MAST AND FORKS/LATER VERSION: DESCRIPTION

Mast and Forks/Later Version

Description
G Later Mast Models
1
3A15B 3B15C 3C15C
3A25B 3B25C 3C25C
A
3A30B 3B30C 3C30C

3
Forward Forward

B Detail of A Detail of F

D
Forward Forward

C
Detail of B, C Detail of D
E

4
Forward
F

Detail of E Detail of G
5
207081 207082

Components
1. Inner mast A. Main roller E. Main roller
2. Outer mast B. Main roller F. Main roller
3. Lift chain C. Main roller G. Mast strip
4. Lift bracket D. Side roller
5. Mast support bearing cap
Diam. of 2EC20/25/
The simplex mast features two lift cylinders 2EC15/18
main roller 25E/30
placed behind the mast columns, right and left, to
provide maximum forward visibility. S 99 (3.90) 113.8 (4.48)

Mast strips are fitted to the top end parts of outer M 100 (3.94) 115 (4.53)
mast. These strips are for backing up the inner L 101 (3.98) 116 (4.57)
mast when the mast is tilted backward. LL 102 (4.016) 117 (4.606)
Unit: mm (in.)

9.1
MAST AND FORKS/LATER VERSION: REMOVAL & INSTALLATION

Removal and Installation

Mast and Lift Bracket Assembly

6
1 207083

Sequence
1. Nut 4. Tilt socket pins
2. Forks and lift bracket 5. Tilt cylinders
3. High-pressure hose for lift cylinders 6. Mast-support bearing caps and bushing

Suggestions
Removing Lift Bracket
1. Tilt the mast forward, and lower the inner mast
all the way. Slacken the lift chains, and
remove the nuts from the anchor bolts.
2. Tilt the mast back to vertical position. Secure
the lift bracket to prevent it from falling over.
Raise the inner mast until the lift bracket
becomes free. Then, back the truck away,
leaving the lift bracket and fork assembly
standing on the floor.

207084

9.2
 MAST AND FORKS/LATER VERSION: REMOVAL & INSTALLATION

Removing Lift Cylinder High-Pressure Removing Mast Support Bearing Caps

Hoses 1. Scribe marks on the bearing caps before
With the mast in the lowest position, disconnect removing them.
the hoses at the flow regulator valve.

Removing Tilt Cylinders

1. Attach a sling to the holes, left and right in
the top cross member of the mast, and lift the
mast with a hoist.

Marks

207087

2. Remove the cap bolts and lift off the mast

assembly, laying it down flat on a level floor.

207085
NOTE
Lay the mast assembly on a floor large enough
for disassembly.
NOTE
Be sure to use a hoist having a capacity enough
to carry the weight of the mast assembly.

Weight of Components
2EC15/18 2EC20/25/ 2EC30
25E
Gross (Simplex 520 725 830
3.3 m mast) (1150) (1600) (1830)

Unit: kg (lb)

2. Remove the tilt socket pins, and separate the

masts from the tilt cylinders.

Tilt socket
pin

207086

9.3
MAST AND FORKS/LATER VERSION: DISASSEMBLY

Disassembly
12 10
15
3

11
10

13
9
2
16 17

2
6

6
7

6 14
1
4
5 207088

Sequence
1. Nut 10. Cylinder clamp, seat, shims, cushion, collar
and bolts
2. Forks and lift bracket
11. Bolt and shims
3. Backrest
12. Mast strip and shims
4. Main roller and shims
13. Main roller and shims
5. Main roller and shims
14. Main roller and shims
6. Side roller, bracket, and shims
15. Inner mast
7. Hose guard
16. Lift cylinders
8. Lift hose (high pressure)
(Rubber hose, T-joint and down safety valve) 17. Outer mast
9. Snap ring and chain wheel

9.4
 MAST AND FORKS/LATER VERSION: DISASSEMBLY

Suggestions
Removing Mast Strips and Main Rollers
Remove bolts 10, 11 to free lift cylinder 16. Cross
the tops of the two lift cylinders. Slide inner mast
15 toward the bottom of outer mast 17, and
remove main rollers 13, 14 and mast strips 12.

Removing Inner Mast

After removing the main rollers, attach a sling to
the inner mast crossmember and slide the inner
mast toward the top of the outer mast until it gets
clear of the outer mast roller shafts. Sling the inner
mast again and remove it from the outer mast.

207089

9.5
MAST AND FORKS/LATER VERSION: DISASSEMBLY

Inspection after Disassembly

Mast Lift Chains, Chain Wheels and Chain
Wheel Supports
1. Check each roller for wear, binding or other
defects. 1. Measure the length of each chain to be sure
that two chains are equal in length. Also
2. Check each roller for flat spots on rolling sur- check the chains for wear, evidence of break-
face. age, link binding and twist.
3. Check the mast member and the welds of 2. Check each chain anchor bolt for cracks or
crossmembers, shafts and supports for damaged thread.
cracks.
3. Check each chain wheel support and chain
4. Check the mast support bushings for wear or wheel for crack or wear. Check to be sure that
other damage. the wheels are capable of smooth rotation.
4. Measure sections of chain that travel over the
chain wheel.

Length of Chain (Per 20 Links)

2EC15/18 2EC20/25/ 2EC30
25E

A 318 (12.52) 381 (15.00) 508 (20.00)

B 327 (12.87) 392 (15.43) 523 (20.59)

Unit: mm (in.)
207090 A = Assembly standard B = Repair or service limit

Lift Bracket
Mast Strips
1. Check the main rollers and side rollers for
Check the mast strips for damage, wear or
smoothness of rotation. Inspect each roller for
wear and cracks. distortion.

2. Check the welds of the bracket for cracks.

3. Check the finger bar for bend or distortion.

Finger bar

207091

Distortion of 5 mm (0.2 in.)

A
finger bar maximum

A = Assembly standard

9.6
 MAST AND FORKS/LATER VERSION: REASSEMBLY

Reassembly
To reassemble, follow the reverse of disassembly
sequence and do the following steps:
Adjusting Mast and Lift Bracket Clearance
Rollers for mast and lift bracket are available in
three sizes (diameters) for selective use. Select
the size that will provide a longitudinal clearances
of 1 mm (0.04 in.) and less.
Clearance
Mast Supports
1. Check mast support bushing for wear.
Replace if worn.
2. Apply a grease to the inside surfaces and
grooves of the caps.
3. Install mast support bushings and caps with
beveling toward the center of truck respective-
ly. Greasing will be facilitated if the mast is lift-
ed by placing wooden blocks under it.

Mast cap
Bushing
Clearance

Lower roller Upper/middle roller

Apply grease
207096
Side with wider cut
203712
Roller Sizes
Diameter of 2EC15/18 2EC20/25/
main roller 25E/30 Precautions for Installing Chain Anchor Kit
Be careful not to install the center plate in the posi-
S 99 (3.90) 113.8 (4.48)
tion for link plate.
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
2
LL 102 (4.016) 117 (4.606) 3
Unit: mm (in.)

Cylinder Clamps
Install each lift cylinder in place (in vertical position)
by fitting to the support, and see if there is any
clearance between the outer mast and cylinder. 1
Reduce the clearance, if any, to zero by shimming.
4 Stamped mark
207094

1. Link plate (marked)

2. Center plate (not marked)
3. Link
4. Split pin
Shims

207093

9.7
MAST AND FORKS/LATER VERSION: REASSEMBLY

Inspection and Adjustment

Forks
1. Carefully inspect the forks for cracks. Special
attention should be given to the heel section
A, all weld areas and B mounting brackets.
Forks with cracks should be removed from
service.
“Wet Test” magnetic particle inspection is gen-
erally preferred due to its sensitivity and the
ease of interpreting the results.
3. Check the fork blade D. The fork should be
withdrawn from service if the thickness is
reduced to less than the tolerant thickness.
Check the heel of fork. 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 intended loads.

D Toe
A

101628 Heel 101630

2. Check the difference in height of one fork tip

Tolerant Thickness Standard Limit
to the other when mounted on the fork carrier.
A difference in fork tip height can result in 2EC15 40 (1.6) 31 (1.2)
uneven support of the load and cause prob-
2EC18 40 (1.6) 33 (1.3)
lems when entering loads.
2EC20 45 (1.8) 36 (1.4)
The maximum allowable difference in fork tip
elevation C is 5 mm (0.20 in.) for pallet forks. 2EC25/25E 45 (1.8) 39 (1.5)
2EC30 45 (1.8) 40 (1.57)
Replace one or both forks when the difference
in fork tip height exceeds the maximum allow- Unit: mm (in.)
able difference.

101629

9.8
 MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT

Chain Tension Adjustment

Tightening Torque
! WARNING
2EC15/18/20/25/25E 2EC30
Personal injury can be caused by sudden 57 84
Nut 2
movement of the mast and lift bracket. (5.8) (8.6)
Nut 3
Blocks must be used to prevent the mast [42.0] [62.2]
and lift bracket from any movement while 98 147
the adjustments are made. Keep hands and Nut 1 (10) (15.0)
feet clear of any parts that can move. [72.3] [108.5]
Unit: N•m (kgf•m) [lbf•ft]
1. Have the truck standing on a level floor, with
6. Adjust until tension is equal on both chains.
the mast vertical and the forks lowered to the
floor. Check to be sure that the lift cylinders
are fully retracted.
2. Set the anchor bolts with nut 3.
3. Raise the forks slightly and push the chains
inward midway between the chain wheel and
anchor alternately to check the tension. When
adjusting the chains by means of the nut 3,
tilt the mast forward to slacken the chains to
facilitate adjustment.
4. Turn nut 3 to adjust the chain tension. Then,
hold the anchor bolt in place with a wrench
and tighten nut 2 to the specified torque.
5. Hold nut 3 in place with a wrench, and tighten
nut 1 to the specified torque.

Anchor bolt

2 nut

3 nut
1 nut
102709

9.9
MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT

Clearance Adjustment on Lift Bracket

Longitudinal Clearance Adjustment on Lift
Bracket Main Rollers
1. Raise the forks a little from the floor. Roller Sizes
2. Insert a bar between the upper part of lift Diameter of 2EC15/18 2EC20/25/
bracket and the inner mast, and push the inner main roller 25E/30
mast to one side. Using a feeler gauge, meas-
ure the clearance F between the main roller S 99 (3.90) 113.8 (4.48)
and inner mast on the opposite side. M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
F LL 102 (4.016) 117 (4.606)
Unit: mm (in.)

4. Lift bracket main rollers (upper and center

rollers).
The upper rollers should be the same in size
or 1-rank larger than the center rollers.

F
207095

0.1 to 1.0 mm
Clearance F
(0.004 to 0.039 in.)

3. If the clearance F is out of specification, use

oversize rollers.

Lower roller Upper/middle roller

207096

9.10
 MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT

Lateral Clearance Adjustment on

Lift Bracket Main Rollers and Side Rollers
1. Raise the mast all the way. For the lift bracket upper main roller or center
2. Set a dial indicator on the inner mast with its main roller, to extend 0.5 mm (0.02 in.), insert
contact point rested on the side of the lift a 0.5 mm (0.02 in.) shim (a) on the inside
bracket. and remove the 0.5 mm (0.02 in.) shim (b)
from the lower stopper, then tighten the bolts.
3. Go over to the opposite side of the mast, and
push the lift bracket to one side with a bar.
Inner mast
Set the indicator to zero.
4. Insert a bar between the inner mast and lift
bracket on the indicator side, and push the lift
Shims (b)
bracket to the opposite side.

Shims (a)

207156

203818

5. Read the indicator.

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

6. Adjust clearance G1 between the middle main

roller and weld plate 2 at the maximum lift
position by increasing or decreasing the thick-
ness of the shim.

1 1
G1

2 2

202276

9.11
MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT

Lateral Clearance Adjustment on

Lift Bracket Main Rollers and Side Rollers,
continued
7. Lower the lift bracket slightly below its maxi- 8. With the lift bracket at the maximum lift posi-
mum lift position, then adjust clearance G2 tion, adjust clearance G3 with shims.
between the side roller and mast by increas-
ing or decreasing the thickness of the shim.

G2

Side roller

Side Roller
G3
207158

202277

Adjust the side roller clearance by adding

shims under the roller bracket.

Shims

Shims
Roller 207157

Bracket
207098

9.12
 MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT

Mast Clearance Adjustment

Longitudinal Clearance Adjustment on Lateral Clearance Adjustment on
Mast Main Rollers Inner Mast Main Rollers
1. Tilt the mast all the way backward. 1. Raise the mast all the way.
2. Using a feeler gauge, measure the clearance 2. Set a dial indicator on the inside of the outer
H between the inner mast lower roller and the mast with its contact point rested on the inner
outer mast. mast.
3. Go over to the opposite side of the mast, and
0.1 to 1.0 mm push the inner mast against the outer mast.
Clearance H
(0.004 to 0.039 in.) Set the indicator to zero.

3. If the clearance H is out of specification, use

oversize rollers.

Roller Sizes
Diameter of 2EC15/18 2EC20/25/
main roller 25E/30
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53) J
L 101 (3.98) 116 (4.57) 204886

LL 102 (4.016) 117 (4.606)

4. Insert a bar between the outer and inner
Unit: mm (in.)
masts on the indicator side, and push the
inner mast to the opposite side.
5. Read the indicator.

H 0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)

207099

J
207101

9.13
MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT
6. If the clearance J is out of specification, adjust K
it by using shims.

Shims
207103

6. If the clearance K is out of specification, adjust

207102
it by using shims.

NOTE

Refer to Main Roller Shim Replacement.

Lateral Clearance Adjustment on

Outer Mast Main Rollers Shims
1. Raise the mast all the way.
207104
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 NOTE
push the outer mast against the inner mast
with a bar. Set the indicator to zero. Refer to Main Roller Shim Replacement.
4. Insert a bar between the outer and inner masts,
and push the inner mast to the opposite side.
5. Read the indicator.

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

204889

9.14
 MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT

Main Roller Shim Replacement Mast Strip Adjustment

1. Remove the lift bracket from the mast. 1. Check the clearance L with the clearance
between the outer mast rollers and inner mast
NOTE set to zero (0) in maximum lift position.

Refer to REMOVAL AND INSTALLATION, L

1. Lift Bracket Removal.

2. Lower the inner mast below the outer mast as

follows:
a. Raise the front end of the machine, and
block that end with a jack stand or the like.
b. Remove the upper set of bolts from the lift
200391
cylinders, and lift the inner mast with a
hoist. Remove the hose guard.
c. Remove the clamps from the lift cylinders. 0.1 to 0.5 mm
Pull the bottom ends of the cylinders from Clearance L
(0.004 to 0.020 in.)
the outer mast, tilt the cylinders to the cen-
ter of the mast, and tie them to the cross-
member of outer mast with rope. 2. If the clearance L is out of specification,
d. Slowly lower the inner mast until it comes adjust it by means of shims.
in contact with the lift cylinders.
e. Now the main rollers can be removed from NOTE
the inner and outer masts. Remove the mast
strips and shims in advance because they Refer to Main Roller Shim Replacement.
are apt to come off under this condition.

3. After adjusting the all clearance, move the

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

Shims

202961

200392

9.15
MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT

Tilt Angle Adjustment

1. Adjust the tire pressure correctly and keep 5. After adjusting the tilt angle, tighten the sock-
the truck level. et bolts to the specified torque.
2. Tilt the mast all the way backward and stop
the engine Tightening torque 127 to 152
for tilt cylinder (13 to 15.5)
3. Measure the backward tilt angle of the mast socket bolt [94 to 112]
at both sides.
Unit: N•m (kgf•m) [lbf•ft]
3. To adjust the tilt angle, loosen the bolt of tilt
cylinder socket, and adjust the cylinder stroke
by turning the rod on either cylinder so that
there is no difference in stroke between the
cylinders, left and right.

Bolt

207105

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

Forward/backward tilt angle 5° to 6° (standard)

9.16
 MAST AND FORKS/LATER VERSION: INSPECTION & ADJUSTMENT
Lift Cylinder Stroke Adjustment
1. Slowly raise the inner mast, and check 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 rocks at that
moment, make a shim adjustment. Abnormal
condition can be told by a little time lag in
stopping between the piston rods, left and
right, and rocking of the rod with a longer
cylinder stroke.
204698
Adjusting Method
1. Raise the inner mast, place blocks under the
left and right sides of the inner mast, and
lower the mast until it rests on the blocks.
202983
2. Remove the set bolt at the top of lift cylinder
which stopped first, retract the piston rod, and
insert shims at the top of piston rod end.
3. Extend the piston rod, and tighten the cylinder
set bolt. Remove the blocks from under the
inner mast.
Set bolt
Shims
200365
4. Slowly lower the inner mast all the way to
make sure that the piston rods move smooth-
ly and that the left and right lift cylinders
come to the end of stroke simultaneously.
Bleeding Lift Cylinders
When air and oil remaining inside the air chamber
of the rod and inside the rod chamber between
the tubes are compressed, they open the check
valve and flow out of the cylinder. Therefore,
there is no need to bleed the lift cylinders.
9.17
MAST AND FORKS/LATER VERSION: SERVICE DATA

Service Data

Inner mast
F L

G1

G3

G2
B
F

Lift Bracket
A
C1
K

H E

J
C2

Outer mast D

207106

9.18
 MAST AND FORKS/LATER VERSION: SERVICE DATA

Service Data
Item Truck Model 2EC15/18 2EC20/25/25E 2EC30
Difference in height between fork tips A 5 (0.20)
100 x 40 100 x 40 125 x 45
A
(3.9 x 1.6) (3.9 x 1.6) (4.92 x 1.8)
Forks Chains

B 2EC15 2EC20
Thickness of forks 100 x 31 100 x 38
(3.9 x 1.2) (3.9 x 1.5) 125 x 39
2EC18 2EC25/25E (4.92 x 1.53)
100 x 33 100 x 40
(width x thickness) (3.9 x 1.3) (3.9 x 1.57)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 101 (3.94) 115 (4.53)
Rollers

Diameter of main roller

L A 101 (3.98) 116 (4.57)
LL A 102 (4.016) 117 (4.606)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
A 523 (20.59) 575 (22.64)
(inside to inside) A

Distance between inner mast main rollers

A 581 (22.87) 639 (25.16)
(outside to outside) B

Distance between lift bracket main rollers

A 485 (19.09) 535 (21.06)
(outside to outside) C1

Distance between lift bracket main rollers

A 487 (19.17) 537 (21.14)
(outside to outside) C2

Distance between lift bracket main rollers

A 491 (19.33) 539 (21.22)
(outside to outside) D

Distance between lift bracket side rollers

Mast and Lift Bracket

A 496 (19.53) 546 (21.50)

(outside to outside) E

Longitudinal clearance of lift bracket middle rollers

A 0.1 to 1.0 (0.004 to 0.039)
(with forks slightly lifted) F

Lateral clearance of lift bracket middle main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G1

Lateral clearance of lift bracket side rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2

Lateral clearance of lift bracket lower main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G3

Longitudinal clearance of mast main rollers

A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H

Lateral clearance of inner mast main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) J

Lateral clearance of outer mast main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) K

Mast strip clearance

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) L

9.19
MAST AND FORKS/LATER VERSION: TROUBLESHOOTING

Troubleshooting

Complaint Possible Cause

Lift bracket and inner mast will
not move smoothly
Lift bracket or inner mast cocks
Mast makes noise
Load drops (drifts)
Mast shakes entirely
Mast is distorted
Fork tips differ in height
a) Main rollers and side rollers having no proper clearance
b) Rollers involved binding on their shafts
c) Rollers damaged
d) Improper mast-to-strip clearance
a) Too much clearance on side rollers, or side rollers damaged
b) Lift chains unequally tensioned
c) Shim adjustments unequally made on left and right lift cylinders
(at maximum height)
Rollers not rotating smoothly on their shafts, or damaged
a) Lift cylinder packing damaged
b) Lift cylinder bore grooved
c) Control valve defective
Mast-support bushing worn
Improper loading or overload
a) Finger bar bent
b) Forks bent
c) Distortion of mast due to off-center loading

9.20