11-1

MAST
Page
V MAST ASSY ................................................................. 11-2
COMPONENTS ................................................................ 11-2
REMOVAL•INSTALLATION ............................................... 11-6
REMOVAL• INSTALLATION (W/LIFT BRACKET) .............. 11-9
MAST DISASSEMBLY•INSPECTION •REASSEMBLY ........ 11-11
LIFT BRACKET DISASSEMBLY• INSPECTION •
REASSEMBLY ............................................................... 11-13
MAST ADJUSTMENT (V MAST) ....................................... 11-15
MAST ROLLER REMOVAL• INSTALLATION ..................... 11-20
CHAIN ................................................................................ 11-21
INSPECTION .................................................................... 11-21
REASSEMBLY .................................................................. 11-21
ADJUSTMENT .................................................................. 11-22
FORK ................................................................................. 11-22
REMOVAL ........................................................................ 11-22
INSTALLATION ................................................................. 11-22
INSPECTION .................................................................... 11-22 11
FV• FSV MAST ASSY .................................................... 11-23
COMPONENTS ................................................................ 11-23
MAST ADJUSTMENT (FV• FSV) ....................................... 11-28
LIFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) ................. 11-32
11-2

V MAST ASSY
COMPONENTS

1• 2• 3 ton series 6101

J3.5 ton series 6101

 11-3

1 ton series 6301

2 ton series 6301

11
13
11-4

3 ton series 6301

J3.5 ton series 6301

 11-5

6302
1• 2 ton series

3 ton series J3.5 ton series

11
13
11-6

REMOVAL•INSTALLATION T = N•m (kgf-cm) [ft-lbf]

11

T = 86.3 ~ 129.4
(880 ~ 1320)
4 [63.7 ~ 95.48]

10

T = 68.6 ~ 107.9
(700 ~ 1100)
[50.6 ~ 79.57]

Removal Procedure
1 Set the mast vertical and fully lower the fork.

2 Disconnect the chain. [Point 1]

3 Remove the chain wheel. [Point 2]

4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift
bracket, and slowly run the vehicle backward to depart from the lift bracket.)

5 Remove the toe board.

6 Disconnect the fork height switch and load sensor wiring.

7 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast, operate the lift lever several times to release the residual pressure in the lift cylinder.)

8 Slightly hoist the mast.

9 Remove the mast support cap.

10 Remove the tilt cylinder front pin. [Point 3]

11 Remove the mast ASSY.

 11-7

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
• Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift
cylinder is replaced. (See page 11-32.)
• Adjust the chain tension after installation. (See page 11-22.)
• When the mast is replaced, perform SAS re-setting after installation. (See section 15.)

Point Operations
[Point 1]
SST Removal-Installation:
SST 09630-23600-71

[Point 2]
SST Removal:
If the fitting is hard, use the SST for removal.
SST 09950-40011

11
13
11-8

[Point 3]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate and lock bolt. Match marks, however, are
unnecessary when the mast or mast ASSY is replaced since
mast tilt angle adjustment is to be done after the replace-
ment.

Removal:
SST 09810-20172-71

SST
 11-9

REMOVAL• INSTALLATION (W/LIFT BRACKET) T = N•m (kgf-cm) [ft-lbf]

T = 86.3 ~ 129.4
T = (880 ~ 1320) 8 2
T = [63.7 ~ 95.48]
7
T = 68.6 ~ 107.9
T = (700 ~ 1100)
T = [50.6 ~ 79.57]

Removal Procedure
1 Set the mast vertical.

2 Remove the fork. (See page 11-22.)

3 Remove the toe board.

4 Disconnect the wiring of the fork height switch and load sensor.

5 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure from the lift cylin-
der.)

6 Slightly hoist the mast.

7 Remove the mast support cap.

8 Remove the tilt cylinder front pin. [Point 1]

9 Remove the mast ASSY W/lift bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
11-10

Note:
• Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
• Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either
lift cylinder is replaced. (See page 11-32.)
• When the mast is replaced, perform SAS re-setting after installation. (See section 15.)

Point Operation
[Point 1]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate and lock bolt. Match marks, however, are
unnecessary when the mast or mast ASSY is replaced since
mast tilt angle adjustment is to be done after the replace-
ment.

Removal:
SST 09810-20172-71

SST
 11-11

MAST DISASSEMBLY•INSPECTION• REASSEMBLY

2
9

7 8

Disassembly Procedure
1 Remove the fork height switch.

2 Remove the hose cover.

3 Disconnect the overflow hose and high pressure hose.

4 Remove each cylinder rod end set bolt, and take each rod end off. [Point 1]

5 Remove each cylinder support. [Point 2]

6 Remove each cylinder bottom set bolt, and remove each lift cylinder.

7 Slide the inner mast in the lowering direction, and remove the lift rollers.

8 Remove the mast strip. [Point 3]

9 Remove the outer mast.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
11-12

Point Operations
Shim
[Point 1]
Disassembly:
Shim adjustment is made at the lift cylinder rod end for
preventing uneven lifting by lift cylinders LH and RH.
Take a note on the cylinder where the adjustment is made
and the number of shims in use.

[Point 2]
Disassmbly:
Take a note on the number of cylinder support shims in
use.
Shim
Reassembly:
Make cylinder support shim adjustment if the mast or ei-
ther cylinder is replaced.
With the cylinder rod end inserted to the inner mast, insert
shim(s) between the cylinder support and outer mast to
eliminate the clearance. The shim thickness should be
slightly greater than the clearance.

[Point 3]
Inspection:
Measure the mast strip thickness.

Limit: 1.5 mm (0.059 in)

 11-13

LIFT BRACKET DISASSEMBLY•INSPECTION •REASSEMBLY T = N•m (kgf-cm) [ft-lbf]

T = 99.54 ~ 184.9
(1015 ~ 1885)
[73.42 ~ 136.3]

Disassembly Procedure
1 Remove lift rollers. [Point 1]

2 Remove side rollers.

3 Remove the back rest.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Disassembly:
SST 09950-40011

SST
11-14

9 mm [Point 2]
1 mm (0.35 in) Reassembly:
(0.04 in) Front side
Install the side roller in the correct direction.
The side chamfered with a greater radius of the roller shall
be on the front side of the vehicle.
Rounded
chamfering
 11-15

MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast

1. Inner mast to roller clearance adjustment

Inner mast
Outer
mast
Bring into contact

Bring into These rollers

contact
A

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into
contact with the outer mast, and inspect the clearance
between the roller side face and mast where they are the
closest.

Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)

If the standard is not satisfied, make adjustment by chang-

ing the inner mast roller shim thickness. (See page 13-22
for the mast roller removal and installation.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

Shims (3) Distribute shims equally to the rollers on the left and right
side.
(4) After the adjustment, see that the inner mast moves
smoothly in the outer mast.
11-16

2. Outer mast roller clearance adjustment

These rollers
Bring into contact

Outer
mast Inner
mast
Bring into
B contact

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into
contact with the outer mast, and inspect the clearance
between the roller side face and mast where they are the
closest.

Standard: B = 0 ~ 0.5 mm (0 ~ 0.020 in)

If the standard is not satisfied, make adjustment by chang-

ing the outer mast roller shim thickness.
(See page 13-22 for the mast roller removal and installa-
tion.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

Shims
(3) Distribute shims equally to the rollers on the left and right
side.
(4) After the adjustment, see that the inner mast moves
smoothly in the outer mast.
 11-17

Roller Adjustment at Lift Bracket

1. Middle/lower lift roller and side roller clearance adjustment

Bring into contact

100 mm (3.94 in)
D

Bring into contact Outer

mast

Bring into contact Inner Lift

mast bracket
C

(1) Bring the center of the side roller in the upper part of the
lift bracket to approx. 100 mm (3.94 in) from the top of
the inner mast.
(2) Remove side rollers.
(3) Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect on the opposite
side the clearance between the roller side face and the
mast where they are the closest. (No adjustment is nec-
essary for the upper lift rollers since they are fastened
by snap rings.)

Standard:
C = 0 ~ 0.8 mm (0 ~ 0.031 in)

If the standard is not satisfied, make adjustment by

changing the lift roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

11-18

(4) Distribute shims equally to the left and right side.

(5) Install side rollers.

Shim

(6) After adjusting the middle and lower lift rollers, bring the
side roller on one side into contact with the outer mast
and measure on the opposite side the clearance between
the side roller and inner mast surface.

Standard:
D = 0 ~ 0.6 mm (0 ~ 0.024 in)

If the standard is not satisfied, make adjustment by chang-

ing the side roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(7) Distribute shims equally to the left and right side. (See
Lift Bracket Disassembly-Inspection-Reassembly section
for the side roller installation method. Shim replacement
is possible on the vehicle.)
(8) After the adjustment, see that the lift bracket moves
smoothly over the entire length of the mast.

Shims
 11-19

Mast Strip Adjustment

1. Mast strip clearance adjustment

Roller

Inner mast

Bring into contact

E
Outer mast

(1) Lower the inner mast fully.

(2) With the inner mast in contact with the outer mast roller,
measure the clearance between the mast strip and in-
ner mast.

Standard: E = 0 ~ 0.8 mm (0 ~ 0.031 in)

If the standard is not satisfied, make adjustment by

changing the mast strip shim thickness. (See page 13-
22 for the mast roller removal/installation method.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth move-
Shim
ment.
11-20

MAST ROLLER REMOVAL•INSTALLATION

1. Remove the lift bracket. (See steps 1 to 4 of the mast
ASSY removal procedure on page 11-6.)
2. Jack up the vehicle, and support tires with wooden blocks.
Also lock the front and rear tires from rotation.
3. Remove the lift cylinders. (See page 12-11.)

4. Remove mast rollers.

(1) Remove wooden blocks under the inner mast, and
Shim
lower the hoisted inner mast slowly until mast rollers
appear.
(2) Support the bottom of the inner mast with wooden
blocks.
(3) Remove the inner mast rollers and shims.

(4) Remove the outer mast rollers and shims.

5. The installation procedure is the reverse of the removal
procedure.
Shim
 11-21

CHAIN
SST
INSPECTION
1. Inspect the chain elongation according to the following
procedure:
SST 09631-22000-71
(1) Since the SST measurement line varies with the chain
type, set the corresponding line on the chain as illus-
trated.
(2) Check the number of the chain to be inspected, and
check the pin center position.
If the pin center is at the arrow mark on the chain gauge,
it is the limit.
Chain Link Pitch Standard
Vehicle model Pitch mm (in) Type Chain No.
1 ton series 15.88 (0.6252) BL534 50
2 ton series 19.05 (0.7500) BL634 60
3 ton series 25.4 (1.0) BL823 80
J3.5 ton series 25.4 (1.0) BL834 80

Note:
• Perform measurement without removing the chain
from the vehicle.
• Inspect elongation over the entire chain length since
it may be localized.
REASSEMBLY
1. Installing direction

Applicable mast FV: Lift bracket

V: Lift bracket FSV inner mast
and portion FSV: Lift bracket
Center of vehicle Center of vehicle Front of vehicle

Rough sketch Cotter pin Cotter pin

Cotter pin

Install the chain with the cotter pin Install the chain with the cotter pin Install the chain with the cotter pin
facing the center of the vehicle. facing the center of the vehicle. on the front side of the vehicle.

2. Chain adjusting nut tightening order

(1) Tighten nuts and . T = 49.0 ~ 78.0 N•m (500 ~ 800 kgf-cm) [36.1 ~ 57.5 ft-lbf]
(2) Tighten nut .
Applicable mast and FV: Front cylinder
Outer mast
portion FSV: Front cylinder

Rough sketch
11-22

ADJUSTMENT
1. Park the vehicle on a flat ground and set the mast vertical.

2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting
nut.

3. Check to see that the chain tension is equal on the left and right side.

4. Check to see no chain twist.

5. See that the fork height is the standard.

6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast
is not in contact with the lift bracket.

FORK
REMOVAL
1. Set the fork at approx. 20 cm (7.9 in) above the ground.
2. Place a wooden block under the knotched portion of the
fork rail.
3. Unlock the fork by lifting the fork stopper pin, and shift
the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.

INSTALLATION
The installation procedure is the reverse of the removal pro-
cedure.

INSPECTION
1. Inspect misalignment of the fork tip ends.

Limit: 10 mm (0.39 in)

If the limit is exceeded, inspect individual fork bend, loose-

ness of fork installation and lift bracket finger bar distor-
tion.
 11-23

FV• FSV MAST ASSY

COMPONENTS

FV (1• 2• 3 ton series) 6101

FV (J3.5 ton series) 6101

11-24

FSV (1• 2• 3 ton series) 6101

FSV (J3.5 ton series) 6101

 11-25

FV (1• 2 ton series) 6302

FV (3 ton series) 6302

11-26

FV (J3.5 ton series) 6302

FSV (1• 2 ton series) 6302

 11-27

FSV (3 ton series) 6302

FSV (J3.5 ton series) 6302

11-28

MAST ADJUSTMENT (FV• FSV)

Lift Roller Adjustment at Mast

1. Inner mast roller (FV • FSV) and middle mast lower roller (FSV) clearance adjustment

Bring into contact

A
Position where the
roller is the closest

FSV mast
FV mast Inner mast
Inner mast

Outer mast
Outer mast

Middle mast

These rollers
These rollers

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the
clearance between the roller side face and mast where they are the closest.

Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right sides.
(4) After the adjustment, see that mutual mast movement is smooth.
 11-29

2. Outer mast roller (FV • FSV) and middle mast upper roller (FSV) clearance adjustment

Bring into contact

Bring into
contact

B
Position where the
roller is the closest

FV mast FSV mast

These rollers These rollers

Outer mast
Outer mast

Middle mast

Inner
mast Inner mast

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on
the opposite side the clearance between the roller side face and mast where they are the closest.

Standard: B = 0 ~ 0.5 mm (0 ~ 0.020 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right sides.
(4) After the adjustment, see that mutual mast movement is smooth.
11-30

Lift/Side Roller Adjustment at Lift Bracket

FV-FSV mast

Lower lift roller

D
Side roller

Bring into contact

Bring into
C contact

100 mm (3.94 in) Lift bracket

Lift bracket
FV FSV

(1) Raise the lift bracket to the uppermost position for the FSV mast, and bring the center of the upper
lift roller to approx. 100 mm (3.94 in) from the top of the inner mast for FV mast.
(2) No adjustment is necessary for the upper lift rollers and intermediate rollers (FV only) since they are
fastened by snap rings.
(3) Shift the lift bracket to one side to bring the lower lift roller and side roller, and measure on the
opposite side the clearance between the roller side face and the mast where they are the closest.

Standard: C = 0 ~ 0.5 mm (0 ~ 0.020 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims
equally to the rollers on the left and right sides.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(4) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers.
Bring the side roller on one side into contact with mast side surface, measure on the opposite side
the clearance between the side roller and the inner mast side surface where they are the closest.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims
equally to the rollers on the left and right sides.)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(5) After the adjustment, check to see that the lift bracket moves smoothly over the entire length of the
mast.
 11-31

Mast Strip Adjustment

Mast strip clearance adjustment

FV mast
Upper roller

Inner mast

Bring into contact

Outer mast

FSV mast
E
Middle mast

Upper roller

Bring into contact

Inner mast

Outer mast

(1) Lower the inner (or middle) mast fully.

(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),
measure the clearance between the mast strip and mast.

Standard: E = 0 ~ 0.8 mm (0 ~ 0.031 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth movement.
11-32

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN

LIFTING)

Note:
• For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on
the left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY, and inner mast SUB-ASSY

1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.

2. Adjustment method
(1) Raise the inner mast, set the SST to the outer mast
tie beam, and lower the inner mast until it reaches the
SST SST.
SST 09610-22000-71
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim
Shim thickness:
0.5 and 1.0 mm (0.020 and 0.039 in)