Professional Documents
Culture Documents
Mitsubishi FG20-30N
Mitsubishi FG20-30N
1. Simplex Mast
1.1 Mast System
Following table shows a combination of truck and mast models:
5A15C33
217234
Mast serial number location
Example: 5 A 15 C 33
Maximum lifting height
["33" stands for 3300 mm (130 in.)]
Order of the minor charge
("A" for the original,
"B" for the first change,
"C" for the second change,
and so on)
Applicable truck model designation
(Example: FG35AN)
15, 20: 1 ton class, 25: 2 ton class,
30, 33: 3 ton class
Mast type
Generation of truck compatible with
the mast
("2" for the original,
"3" for the first change,
and so on up to "9") 214841
How to read mast model code
12-1
MAST AND FORKS
1 Side roller
2
Detail of A Detail of D
3
Inner mast Detail
Inner mast
Outer mast F
Detail E
Lift bracket
Lift bracket
B
E
Detail of B Detail of E and F
4
Inner mast Outer mast
Lift bracket
Mast strip
F
5
Shims
Detail of C Detail of G
217217
12-2
MAST AND FORKS
Free-lift height
12-3
MAST AND FORKS
217218
Sequence
1 Nut, Spring 4 Tilt socket pin,Tilt cylinder
2 Fork, Lift bracket 5 Mast-support bearing cap, Bushing
3 High-pressure hose for lift cylinder
12-4
MAST AND FORKS
Do not touch any levers except the tilt lever while the
engine is running.
Never loosen tilt socket bolts except for during tilt cyl-
inder disassembling.
217220
12-5
MAST AND FORKS
12-6
MAST AND FORKS
11
10
13
9
16 17
2
8
2
6
7
6 14
1 4
5
217223
Sequence
1 Nuts, Spring 8 Lift hose (high pressure), 12 Mast strips, Shims
2 Fork, Lift bracket Rubber hose, T-joint, 13 Main roller, Shims
3 Backrest Down safety valve 14 Main roller, Shims
4 Main roller, Shims 9 Snap ring. Chain wheel 15 Inner mast
5 Main roller, Shims 10 Cylinder clamps, Seats, Shims, 16 Lift cylinder
6 Side bracket lower roller Cushion, Collar, Bolts 17 Outer mast
7 Hose guard 11 Bolt shims
12-7
MAST AND FORKS
(3) Lift chains, chain wheels and chain wheel sup- Chain elongation
ports
Unit: mm (in.)/20 links
(a) Measure the length of each chain to make sure Truck type
that the two chains are equal in length. Also Item 1 ton 2 ton 3 ton
check the chains for wear, indication of break- class class class
age and link binding and twisting.
317.5 381 508
A
(b) Check each chain anchor bolt for cracks or Simplex (12.5) (15) (20)
defects on thread. Mast 327 392 523
B
(12.9) (15.4) (20.6)
(c) Check each chain wheel support and chain
wheel for crack or wear. Check that the wheels A: Standard value B: Repair or service limit
rotate smoothly.
12-8
MAST AND FORKS
F 2 F 3
1 2 1 1
214830
Reassembly
1 Lift bracket 4 Lift bracket lower roller
2 Lift bracket upper roller 5 Side roller
3 Lift bracket middle roller 6 Inner mast
The lift bracket has three main roller bearings at one Adjust the clearance to the specification with shims (a)
side and the side roller at both sides as shown. and (b) for the middle roller and with shim (c) for the
Clearances F, G and G1 must be maintained between lower roller.
these rollers and thrust surface of the inner mast for
Unit: mm (in.)
smooth operation.
0.1 to 0.5
Clearance G
(0.004 to 0.020)
Clearance G
Clearance between roller side surface and inner mast
thrust surface (right-to-left play): Clearance F
Clearance G is used for determining the correct Clearance between roller circumference and inner
amount of shims at the bearing seat. mast thrust surface (back-to-front play):
Move the lift bracket to the top of the inner mast and Clearance F is used for determining the proper size of
slide the bracket to either the left-most or rightmost the rollers.
position. Select appropriate diameter rollers so that the clear-
Take measurements of clearance G between the side ance meets the specification. Make sure the rollers
surface of roller and inner mast. rotate smoothly when installed.
Unit: mm (in.)
Clearance F 1.0 (0.04) or less
Note: It is not necessary to adjust the lift bracket up-
per roller with shims.
12-9
MAST AND FORKS
Clearance G1
Clearance between side roller circumference and
inner mast side roller thrust surface: Move the side
roller to the upper end of the inner mast and slide the
lift bracket to either the left-most or rightmost position.
Take measurement of clearance G1 between the
roller circumference and inner mast.
Adjust the clearance with shims (d) to the specifica-
tion.
Unit: mm (in.)
0.1 to 0.5
Clearance G1
(0.004 to 0.020)
12-10
MAST AND FORKS
213938
12-11
MAST AND FORKS
Shim (e)
(1) Measure clearance F between the rollers' rolling
contact surfaces and masts.
If the measured clearances do not conform to the
Inner mast Outer mast
standard values, replace with rollers of correct
diameters listed in the table below. G
0.1 to 0.5 mm
Lift bracket (0.004 to 0.020 in.)
Note: For measuring procedures, refer to "Inspection lower roller F 1 mm (0.04 in.)
and Adjustment." or less
Shim (f)
Unit: mm (in.)
(Lower mast)
Truck type
Size (diameter) 2 ton class
1 ton class
3 ton class
Lift bracket
S 99 (3.90) 113.8 (4.48)
213940
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.61)
Unit: mm (in.)
Truck type
Item 2 ton class
1 ton class
3 ton class
Shim (e) 2 (0.079) 1 (0.039)
Shim (f) 2 (0.079) 1 (0.039)
12-12
MAST AND FORKS
213943
(4) With the cylinder rods fully retracted and the cylin-
ders set vertically, measure clearance H.
Adjust the clearance to be 1.6 mm (0.06 in.) or
less by adding or removing shims (m).
12-13
MAST AND FORKS
Stamped
mark 2
Joint
217228
1 Link
2 Center plate (without mark)
3 Link plate (with a stamped mark)
4 Split pin
12-14
MAST AND FORKS
Simplex mast
Tightening torque A
Unit: N·m (kgf·m) [lbf·ft]
Truck model
Item Second cylinder
1, 2 ton 3 ton
classes class
49.0 ± 4.9
Nut A (5.0 ± 0.5)
A
[36.1 ± 3.6] B
58.8 ± 5.9
(6.0 ± 0.6)
Nut B
[43.2 ± 4.2]
49.0 ± 4.9
Nut C (5.0 ± 0.5)
[36.1 ± 3.6] 58.8 ± 5.9 C
(6.0 ± 0.6) B
39.2 ± 3.9
[43.2 ± 4.2]
Nut D (4.0 ± 0.4)
[28.9 ± 2.8]
39.2 ± 3.9
Nut E (4.0 ± 0.4)
D
[28.9 ± 2.8]
39.2 ± 3.9
Nut F (4.0 ± 0.4)
Second cylinder
[28.9 ± 2.8] 214824
12-15
MAST AND FORKS
(b) Remove the upper set bolts from the lift cylin-
ders, and lift the inner mast with a hoist.
Remove hose guard.
(c) Remove the clamps from the lift cylinders. Pull Cylinder
out the bottom ends of the cylinders from the clamp parts
outer mast, tilt the cylinders to the center of the Shim Mast roller
mast, and tie them to the cross-member of
outer mast with rope.
(d) Slowly lower the inner mast until it comes in Cylinder
contact with the lift cylinders. clamp parts
(e) Now the main rollers can be removed from the Mast strip
inner and outer masts. Remove the mast strips
and shims in advance because they are apt to
217230
come off under this condition.
(3) Perform clearance adjustment of the removed roll-
ers using shims, replacement of rollers, and/or
clearance adjustment of the mast strips as neces- Lift the inner mast
with a hoist
sary.
To reassemble the mast, follow the removal
sequence in reverse.
217231
12-16
MAST AND FORKS
6.1 Forks
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
Forks are often mistreated and forgotten. As insub- Maintenance shops may bend forks back into shape,
stantial as they seem, neglecting forks could make weld on them, or drill holes through them. Lift truck
them dangerous. users can add attachments to the truck that will put
Forks carry larger loads than almost any lifting device stress on the forks. Drum clamps and portable booms
but there are no mandatory requirements for mainte- can be supported on the forks–but what is contained
nance or inspection. in the drum or on the boom hook makes the differ-
ence in safety.
You can find thousands of extra parts for lift trucks in
some fleet repair shops, but you'll seldom see spare Forks are often used to open rail car doors and break
forks. Even when all the trucks on the fleet are the loads out or away from other loads. They are also
same, fleet maintenance managers rarely order spare used to pick up capacity loads not seated against the
forks. Forks can last a long time if treated properly, but fork shank and to pick up off-balanced loads far from
they can be deceptive. Careful inspection is required the side of the truck. The fork tips are sometimes
to ensure forks are not worn. inserted under other fork trucks to lift them during
maintenance operations.
It's true that most forks are customized to the truck by
model and capacity: They are big, heavy and thought Lift trucks may collide with building columns and
of as indestructible. However, forks can be abused or walls, and though the forks show no discernible bend,
ruined in the course of daily work. they may be damaged beyond safety.
Here are some examples of ways that forks can be Any time excessive heat is applied to any part of a
damaged: fork during repair, hidden damage may occur.
Forks can be overloaded either by picking up a load The fork itself is a concern but so are the hooks that
too far out on the forks, or simply by picking up loads secure them to the lift carriage.
heavier than the truck rating.
12-17
MAST AND FORKS
12-18
MAST AND FORKS
12-19
MAST AND FORKS
6.4 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(1) Back-to-front clearance check on lift bracket main
rollers F
(a) Raise the forks slightly from the ground.
(b) 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, mea-
sure clearance F between the main roller and
inner mast on the opposite side.
Unit: mm (in.)
Clearance F 1.0 (0.04) or less F 213966
(c) If clearance is out of specification, use oversize
rollers.
For roller replacement procedure, refer to
"Choosing correct roller diameters" on (1).
12-20
MAST AND FORKS
G
213970
213971
(c) If clearance is out of specification, use oversize
rollers. For mast roller replacement and instal-
lation procedures, refer to "Installing mast roll-
ers" on 4.2.2 Installing Mast Rollers.
(2) Right-to-left clearance inspection on inner mast
main rollers
(a) Raise the mast to the top.
(b) Set a dial indicator on the inside of the outer
mast with its contact point rested on the inner
mast.
(c) Go over to the opposite side of the mast, and
push the inner mast against the outer mast.
Set the indicator to zero.
G
213972
(d) Insert a bar between the outer and inner masts
on the indicator side, and push the inner mast
to the opposite side.
12-21
MAST AND FORKS
213974
(d) Insert a bar between the outer and inner masts
on the indicator side, and push the inner mast
to the opposite side. G
(e) Read the indicator. This reading is clearance G
between the outer mast roller and inner mast.
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
12-22
MAST AND FORKS
213976
(2) If clearance G2 is out of specification, adjust it by
adding or removing shims.
For adjustment procedure, refer to "Measuring
and adjusting clearance G2 between the mast
strip and inner mast" on 4.2.3 Installing Mast
Strips (all mast models).
(3) After all clearances are adjusted, move the mast
and lift bracket slowly to ensure that they move
smoothly through their full stroke.
A : Forward B: Backward
Mast 1 ton class 2 ton class 3 ton class
model F B F B F B
Simplex 5° 10° 5° 9° 5° 6°
Duplex 5° 10° 5° 9° 5° 6°
Triplex 5° 10° 5° 6° 5° 6°
12-23
MAST AND FORKS
6.8 Right and Left 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 cyl-
inder stroke.
213978
(d) Slowly lower the inner mast to the bottom to Inner mast
ensure the piston rods move smoothly and that
the left and right lift cylinders come to the end Shim (l)
of stroke simultaneously at the maximum lift
position of inner mast. Cylinder bracket
213943
12-24
MAST AND FORKS
Clearance between lift rollers and side rollers incorrect Readjust clearance.
Lift bracket and
Relubricate side rollers and replace
inner mast do not Rollers not rotating smoothly on their shafts
other rollers.
move smoothly.
Mast strip clearance incorrect Adjust shims.
Too much clearance on side rollers Readjust by adding shims.
Lift bracket or inner
Lift chains unequally tensioned Readjust chain tension.
mast are not in a
level position. Shim adjustments unequally made on between left and
Remove or add shims.
right lift cylinders (at maximum height)
Mast makes noise. Rollers not rotating smoothly on their shafts Check and adjust or replace rollers.
Lift cylinder Lift cylinder packing damaged Replace.
descends due to a
load (Drift). Sliding (inside) surface of lift cylinder tube damaged Replace.
Whole mast shakes. Mast-support bushing or metal worn Retighten or replace.
Mast is distorted. Off-center loading or overload Replace mast assembly.
Distortion of finger bar
Fork tips differ in
Distortion of forks Repair or replace.
height.
Uneven loading
12-25
MAST AND FORKS
12-26
MAST AND FORKS
F G2
G
F
G1
F
G
G
B2
C
Lift bracket
12-27
MAST AND FORKS
9. Duplex Mast
9.1 Mast System
Following table shows a combination of truck and mast models:
5B25C33
217235
Mast serial number location
Example: 5 B 25 C 33
Maximum lifting height
["33" stands for 3300 mm 130 in.)]
Order of the minor charge
("A" for the original,
"B" for the first change,
"C" for the second change,
and so on)
Applicable truck model designation
(Example: FG25AN)
15, 20: 1 ton class, 25: 2 ton class,
30, 33: 3 ton class
Mast type
Generation of truck compatible with
the mast
("2" for the original,
"3" for the first change,
and so on up to "9") 214832
How to read mast model code
12-28
MAST AND FORKS
8
Front
1
Front
2
5
10 Front
Front
217236
12-29
MAST AND FORKS
The duplex mast provides a free lift amount until the The shoulder sections of the mast main rollers contact
top of lift bracket reaches the mast height. the mast rails. The rollers are installed perpendicular
The mast assembly consists of the inner mast, outer to the sliding surfaces.
mast, lift bracket, first lift cylinder and second lift cylin- The main rollers used in the duplex mast models are
ders. the same as those used in the simplex mast models.
The first lift cylinder raises the lift bracket, while the
second lift cylinders operate the inner mast and lift
bracket.
For lifting operation, oil is first sent to the first lift cylin-
der 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.
Free-lift
Reverse the lifting sequence to activate the lowering height Outer mast
mechanism.
12-30
MAST AND FORKS
A
A
First
cylinder
4
1
Second
cylinder
5
2
217137
Sequence
1 Nuts, Spring 4 Tilt socket pin, Tilt cylinder
2 Fork, Lift bracket assembly 5 Mast support bearing cap, Bushing
3 High-pressure hose for lift cylinder
217244
(2) Position the mast upright. Raise the inner mast
until main rollers 6 of the lift bracket become free.
Then, slowly move the vehicle in reverse to sepa-
rate from lift bracket 2.
6
Do not shut off the function of the mast interlock sys-
tem by means of "GSE" service tool. 2
217240
12-31
MAST AND FORKS
217238
Do not touch any levers except the tilt lever while the
engine is running.
Never loosen tilt socket bolts except for during tilt cyl-
inder disassembling.
217220
12-32
MAST AND FORKS
12-33
MAST AND FORKS
10 14
1
8
13 15 16
9
11 14
6
5
1 1
6 12
4
12
2 9
2 18
3
17
7
217241
Sequence
1 High-pressure hose for first cylinder, Clamper 10 Bolt, Washer, Shim
2 Bolts, Washer, Shim 11 Mast strip, Shim
3 First lift cylinder 12 Main roller, Shim
4 Chain guard 13 Inner mast
5 Chain wheel support, Pin 14 Second lift cylinder
6 Chain wheel, Snap ring 15 Cylinder bracket
7 Hose guard, Bolt, Washer 16 O-ring, Plug
8 High-pressure hose 17 Mast support cap, Bolt, Washer
9 Cushion, shim, Bracket 18 Outer mast, Grease nipple
12-34
MAST AND FORKS
Start by
With the lift bracket facing up, place the mast horizon-
3
tally on wood blocks.
Place a wood block as a wedge to prevent the inner
mast from sliding.
14
213929
12-35
MAST AND FORKS
(3) Lift chains, chain wheels and chain wheel sup- Chain elongation
ports
Unit: mm (in.)/20 links
(a) Measure the length of each chain to make sure Truck type
that the two chains are equal in length. Also Item 1 ton 2 ton 3 ton
check the chains for wear, indication of break- class class class
age and link binding and twisting.
317.5 381 508
A
(b) Check each chain anchor bolt for cracks or (12.50) (15.00) (20.00)
Duplex mast
defects on thread. 327 392 523
B
(12.87) (15.43) (20.59)
(c) Check each chain wheel support and chain
wheel for crack or wear. Check that the wheels A: Standard value B: Repair or service limit
rotate smoothly.
12-36
MAST AND FORKS
F 2 F 3
1 2 1 1
214830
Reassembly
1 Lift bracket 4 Lift bracket lower roller
2 Lift bracket upper roller 5 Side roller
3 Lift bracket middle roller 6 Inner mast
The lift bracket has three main roller bearings at one Adjust the clearance to the specification with shims (a)
side and the side roller at both sides as shown. and (b) for the middle roller and with shim (c) for the
Clearances F, G and G1 must be maintained between lower roller.
these rollers and thrust surface of the inner mast for
Unit: mm (in.)
smooth operation.
0.1 to 0.5
Clearance G
(0.004 to 0.020)
Clearance G
Clearance between roller side surface and inner mast
thrust surface (right-to-left play): Clearance F
Clearance G is used for determining the correct Clearance between roller circumference and inner
amount of shims at the bearing seat. mast thrust surface (back-to-front play):
Move the lift bracket to the top of the inner mast and Clearance F is used for determining the proper size of
slide the bracket to either the left-most or rightmost the rollers.
position. Select appropriate diameter rollers so that the clear-
Take measurements of clearance G between the side ance meets the specification. Make sure the rollers
surface of roller and inner mast. rotate smoothly when installed.
Unit: mm (in.)
Clearance F 1 (0.04) maximum
Note: It is not necessary to adjust the lift bracket up-
per roller with shims.
12-37
MAST AND FORKS
Clearance G1
Clearance between side roller circumference and
inner mast side roller thrust surface: Move the side
roller to the upper end of the inner mast and slide the
lift bracket to either the left-most or rightmost position.
Take measurement of clearance G1 between the
roller circumference and inner mast.
Adjust the clearance with shims (d) to the specifica-
tion.
Unit: mm (in.)
0.1 to 0.5
Clearance G1
(0.004 to 0.020)
Measure clearance G between the middle roller Shim (b) Thrust plate
and thrust plate. If the measured clearance does G
not conform to the standard value, adjust clear- 0.1 to 0.5 mm
(0.004 to 0.020 in.)
ance G in the manner described below.
Note: For measuring procedures, refer to "Inspection 213936
and Adjustment."
Adjusting method
If clearance G is excessive, increase the thickness
of shims (a) as required. Increase the thickness of
shims (b) by the same amount that are added to
shims (a). Shim (a) is available in two sizes: 1 mm
(0.04 in.) and 0.5 mm (0.020 in.). Shim (b) is avail-
able in only one size, 1 mm (0.04 in.). If shims (a)
are increased by 0.5 mm (0.020 in.), shims (b) do
not need to be increased by the equal amount.
At the factory, shims (a) are usually adjusted to 1 mm
(0.04 in.) and shims (b) to 2 mm (0.08 in.) for the ship-
ment.
12-38
MAST AND FORKS
213938
213939
Adjusting method
If clearance G1 is excessive, increase the thick-
ness of shims (d) as required.
At the factory, shims (d) are usually adjusted to 1 mm
(0.04 in.) for the shipment.
12-39
MAST AND FORKS
Unit: mm (in.)
Truck type
Item 2 ton class
1 ton class
3 ton class
Shim (e) 2 (0.08) 1 (0.04)
Shim (f) 2 (0.08) 1 (0.04)
12-40
MAST AND FORKS
(4) With the cylinder rods fully retracted and the cylin-
ders positioned vertically, measure clearance H.
213943
Adjust the clearance to be 1.6 mm (0.06 in.) or
less by adding or removing shims (m).
Unit: mm (in.)
Clearance H 1.6 (0.06) maximum
Adjusting method
If clearance H is excessive, add shims (m). Nor-
mally on a new truck, the second lift cylinders are
not fitted with shims (m). If the clearance is 3.2 mm
(0.13 in.) or more, make sure to include a 3.2 mm
(0.13 in.) thick sheet in the shim pack that is to be
installed.
Shim (m)
(5) After reassembly, perform an operation test to
check if the stroke of the left and right cylinders is
the same. Refer to "14.8 Right and Left Lift Cylin-
der Stroke Inspection and Adjustment."
213944
12-41
MAST AND FORKS
214840
12-42
MAST AND FORKS
Duplex Mast
Tightening torque Unit: N·m (kgf·m) [lbf·ft]
Tightening
Item Truck model F
torque
58.8 ± 5.9
Nut A (6.0 ± 0.6) E
[43.2 ± 4.2] 1 to 3 ton
49.0 ± 4.9 classes
Nut B (5.0 ± 0.5)
[36.1 ± 3.6]
39.2 ± 3.9 1 to 2 ton A
(4.0 ± 0.4)
[28.9 ± 2.8] classes
Nut C
58.8 ± 5.9 3 ton Second
(6.0 ± 0.6) cylinder
[43.2 ± 4.2] class
A Second
39.2 ± 3.9 1 to 2 ton
(4.0 ± 0.4) E B cylinder
[28.9 ± 2.8] classes
Nut D 58.8 ± 5.9
(6.0 ± 0.6)
3 ton
[43.2 ± 4.2] class B
58.8 ± 5.9
Nut E (6.0 ± 0.6) C
[43.2 ± 4.2]
58.8 ± 5.9 1 to 3 ton E
Nut F (6.0 ± 0.6) classes
[43.2 ± 4.2] D
58.8 ± 5.9
Nut G (6.0 ± 0.6)
[43.2 ± 4.2] G First cylinder 217242
12-43
MAST AND FORKS
12-44
MAST AND FORKS
14.1 Forks
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
Forks are often mistreated and forgotten. As insub- Maintenance shops may bend forks back into shape,
stantial as they seem, neglecting forks could make weld on them, or drill holes through them. Lift truck
them dangerous. users can add attachments to the truck that will put
Forks carry larger loads than almost any lifting device stress on the forks. Drum clamps and portable booms
but there are no mandatory requirements for mainte- can be supported on the forks–but what is contained
nance or inspection. in the drum or on the boom hook makes the differ-
ence in safety.
You can find thousands of extra parts for lift trucks in
some fleet repair shops, but you'll seldom see spare Forks are often used to open rail car doors and break
forks. Even when all the trucks on the fleet are the loads out or away from other loads. They are also
same, fleet maintenance managers rarely order spare used to pick up capacity loads not seated against the
forks. Forks can last a long time if treated properly, but fork shank and to pick up off-balanced loads far from
they can be deceptive. Careful inspection is required the side of the truck. The fork tips are sometimes
to ensure forks are not worn. inserted under other fork trucks to lift them during
maintenance operations.
It's true that most forks are customized to the truck by
model and capacity: They are big, heavy and thought Lift trucks may collide with building columns and
of as indestructible. However, forks can be abused or walls, and though the forks show no discernible bend,
ruined in the course of daily work. they may be damaged beyond safety.
Here are some examples of ways that forks can be Any time excessive heat is applied to any part of a
damaged: fork during repair, hidden damage may occur.
Forks can be overloaded either by picking up a load The fork itself is a concern but so are the hooks that
too far out on the forks, or simply by picking up loads secure them to the lift carriage.
heavier than the truck rating.
12-45
MAST AND FORKS
12-46
MAST AND FORKS
Chain elongation
Unit: mm (in.)/20 links
Truck type
Item 1 ton 2 ton 3 ton
class class class
318 381 508
A
(12.52) (15.00) (20.00) 20 links
Duplex mast
327 392 523
B
(12.87) (15.43) (20.59)
A: Standard value (new) B: Service limit
213965
12-47
MAST AND FORKS
14.4 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(1) Back-to-front clearance check on lift bracket main
rollers F
(a) Raise the forks slightly from the ground.
(b) Insert a bar between the upper part of lift
bracket and the inner mast, and slide the inner
mast to one side. Using feeler gauges, mea-
sure clearance F between the main roller and
inner mast on the opposite side.
Unit: mm (in.)
F 1 (0.04) maximum F 213966
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
For adjustment, refer to "Adjusting clearance G1
between the middle roller and thrust plate" on 12.2.1
(2) Adjusting clearance G between the middle roller
and thrust plate.
12-48
MAST AND FORKS
inner mast.
Unit: mm (in.)
F 1 (0.04) maximum
12-49
MAST AND FORKS
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
213974
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
12-50
MAST AND FORKS
Unit: mm (in.)
0.1 to 0.5
G2
(0.004 to 0.020)
12-51
MAST AND FORKS
14.8 Right and Left 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.
(d) Slowly lower the inner mast to the bottom to Inner mast
ensure the piston rods move smoothly and that
the left and right lift cylinders come to the end Shim (l)
of stroke simultaneously at the maximum lift
position of inner mast. Cylinder bracket
213943
12-52
MAST AND FORKS
Clearance between lift rollers and side rollers incorrect Readjust clearance.
Lift bracket and
Relubricate side rollers and replace
inner mast do not Rollers not rotating smoothly on their shafts
other rollers.
move smoothly.
Mast strip clearance incorrect Adjust shim.
Too much clearance on side rollers Readjust by adding shims.
Lift bracket or inner
Lift chains unequally tensioned Readjust chain tension.
mast are not in a
level position. Shim adjustments unequally made on between left and
Remove or add shims.
right lift cylinders (at maximum height)
Mast makes noise. Rollers not rotating smoothly on their shafts Check and adjust or replace rollers.
Lift cylinder Lift cylinder packing damaged Replace.
descends due to a
load (Drift). Sliding (inside) surface of lift cylinder tube damaged Replace.
Whole mast shakes. Mast-support bushing or metal worn Retighten or replace.
Mast is distorted. Off-center loading or overload Replace mast assembly.
Distortion of finger bar
Fork tips differ in
Distortion of forks Repair or replace.
height.
Uneven loading
12-53
MAST AND FORKS
12-54
MAST AND FORKS
F G2
G
F
G1
F
G
G
B2
C
Lift bracket
12-55
MAST AND FORKS
17.Triplex Mast
17.1 Mast System
Triplex mast
Following table shows a combination of truck and mast models:
5C33C37
217243
Mast serial number location
Example: 5 C 33 C 37
Maximum lifting height
["37" stands for 3700 mm (146 in.)]
Order of the minor charge
("A" for the original,
"B" for the first change,
"C" for the second change,
and so on)
Applicable truck model designation
(Example: FG35AN)
15, 20: 1 ton class, 25: 2 ton class,
30, 33: 3 ton class
Mast type
Generation of truck compatible with
the mast
("2" for the original,
"3" for the first change,
and so on up to "9") 214853
How to read mast model code
12-56
MAST AND FORKS
10
Front
3
Cross section of lift Cross section of
bracket upper main roller hose pulley
4
5
Front Front
2 6
Front
217263
The triplex mast provides a free lift amount until the For lifting operation, oil is first sent to the first lift cylin-
top of lift bracket reaches the mast height. der which raises the forks until the cylinder rod
The mast assembly consists of the inner mast, middle reaches its stroke end.
mast, outer mast, lift bracket, first lift cylinder and sec- When the first lift cylinder rod extends fully, the second
ond lift cylinders. lift cylinders raise the assembly consisting of the lift
The first lift cylinder raises the lift bracket, while the bracket, first lift cylinder, inner mast and middle mast.
second lift cylinder operates the three-stage telescopic The shoulder sections of the mast main rollers contact
mechanism and lift bracket. Two pairs of lift chains are the mast rails. The rollers are installed perpendicular
installed. The cylinders and lift chains are designed for to the sliding surfaces.
smooth and effective operation.
The main rollers used in the triplex mast models are
the same as those used in the simplex mast models.
12-57
MAST AND FORKS
12-58
MAST AND FORKS
A
A
First
cylinder
4
1
Second
cylinder
5
2
217137
Sequence
1 Nut, Spring 4 Tilt socket pin, Tilt cylinder
2 Fork, Lift bracket assembly 5 Mast support bearing cap, Bushing
3 High-pressure hose for lift cylinder
217244
6
Do not shut off the function of the mast interlock sys-
tem by means of "GSE" service tool. 2
217240
12-59
MAST AND FORKS
217238
Do not touch any levers except the tilt lever while the
engine is running.
Never loosen tilt socket bolts except for during tilt cyl-
inder disassembling.
217220
12-60
MAST AND FORKS
1
217276
12-61
MAST AND FORKS
1 1
9 16 1
23
10 26
28
22
First cylinder
24 25
12
21 19
7 8
6 20
8
7
27 30
14
5
13 Second
3 cylinder
29
2 4 11 18 217245
Sequence
1 Hose for first lift cylinder, Clamp, Bolt, Washer 17 Snap ring, Hose pulley, Shaft, Snap ring, Chain
2 Bolt, Washer wheel
3 Shim 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose
5 Chain guard 20 Hose, T-joint, Down safety valve
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, shim, Bracket
8 Nut, Spring (chain for second lift cylinder) 23 Bolt, Washer, Shim
9 Mast strip, Shim 24 Second lift cylinder
10 Main roller, Shim 25 Mast strip, Shim
11 Main roller, Shim 26 Main roller, Shim
12 Inner mast 27 Main roller, Shim
13 Nut 28 Middle mast
14 Lift chain (for first lift cylinders) 29 Cap, Bolt, Washer
15 Chain guard, Bolt, Washer 30 Outer mast, Grease nipple
16 Snap ring, Chain wheel
12-62
MAST AND FORKS
Start by
With the lift bracket facing up, place the mast horizon-
tally on wood blocks.
Place a wood block as a wedge to prevent the inner
and middle masts from sliding.
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 replac-
ing rollers or selecting shims to adjust clearances.
Suggestions for Disassembly
(1) Removing first lift cylinder 4
4
(a) Remove retaining bolts from the first lift cylin-
der.
(b) Hitch slings on the first lift cylinder, and gently
remove the cylinder. Use two slings. Wind or
tie slings securely to prevent slipping.
217246
11
10 217247
12 217248
12-63
MAST AND FORKS
29
26 217249
Inspections after Disassembly
(1) Mast
(a) Check each roller for wear, binding or other
defects.
(b) Check each roller on rolling surface for pitting
or other defects.
(c) Check the mast member and the welded joints
of cross-members, shafts and supports for
cracks.
(d) Check the mast support bushings for wear or
217226
other defects.
Unit: mm (in.)
Distortion of finger bar A 5 (0.2) maximum Straightedge
A: Standard value 217134
12-64
MAST AND FORKS
F 2 F 3
1 2 1 1
214830
Reassembly
1 Lift bracket 4 Lift bracket lower roller
2 Lift bracket upper roller 5 Side roller
3 Lift bracket middle roller 6 Inner mast
The lift bracket has three main roller bearings at one Adjust the clearance to the specification with shims (a)
side and a side roller at both sides as shown. and (b) for the middle roller and with shim (c) for the
Clearances F, G and G1 must be maintained between lower roller.
these rollers and thrust surface of the inner mast for
smooth operation. Unit: mm (in.)
0.1 to 0.5
Clearance G Clearance G
(0.004 to 0.020)
Clearance between roller side surface and inner mast
thrust surface (right-to-left play): Clearance F
Clearance G is used for determining the correct Clearance between roller circumference and inner
amount of shims at the bearing seat. mast thrust surface (back-to-front play):
Move the lift bracket to the top of the inner mast and Clearance F is used for determining the proper size of
press the bracket to either the left-most or rightmost the rollers.
position. Select appropriate diameter rollers so that the clear-
Take measurements of clearance G between the side ance meets the specification. Make sure the rollers
surface of roller and inner mast. rotate smoothly when installed.
Note: It is not necessary to adjust the lift bracket up- Unit: mm (in.)
per roller with shims. Clearance F 1 (0.04) maximum
12-65
MAST AND FORKS
Clearance G1
Clearance between side roller circumference and
inner mast side roller thrust surface: Move the 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.
Adjust the clearance with shims (d) to the specifica-
tion.
Unit: mm (in.)
0.1 to 0.5
Clearance G1
(0.004 to 0.020)
12-66
MAST AND FORKS
213938
12-67
MAST AND FORKS
Unit: mm (in.)
Truck type
Item 2 ton class
1 ton class
3 ton class
Shim (g) 1 (0.04) 1 (0.04)
Shim (h) 2 (0.08) 1 (0.04)
Shim (i) 2 (0.08) 1 (0.04)
Shim (j) 2 (0.08) 1 (0.04)
12-68
MAST AND FORKS
Unit: mm (in.)
Clearance G2 0.1 to 0.5 (0.004 to 0.020 )
Shim (k)
Adjusting method
Inner mast 217250
If clearance G2 is excessive, increase the thick-
ness of shims (k) as required.
Check the smooth movement by moving slowly up
and down the bracket after the clearance is
adjusted.
At the factory, shims (k) are usually adjusted to 1 mm
(0.04 in.) for the shipment.
213943
(4) With the cylinder rods fully retracted and the cylin-
ders positioned vertically, measure clearance H.
Adjust the clearance to be 1.6 mm (0.06 in.) or
less by adding or removing shims (m).
Unit: mm (in.)
Clearance H 1.6 (0.06) maximum Shim (m)
Adjusting method
If clearance H is excessive, add shims (m). Nor-
mally on a new truck, the second lift cylinders are
not fitted with shims (m). If the clearance is 3.2 mm 214855
(0.13 in.) or more, make sure to include a 3.2 mm
(0.13 in.) thick sheet in the shim pack that is to be
installed.
(5) After reassembly, perform an operation test to
check if the stroke of the left and right cylinders is
the same. Refer to 22.8 Right and Left Lift Cylin-
der Stroke Inspection and Adjustment.
12-69
MAST AND FORKS
214840
12-70
MAST AND FORKS
Triplex Mast
Tightening torque Unit: N·m (kgf·m) [lbf·ft]
Tightening
Item Truck model
torque
58.8 ± 5.9
Nut A (6.0 ± 0.6)
[43.2 ± 4.2] 1 to 3 ton
49.0 ± 4.9 classes
Nut B (5.0 ± 0.5)
[36.1 ± 3.6]
39.2 ± 3.9 1 to 2 ton
(4.0 ± 0.4)
[28.9 ± 2.8] classes
Nut C A
58.8 ± 5.9 3 ton E
(6.0 ± 0.6)
[43.2 ± 4.2] class
39.2 ± 3.9
(4.0 ± 0.4) 1 to 2 ton
[28.9 ± 2.8] classes E
Nut D
58.8 ± 5.9 3 ton F
(6.0 ± 0.6) A
[43.2 ± 4.2] class First cylinder Second cylinder
Second cylinder
58.8 ± 5.9
Nut E (6.0 ± 0.6)
C
B
[43.2 ± 4.2] 1 to 3 ton
58.8 ± 5.9 classes
Nut B
F (6.0 ± 0.6)
[43.2 ± 4.2] D 217251
12-71
MAST AND FORKS
12-72
MAST AND FORKS
12-73
MAST AND FORKS
22.1 Forks
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
Forks are often mistreated and forgotten. As insub- Maintenance shops may bend forks back into shape,
stantial as they seem, neglecting forks could make weld on them, or drill holes through them. Lift truck
them dangerous. users can add attachments to the truck that will put
Forks carry larger loads than almost any lifting device stress on the forks. Drum clamps and portable booms
but there are no mandatory requirements for mainte- can be supported on the forks–but what is contained
nance or inspection. in the drum or on the boom hook makes the differ-
ence in safety.
You can find thousands of extra parts for lift trucks in
some fleet repair shops, but you'll seldom see spare Forks are often used to open rail car doors and break
forks. Even when all the trucks on the fleet are the loads out or away from other loads. They are also
same, fleet maintenance managers rarely order spare used to pick up capacity loads not seated against the
forks. Forks can last a long time if treated properly, but fork shank and to pick up off-balanced loads far from
they can be deceptive. Careful inspection is required the side of the truck. The fork tips are sometimes
to ensure forks are not worn. inserted under other fork trucks to lift them during
maintenance operations.
It's true that most forks are customized to the truck by
model and capacity: They are big, heavy and thought Lift trucks may collide with building columns and
of as indestructible. However, forks can be abused or walls, and though the forks show no discernible bend,
ruined in the course of daily work. they may be damaged beyond safety.
Here are some examples of ways that forks can be Any time excessive heat is applied to any part of a
damaged: fork during repair, hidden damage may occur.
Forks can be overloaded either by picking up a load The fork itself is a concern but so are the hooks that
too far out on the forks, or simply by picking up loads secure them to the lift carriage.
heavier than the truck rating.
12-74
MAST AND FORKS
12-75
MAST AND FORKS
Chain elongation
Unit: mm (in.)/20 links
Truck type
Item 1 ton 2 ton 3 ton
class class class
317.5 381 508
A
(12.50) (15.00) (20.00) 20 links
Triplex mast
327 392 523
B
(12.87) (15.43) (20.59)
A: Standard value (new) B: Service limit
213965
12-76
MAST AND FORKS
22.4 Adjusting Clearance between Lift Bracket Roller and Inner Mast
(1) Back-to-front clearance check on lift bracket main
rollers F
(a) Raise the forks slightly from the ground.
(b) Insert a bar between the upper part of lift
bracket and the inner mast, and slide the inner
mast to one side. Using feeler gauges, mea-
sure clearance F between the main roller and
inner mast on the opposite side.
Unit: mm (in.)
F 1 (0.04) maximum F 213966
12-77
MAST AND FORKS
Unit: mm (in.)
F 1 (0.04) maximum
12-78
MAST AND FORKS
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
213974
Unit: mm (in.)
0.1 to 0.5
G
(0.004 to 0.020)
12-79
MAST AND FORKS
Unit: mm (in.)
0.1 to 0.5
G2
(0.004 to 0.020)
12-80
MAST AND FORKS
22.8 Right and Left 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 cyl-
inder stroke.
213978
(d) Slowly lower the inner mast to the bottom to Inner mast
ensure the piston rods move smoothly and that
the left and right lift cylinders come to the end Shim (l)
of stroke simultaneously at the maximum lift
position of inner mast. Cylinder bracket
213943
12-81
MAST AND FORKS
Clearance between lift rollers and side rollers incorrect Readjust clearance.
Lift bracket and
Relubricate side rollers and replace
inner mast do not Rollers not rotating smoothly on their shafts
other rollers.
move smoothly.
Mast strip clearance incorrect Adjust shims.
Too much clearance on side rollers Readjust by adding shims.
Lift bracket or inner
Lift chains unequally tensioned Readjust chain tension.
mast are not in a
level position. Shim adjustments unequally made on between left and
Remove or add shims.
right lift cylinders (at maximum height)
Mast makes noise. Rollers not rotating smoothly on their shafts Check and adjust or replace rollers.
Lift cylinder Lift cylinder packing damaged Replace.
descends due to a
load (Drift). Sliding (inside) surface of lift cylinder tube damaged Replace.
Whole mast shakes. Mast-support bushing or metal worn Retighten or replace.
Mast is distorted. Off-center loading or overload Replace mast assembly.
Distortion of finger bar
Fork tips differ in
Distortion of forks Repair or replace.
height.
Uneven loading
12-82
MAST AND FORKS
12-83
MAST AND FORKS
G
G2
G1
F G
G
B2
F
G
G
B1
C
Lift bracket
Mast width is slightly wide at the lower portion than at the upper portion.
Measure the clearance at the mast upper position.
214859
12-84