How to Replace Forklift Mast Rollers

This article will outline how to accurately and efficiently calculate which mast and carriage rollers are needed for a specific model in addition to answering how to replace forklift mast rollers. This includes: mast model, bearing part number, outer diameter size.

Installing Lift Bracket Rollers (for all mast models)

To disassemble, follow the sequence in reverse.

reassembly mast

Sequence:

1. Lift Bracket2. Lift bracket upper rollers3. Lift bracket middle rollers
4. Lift bracket lower rollers5. Side rollers6. Inner Mast

Definitions

Clearance G: clearance between roller side surface and inner mast thrust surface. This is used to determine the amount of shims at the bearing seat. Measure Clearance G between the side of the surface of the roller and inner mast. Measurement range: 0.1 to 0.5 mm (0.004 to 0.020 in.)

Clearance F: clearance between roller circumference and inner mast thrust surface. This is used to determine the proper size of the rollers. Measurement Range: 1.0 mm (0.04 in.) or less

Clearance G1: clearance between side roller circumference and inner mast side roller thrust surface. Measurement Range: 0.1 to 0.5 mm (0.004 to 0.020 in.)

Instructions

  1. Choosing Correct Roller Diameters

    Measure clearance F for upper roller 2, middle roller 3, and lower roller 4. If not in the range, replace the rollers. The rollers should function smoothly.

  2. Adjusting clearance G between the middle roller and thrust plate

    Measure clearance G between the middle roller and thrust plate. If not in the measurement range, adjust clearance G.

    If clearance G is too high, increase the thickness of shims, and vice versa.

  3. Adjusting clearance G between lower rollers and inner mast

    Measure clearance G between the lower rollers and inner mast. Adjust clearance G as described in the previous point.

  4. Installing main rollers

    Use a driving tool to properly install main rollers on shafts. Do not strike the outer roller surface while installing.

  5. Adjusting clearance G1 between the side roller and inner mast

    Measure the clearance of G1 between the side roller’s rolling contact surface and inner mast. If the measure is not in the range mentioned above, adjust the clearance in the following manner: if G1 clearance is excessive, increase the thickness of the shims and vice versa.

Diagram describing how to install main rollers

How to Replace Forklift Mast Rollers (for all mast models)

install mast rollers

Instructions

  1. Measure clearance F between the rollers’ contact surface and masts

    If this value is not in the range (1.0 mm / 0.04in, or less), replace with rollers with the correct diameters listed in the table below (figure 1)

  2. Measure clearance G between the rollers and the masts

    If the measured clearances exceeds the range (0.1 to 0.5mm, 0.004 to 0.020 in.)

All mast rollers are identical in shape and size. Thus, clearance F should be 1.0 mm (0.04 in.) or less and clearance G should be 0.1 to 0.5 mm (0.004 to 0.020 in.). If the measured clearances are incorrect, replace the rollers with the correct diameters listed in the below in figure 1.

If measured value clearance G exceeds the standard value, increase the thickness of shims (e) – (j). Standard values can be seen here:

Item1 ton class (mm)2, 3 ton classes (mm)
Shim (e)21
Shim (f)21
Shim (g)11
Shim (h)21
Shim (i)21
Shim (j)21
mast and carriage main rollers sizes
Figure 1

Where do I find the part numbers?

mast part number location

Have Questions?

Leave a comment below or gives us a call at (616) 796-6638 and we can help calculate your mast and carriage rollers!


Post by Intella Parts Company, LLC

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