-pressure hose (First lift cylinder) 13 Stopper, Shim, Bolt, Washer
3 Bolt, Washer, Shims 14 Main roller, Shims
4 First lift cylinder 15 Inner mast
5 Chain guard, Bolt 16 Second lift cylinder
6 Chain wheel, Snap ring 17 Down safety valve, O-ring
7 Chain wheel support, Bolt, Washer 18 Elbows, O-rings
8 Down safety valve, O-ring 19 Cylinder bracket
9 High-pressure hose (Second lift cylinder), 20 Mast support bearing cap, Bolt, Washer
Connector 21 Mast support bushing
10 Cushion, Collar, Shim, Bolt, Washer, Clamp 22 Outer mast, Grease nipple
11 Bolt, Washer, Shims

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

11-13
MAST AND FORKS

Start by:
(1) With the lift bracket 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.
(2) 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 11-28 through 11-32. 207006

Suggestions for Disassembly

1. Removing first lift cylinder 4

(1) Remove retaining bolts 3 from the first lift cylinder.
(2) Hitch slings on first lift cylinder 4, and gently remove
the cylinder.
Use two slings. Wind or tie slings securely to prevent
slipping.

2. Removing second lift cylinders 16

(1) Remove clamps and bolts 10 from the second lift
cylinders.
(2) Remove bolts 11 from the upper rod sections of the
second lift cylinders. Remove the second lift cylinders
from the mast and place them on a suitable surface. In
the illustration, the cylinder is shown together with the
outer mast.
(3) Check the number of shims 11 and the shim thickness
at the rod end sections.

3. Removing main rollers 14 and mast strips 12

Slide the inner mast down, then remove main rollers 14, 207007
mast strips and shims 12.

4. Removing inner mast 15

Using slings, lift and remove inner mast 15, steering it clear
of the roller shaft sections of outer mast 22.

207008

11-14
 MAST AND FORKS

Triplex Mast
Disassembly

208723

Sequence
1 Hose for first lift cylinder, Clamp, Bolt, 16 Lift chain (for second lift cylinder)
Washer 17 Chain guard, Bolt
2 Bolt, Washer 18 Snap ring, Chain wheel
3 Shims 19 Hose, Band
4 First lift cylinder 20 Joint, Connector, Bolt, Washer
5 Stopper bolt, Washer 21 Bolt, Seat, Cushion, Collar
6 Chain wheel support 22 Cushion, Shims, Bracket
7 Chain guard, Plug 23 Bolt, Washer, Shims
8 Snap ring, Chain wheel 24 Second lift cylinder
9 Pulley bracket, Pulley, Bar, Bolt 25 Mast strip, Shims
10 Nut (chain for second lift cylinder) 26 Stopper, Shim, Bolt, Washer
11 Mast strip, Shims 27 Main roller, Shims
12 Stopper, Shim, Bolt, Washer 28 Middle mast
13 Main roller, Shims 29 Cap, Bolt, Washer
14 Inner mast 30 Mast support bushing
15 Nuts 31 Outer mast

11-15
MAST AND FORKS

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

Start by:
(1) With the lift bracket 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.
(2) 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 11-28 through 11-32.

Suggestions for Disassembly

1. Removing first lift cylinder 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.

207811

2. Removing inner mast and main rollers

Lower inner mast 14 until the main rollers can be removed.
Remove main rollers 12, 13 and mast strips 11.

207812

11-16
 MAST AND FORKS

3. Removing inner mast

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

207813

4. Removing second lift cylinder 24, main rollers 27

from middle mast 28 and outer mast 31
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 27 can be removed. Then,
remove the main rollers.

207814

11-17
MAST AND FORKS

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 cross-
members, shafts and supports for cracks.
(4) Check the mast support bushings for wear or other
defects. 206945

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 (0.2), maximum 207091

3. Lift chains, chain wheels and chain wheel supports

(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.

A: Standard value B: Repair or service limit

Unit: mm (in)
Mast model 4V40A, 4V45A/50A,
4F40A, 4F45A/50A,
Item 4M40A 4M45A/50A

A 508 (20) 635 (25)

Length of lift chain
(per 20 links)
B 523 (20.6) 654 (25.7)

4. Mast strips
Check the mast strips for damage, wear or distortion.

11-18
 MAST AND FORKS

Reassembly
Follow the disassembly sequence in reverse. Be careful with the following key point.
Suggestions for Reassembly
1. Installing lift bracket rollers (all mast models)

208729

Sequence
1 Lift bracket upper roller F: Clearance between roller circumference and
2 Lift bracket middle roller inner mast thrust surface (back-to-front play)
3 Lift bracket lower roller G: Clearance between roller side surface and
4 Side roller inner mast thrust surface (right-to-left play)
5 Lift bracket 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 and
G 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 F 1.0 mm (0.04 in.) or less

• Clearance G is used for determining the correct amount

of shims at the bearing seat.

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

11-19
MAST AND FORKS

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

Note: Always use S-size rollers for the two middle Unit: mm (in.)
rollers. Mast Models 4V40A, 4V45A/50A,
• As for upper roller 1 and lower roller 3, take 4F40A, 4F45A/50A,
Item 4M40A 4M45A/50A
measurements of clearance F. Based on the value, select
rollers of the appropriate size from the table. S 117 (4.60) 129 (5.08)
• Rollers should rotate smoothly when installed. Diameter of M 118 (4.64) 130 (5.12)
main roller
(2) Measuring and adjusting right-to-left clearance G at lift
L 119 (4.68) 131 (5.16)
bracket middle and lower rollers
• Measurement
Move lift bracket to the top of the inner mast and press Lift bracket middle/lower roller
the bracket to either the leftmost or rightmost position.
Take measurements of clearance G between the side
surface of roller and inner mast.
• Adjustment
If clearance G is excessive, a proper amount of shims
should be added at location A and the same amount of
shims should be removed from location B, theoretically.
However, shims for location A are available in only three
sizes: 0.5 mm (0.02 in), 1.0 mm (0.04 in), and 2.0 mm
(0.08 in). Shims for location B are available in only one
size: 1.0 mm (0.04 in).
When a 0.5 mm (0.02 in.) thick shim is added at location
A, there is no smaller shim to replace the shim at location
B. Therefore, it is not necessary to remove the shim from 208730
location B [the 0.5 mm (0.02 in.) difference can be
ignored].
Note: It is not necessary to adjust the lift bracket upper
roller with shims.
(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
(4) Measuring and adjusting clearance G1 between side
roller and inner mast Side roller
• Measurement
Move side roller to the upper end of the inner mast and
press the lift bracket to either the leftmost or rightmost
position. Take measurement of clearance G1 between
the roller circumference and inner mast.
• Adjustment
Move lift bracket to the top of the inner mast and press
the bracket to either the leftmost or rightmost position.
Take measurements of clearance G1 between the rollers’
208731
side surface and inner mast.
11-20
 MAST AND FORKS

2. Installing mast rollers (all mast models)

Triplex mast
Mast rollers are identical in shape and size with lift bracket
lower rollers.
Therefore:
• Clearance F should be 1.0 mm (0.04 in) or less.
• Clearance G should be 0.1 to 0.5 mm (0.004 to 0.020 in).
For mast rollers, both clearances F and G should meet
specifications.
(1) Select appropriate roller size. Refer to “Selecting main 208732
rollers of the appropriate diameter” on page 11-20. Outer mast roller and middle mast upper roller
(2) Adjust to proper clearance. Refer to “Measuring and
adjusting right-to-left clearance G at lift bracket middle
Triplex mast
and lower rollers” on page 11-20.
(3) The installation procedure and precautions are same as
those for the lift bracket main rollers.

208733A

Lift bracket, middle mast lower roller and

inner mast roller

3. Measuring and adjusting clearance G2 between

mast strip and inner mast (all mast models)
• Measurement
Make a clearance between the mast strip and inner mast.
Insert a thickness gage to measure the clearance G2.

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

• Adjustment
If clearance G2 is excessive, add a proper amount of
shims under the mast strip. Usually, a 1.0 mm (0.04 in)
thick shim is already used.

208734

11-21
MAST AND FORKS

4. Installing first lift cylinder (duplex mast and triplex

mast models)
Adjust with shims so that the first lift cylinder becomes
vertical when it is installed and placed at the lowered
position.
• Usually, a 1.0 mm (0.04 in) thick shim is already used.
• Adjustment shims are 1.0 mm (0.04 in) thick.
• Forward inclination is undesirable. It should be rather
inclined rearward.
208735

5. Installing second lift cylinders (all mast models)

(1) Install cylinder bracket on lift cylinder.
(2) Install lift cylinder between outer mast and inner mast.
(3) Attach the upper part of the cylinder rod to the
appropriate position on the inner mast. If shim A was
removed during disassembly, install shim A. Usually,
shim A is not used.

206974A

(4) With the cylinder rod fully retracted, take measurement

of clearance H.

Clearance H 1.6 mm (0.063 in) or less

If the clearance H is excessive, add shim B to adjust.

Usually, shim A is not used.
1.6 mm (0.063 in) thick shims are available as service
parts. 207003A
(5) After reassembly, perform an operation test to check if
the stroke of the left and right cylinders is the same. For
check procedure, refer to page 11-38.

11-22
 MAST AND FORKS

6. Installing chain on lift bracket

1 2 3 4 5

Link plate Link

Sprit pin

B B
Stamped Center plate
mark
A A A A

208736

1 Mast model 4V40A (simplex) 4 Mast model 4M40A, 45A, 50A (triplex), first chain
2 Mast model 4V45A, 50A (simplex) 5 Mast model 4M40A, 45A, 50A (triplex), second
3 Mast model 4F40A, 45A, 50A (duplex) chain

(1) 4V40A only (Illustration 1 )

Be careful not to install the center plate in the position
for link plate.
(2) Other models (Illustration 2 through 5 )
Tighten nuts to torques specified in the table.
(3) Install chain on the lift bracket first. Then place the Unit: N·m (kgf·m) [lbf·ft]
chain around the chain wheel and install on the cylinder Mast 4V45A/50A,
side. Adjust the tension of the chain with the anchor Model 4F40A, 4M40A 4F45A/50A,
bolt nuts at the cylinder side. 4M45A/50A
Item
For adjustment procedure, refer to page 11-27.
Nut A 147 +− 490 (15 +− 5.0
0 ) 176 +− 490 (18 +− 5.0
0 )
(4) If either of the anchor bolts at both ends of the chain [108 +− 360 ] [130 +− 360 ]
assembly is damaged, anchor kits are available as
service parts. +0 +0 +0
Nut B 103 (10.5
− 19.6 − 2.0 ) 139 (14.2 +− 02.0 )
− 19.6

[75 +− 014.0 ] [103 +− 014.0 ]

11-23
MAST AND FORKS

7. Installing hydraulic lines

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

(1) Hydraulic lines in simplex mast models (2) Hydraulic lines in triplex mast models

Lift cylinder C

B C
A C
Flow
C regulator
valve First
cylinder
B C

A C
Lift cylinder

Second
B cylinder C

208737 B
C A
Flow
Tightening torques regulator valve
Unit: N·m (kgf·m) [lbf·ft]
B
Part to be tightened Tightening torque
A C
Nut A 98.1 ± 9.8 (10 ± 1.0) [72.3 ± 7]
Second
Nut B 58.8 (6.0) [43.4] cylinder

Nut C 58.8 (6.0) [43.4] B

208738

Installation of a fitting with straight threads and

O-ring seal
1. Turn lock nut 3 to move it as close to fitting body 2 as
possible. Place washer 4 and O-ring seal 5 against the
lock nut.
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. Elbow body assembly
4. Tighten lock nut 3 to the specified torque. 1 End of fitting body 4 Backup washer
(connects to tube) 5 O-ring seal
2 Fitting body 6 End of fitting that
3 Locknut goes into other part.
11-24
 MAST AND FORKS

(3) Hydraulic lines in duplex mast models

D C

Second cylinder
E

B C
A

Flow
regulator
C Second
valve
cylinder

B
C
A

C C
C B

First cylinder C
208739

Tightening torques
Unit: N·m (kgf·m) [lbf·ft]
Part to be tightened Tightening torque
Nut A 98.1 ± 9.8 (10 ± 1.0) [72.3 ± 7]
Nut B 58.8 (6.0) [43.4]
Nut C 58.8 (6.0) [43.4]
Nut D 118 (12) [86.8]
Plug E 118 (12) [86.8]

NOTE

When installing fittings B and D , follow the

procedure under “Installation of a fitting with straight
threads and O-ring seal” on page 11-24.

11-25
MAST AND FORKS

Inspection and Adjustment

The inspection and adjustment procedures described in the

following pages can be carried out without performing
major service work. These can be used for checking
abnormalities or testing operation after disassembly and
reassembly.

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 preferred due A
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
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 allowable difference. 101629

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

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. Remove the
forks from service when the blade length is no longer
adequate for the load size.
A: Standard value B: Repair or service limit 101630
Unit: mm (in.)
Truck
Models GP40K GP40KL GP45K GP50K
DP40K DP40KL DP45K DP50K
Item

A 50 (2) 60 (2.4)
Fork
thickness
B 45 (1.77) 48 (1.9) 55 (2.2)

11-26
 MAST AND FORKS

Chain Tension Inspection and Adjustment

Simplex 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) Place the mast vertical on a level ground, then lower the
forks to the ground. Check that the lift cylinders are
fully retracted. 102709

(2) Raise the forks approx. 100 mm (4.0 in.) from the
ground. Tightening torque
(3) Turn the key to the (OFF) position. Unit: N·m (kgf·m) [lbf·ft]
(4) Place blocks approx. 90 mm (3.5 in.) high below the Mast model 4V40A, 4V45A/50A,
forks. 4F40A, 4F45A/50A,
(5) Push the chains at the middle point between the chain Item 4M40A 4M45A/50A
+0 +0
wheel and chains fixed end on the lift bracket. Check 103 −+19.6 139 −+19.6
Upper nut ➁
0 0
the right and left chains for even tightness. (10.5 − 2.0 ) (14.2 − 2.0 )
+0 +0
[75 − 14 ] [103 − 14 ]
2. Adjustment of right and left chain balance
+ 49 + 49
(1) Remove the blocks below the forks. 147 − 0 176 − 0
Double nut lower ➀
+ 5.0 + 5.0

Turn the key to I (ON) position. (15 − 0 ) (18 − 0 )

+ 36 + 36
[108 − 0 ] [130 − 0 ]
(2) Lower the forks to the ground and tilt forward until the
tips come in contact with the ground.
The chains are now slack to facilitate the adjustment.
(3) Turn the key to the (OFF) position.
(4) Loosen double nut (lower) ➀, then upper nut ➁.
(5) Turn double nut (upper) ➂ to adjust the chain tension.
(6) Turn the key to the I (ON) position, and place the mast
vertical again.
(7) Repeat (2) through (5) of procedure 1, to check the 102708
chain tension.

3. Tightening of nuts after adjustment

(1) Hold the anchor bolt 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 double nut (lower) ➀ 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. 207818

11-27
MAST AND FORKS

Duplex Mast and Triplex Mast

Duplex mast Triplex mast

207633 207635

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.
(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 A: Standard value B: Repair or service limit
page 11-23. Mast model 4V40A, 4V45A/50A,
4F40A, 4F45A/50A,
NOTE Item 4M40A 4M45A/50A
To lubricate lift chains, molybdenum disulfide oil
A 508 (20) 635 (25)
(spray type) is recommended since it is easy to use and Chain extension
provides long lubrication. mm (in.)/20 links
B 523 (20.6) 654 (25.7)
Super chain guard oil: 9101M-00150

11-28
 MAST AND FORKS

Checking Clearance between Lift Bracket

Roller and Inner Mast
NOTE
Lift bracket middle roller
• The check procedure for the lift bracket is the same
for the Simplex mast, Duplex mast and Triplex
mast.

For the lift bracket to move smoothly, it is essential that the

following three clearances are within the specified ranges.
(1) Clearance F between main roller circumference and
mast thrust surface a
Clearance F 1.0 mm (0.04 in.) or less

(2) Clearance G between roller side surface and mast thrust

208730A
surface b
Clearance G 0.1 to 0.5 mm (0.004 to 0.020 in.) Typical example of relation between main roller and
inner mast
(3) Clearance G1 between side roller circumference and *: Only the middle roller requires clearance to the
mast side roller thrust surface thrust plate.
Clearance G1 0.1 to 0.5 mm (0.004 to 0.020 in.)

Necessity of clearance check for lift bracket rollers

Clearance
Clearance F Clearance G
Roller

Upper roller require **not require

Middle roller ***

not require require
208731A
Lower roller require require
Relation between side roller and inner mast
**: Not necessary to adjust. Roller structure allows no
shim adjustment.
***: Always use S-size rollers.

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

rollers
(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. 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 11-19 and 11-20.
11-29
MAST AND FORKS

2. Right-to-left clearance check 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 contact
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.
(4) Insert a bar between the inner mast and lift bracket on
203818
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
and thrust plate ➁.
(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 11-20. 207821

➀ Upper roller ➁ Thrust plate

(7) Lower the lift bracket slightly from the top, then check
clearance G1 between the side roller.
If clearance G1 is out of specification, it is necessary to
add shims to the seat of the roller bracket to adjust to
correct clearance. Remove lift bracket from mast and
adjust the shim thickness. For adjustment and
installation procedures, refer to “Installing lift bracket
rollers” on page 11-19.

206687A

(8) With the lift bracket at the top, check clearance G.

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
installation procedures, refer to “Installing lift bracket
rollers” on page 11-19.

NOTE
The lower main rollers are the same to the middle
main rollers in construction. 207822

11-30
 MAST AND FORKS

Checking Clearance for Mast Roller

NOTE
• Adjust mast clearances at the locations indicated
below.
1. Simplex mast and Duplex mast: Main rollers
between the outer mast and inner mast
2. Triplex mast: Main rollers between the outer
mast and middle mast, and main rollers between
the middle mast and inner mast.
• For the structure, refer to “Installing mast rollers”
on page 11-21.

Regardless of the mast model, the inner mast slides up and

Triplex mast
down guided by the outer mast. Mast rollers are provided
for smooth movement and clearances at two locations must
be within specified ranges.
(1) Clearance F between main roller circumference and
mast thrust surface a
Unit: mm (in.)
Clearance F 1.0 (0.04) or less

(2) Clearance G between roller side surface and mast 208733

channel surface b
Unit: mm (in.) Lift bracket, middle mast lower roller and inner
mast roller
Clearance G 0.1 to 0.5 (0.004 to 0.020)

Check clearances between the mast rollers and mast

channels as follows:

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

rollers
F
(1) Tilt the mast fully backward.
(2) Using feeler gauges, measure the clearance F between
the inner mast lower roller and outer mast.
(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 11-21. For
207099
mast roller removal procedure, refer to “Removing mast
rollers” on page 11-33.

11-31
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
204886
indicator side, and push the inner mast to the opposite
side.
(5) Read the indicator.
This reading is the clearance G between inner mast
roller and outer mast.
(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,
refer to “Installing mast rollers” on page 11-21. For
mast roller removal procedure, refer to “Removing mast
rollers” on page 11-33.

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
roller and inner mast.
(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 rollers”
on page 11-21. For mast roller removal procedure,
refer to “Removing mast rollers” on page 11-33.

11-32
 MAST AND FORKS

Removing mast rollers (simplex mast)

1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 11-5.

2. Lower the inner mast below the outer mast 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 cylinders, and
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.
(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
202961
condition.

11-33
MAST AND FORKS

Removing mast rollers (duplex mast)

1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 11-8.

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.

207824

3. Position the inner mast lower than the outer mast by

following operations.
(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 cylinders, and
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.

11-34
 MAST AND FORKS

Removing mast rollers (triplex mast)

1. Separate the lift bracket from the mast.

NOTE
For lift bracket separating procedure, refer to
“Removing lift bracket” on page 11-8.

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.

First lift
cylinder

207787

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

following operations.
(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 crane.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
207826
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 support.
(7) 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.

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

11-35
MAST AND FORKS

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) Hitch slings 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) 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.

207827

11-36
 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
maximum lift position.
Unit: mm (in.)
Clearance G2 0.1 to 0.5 (0.004 to 0.020)

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 200391

procedure, refer to “Measuring and adjusting clearance

G2 between mast strip and inner mast” on page 11-21.
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. 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 turning the rod.
Adjust cylinder so that there is no difference in stroke
tilt angle between the cylinders, right and left. 207828

NOTE Standard tilt angle

It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted. Forward Backward
Mast Models

Simplex less than 6° 10°

mast, 4.5 m (14.8 ft)
5. After adjusting the tilt angle, tighten the socket bolts to lifting
the specified torque. height more than 6° 6°
4.5 m (14.8 ft)

262 ± 13 N·m Duplex mast 6° 12°

Tightening torque for tilt
(27 ± 1.4 kgf·m) Triplex mast 6° 6°
cylinder socket bolt
[195 ± 10 lbf·ft]

11-37
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
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 ensure the
piston rods move smoothly and that the left and right
lift cylinders come to the end of stroke simultaneously.

206974

11-38
 MAST AND FORKS

Troubleshooting
a) Clearance between lift rollers and side rollers Readjust clearance.
incorrect
Lift bracket and
inner mast will not b) Rollers binding on their shafts Relubricate of replace.
move smoothly 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.)
a) Too much clearance on side rollers Readjust by means of shims.
0.1 to 0.5mm
Lift bracket or (0.004 to 0.020 in.)
inner mast binds
b) Lift chains unequally tensioned Readjust.
c) Shim adjustments unequally made on between left Readjust.
and right lift cylinders (at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts Relubricate of replace.

Load descends a) Lift cylinder packing damaged Replace.

(drift) b) Sliding (inside) surface of lift cylinder tube Replace.
damaged
Whole mast shakes Mast-support bushing or metal worn Retighten or replace.

Mast is distorted Off-center loading or overload Replace mast assembly.

a) Finger bar bent Repair or replace.

Fork tips differ in
b) Forks bent Repair or replace.
height
c) Un-even loading Repair or replace.

Low oil temperature Increase oil temperature to

40 to 50 °C (104 to 122 °F).
Second lift
cylinders operate Insufficient clearances between lift bracket rollers and Readjust rollers.
while first lift sliding surfaces
cylinder is moving. Clogged pipe Inspect and clean hydraulic
(Triplex mast)
lines.
Insufficient air bleeding Bleed air completely.

Lift bracket is
spongy when it
Insufficient air bleeding Bleed air completely.
stops in lifting
operation.

11-39
MAST AND FORKS

Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model GP40K, GP40KL GP45K GP50K
Item DP40K, DP40KL DP45K DP50K
Gap of fork end heights A 5 (0.2) or less
A 50 (2.0) 60 (2.4)
Fork thickness
B 45 (1.77) 48 (1.9) 55 (2.2)
Forks and A 508 (20) 635 (25)
chains Chain extension (mm/20 links)
B 523 (20.6) 654 (25.7)
Tightening torque of lock nut (double nut) for 147 +− 49
0 176 +− 49
0
+5 +5
chain anchor bolts (both ends) A (15 − 0 ) (18 − 0 )
+ 36 + 36
N·m (kgf·m) [lbf·ft] [108 − 0 ] [130 − 0 ]
M A 118 (4.64) 130 (5.12)
Main roller external diameter
L A 119 (4.68) 131 (5.16)
Rollers (for lift bracket and mast)
S A 117 (4.60) 129 (5.08)
Side roller external diameter A 52 (2.05)
Width of outer mast B A 780 (30.7)
Simplex mast and
Width of inner mast B2 A 666 (26.2) 656 (25.8)
duplex mast
Dimensions Width of lift bracket C A 534 (21.0) 522 (20.5)
(for Width of outer mast B A 780 (30.7)
reference)
Width of middle mast B1 A 666 (26.2) 656 (25.8)
Triplex mast
Width of inner mast B2 A 554 (21.8) 536 (21.1)
Width of lift bracket C A 422 (16.6) 402 (15.8)
Clearance between main roller
A 1.0 (0.04) or less
circumference and mast thrust surface F

Mast Clearance between main roller side

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 and lower
Clearance roller circumference and inner mast A 1.0 (0.04) or less
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
Finger bar bend A 5 (0.2) or less
Tightening torque of mast cap mounting bolt
A 290 (29.6) [214]
N·m (kgf·m) [lbf·ft]

11-40
 MAST AND FORKS

Truck Model GP40K, GP40KL GP45K GP50K

Item DP40K, DP40KL DP45K DP50K

208742

11-41