MAST AND FORKS/EARLIER VERSION: DESCRIPTION

Mast and Forks/Earlier Version

Description

Earlier Mast Models

3A15A 3B15B 3C15B
3A25A 3B25B 3C25B
G
3A30A 3B30B 3C30B
1

2
3

D
E

4
F

205973 205020

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/
2EC15/18
main roller 25E/30
S 99 (3.90) 114 (4.49)
M 100 (3.94) 115 (4.93)
L 101 (3.98) 116 (4.57)

8.1
MAST AND FORKS/EARLIER VERSION: DESCRIPTION

General Information
The simplex mast features two lift cylinders placed
behind the mast columns, left and right, to provide
maximum forward visibility.
Each main roller is of declining type and takes up
thrust forces acting in two directions, front-back
and sideways. The roller shaft is slightly tilted to
orient the roller in such a way as to provide the
two-direction counteraction.
It is ideal that the roller end face should be in light
contact with the mast. However, in actual mast
operation, some clearance inevitably occurs
between the roller and mast as the mast extends
(for lifting) or contracts (for lowering.) The
Caterpillar mast is designed to minimize the clear-
ance when the mast is fully extended—a condition
for which stability assumes greater importance.
Mast strips are fitted near the top of the outer
mast. These strips help support the inner mast
during back-tilting.

8.2
 MAST AND FORKS/EARLIER VERSION: REMOVAL & INSTALLATION

Removal and Installation

Mast and Lift Bracket Assembly

2
6 5 3 4
1

205974

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

8.3
MAST AND FORKS/EARLIER VERSION: REMOVAL & INSTALLATION

Suggestions
Removing Lift Bracket Removing Lift Cylinder Low-Pressure
1. Tilt the mast forward and lower the inner mast Hoses
all the way. Slacken the lift chains and remove 1. Power up the truck. Extend the mast all the
the nuts from the anchor bolts. way and turn the truck off. Disconnect the
hoses at the return connector.

To RH lift cylinder

To tank

Return connector

205975 To LH lift cylinder

205976
2. Tilt the mast back to vertical position. Raise the
inner mast until the lift bracket becomes free. 2. Lower the mast.
Back the truck away, leaving the lift bracket and
fork assembly standing on the floor.
Removing Lift Cylinder High-Pressure
Hoses
With the mast in the lowest position, disconnect
the hoses at the flow regulator valve.

8.4
 MAST AND FORKS/EARLIER VERSION: REMOVAL & INSTALLATION

Removing Tilt Cylinders

1. Attach a sling to the left and right holes in the 2. Mark the rod end of each tilt cylinder. Marking
top crossmember of the mast and lift the mast is not necessary when the cylinders are being
with a hoist. replaced. In such a case, adjust the tilt angle
and the stroke of both cylinders to eliminate
the difference in stroke between the two.

Mark

205970

201737
NOTE
Be sure to use a hoist with enough capacity to 3. Using a wrench, turn each rod to disconnect
carry the weight of the mast assembly. it from the mast.

Removing Mast Support Bearing Caps

1. Scribe marks on the bearing caps before
Weight of Components
removing them.
2EC15/18 2EC20/25/ 2EC30
25E
Outer mast 140 190 205
(310) (420) (450)
Inner mast 135 180 190
(300) (400) (420)
Lift bracket 105 150 175
(with backrest) (230) (330) (390)
Marks
Forks (2) 80 130 165
(180) (290) (360)
Lift cylinders 60 75 95
and others (130) (170) (210)
200372
Gross (Simplex 520 725 830
3.3 m mast) (1150) (1600) (1830)
2. Remove the cap bolts and lift off the mast
Unit: kg (lb)
assembly, laying it down flat on a level floor.

NOTE
Lay the mast assembly on a floor large enough
for disassembly.

8.5
MAST AND FORKS/EARLIER VERSION: DISASSEMBLY

Disassembly

13

3 12
10 11
6
16 9
4 14 18

17
7

5
15
2 8
1
205977

Sequence
1. Nut 10. Snap ring and chain wheel
2. Forks and lift bracket 11. Cylinder clamp, seat, shims, cushion, collar
and bolts
3. Backrest
12. Bolt and shims
4. Main roller and shims
13. Mast strip and shims
5. Snap ring and main roller
14. Main roller and shims
6. Side roller, bracket, and shims
15. Main roller and shims
7. Hose guard
16. Inner mast
8. High-pressure lift hose
(Rubber hose, T-joint and down valve) 17. Lift cylinder
9. Low pressure rubber hose 18. Outer mast

8.6
 MAST AND FORKS/EARLIER VERSION: DISASSEMBLY

Suggestions
Removing Mast Strips and Main Rollers
Remove bolts 11, 12 to free lift cylinder 17. Cross
the tops of the two lift cylinders. Slide inner mast
16 toward the bottom of outer mast 18, and
remove main rollers 14, 15 and mast strips 13.

Removing Inner Mast

After removing the main rollers, attach 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.

204876

8.7
MAST AND FORKS/EARLIER VERSION: DISASSEMBLY

Inspection after Disassembly

Mast Lift Chains, Chain Wheels and
1. Check each roller for wear, binding or other Chain Wheel Supports
defects. 1. Measure the length of each chain to be sure
2. Check each roller for flat spots on rolling sur- that two chains are equal in length. Also
face. check the chains for wear, evidence of break-
age, link binding and twist.
3. Check the mast member and the welds of
crossmembers, shafts and supports for
Length of Chain (Per 20 Links)
cracks.
2EC15/18 2EC20/25/ 2EC30
4. Check the mast support bushings for wear or 25E
other damage.
A 318 (12.52) 381 (15.00) 508 (20.00)

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

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

2. Check each chain anchor bolt for cracks or

damaged thread.
3. Check each chain wheel support and chain
wheel for crack or wear. Check to be sure that
the wheels are capable of smooth rotation.
204877
Mast Strips
Lift Bracket Check the mast strips for damage, wear or
1. Check the main rollers and side rollers for distortion.
smoothness of rotation. Inspect each roller for
wear and cracks.
2. Check the welds of the bracket for cracks.
3. Check the finger bar for bend or distortion.

Finger bar

204878

Distortion of 5 mm (0.2 in.)

A
finger bar maximum

A = Assembly standard

8.8
 MAST AND FORKS/EARLIER VERSION: REASSEMBLY

Reassembly
To reassemble, follow the reverse of disassembly Mast Supports
sequence and do the following steps:
1. Apply a grease to the inside surfaces and
Adjusting Mast and Lift Bracket Clearance grooves of the caps.

Rollers for mast and lift bracket are available in

three sizes (diameters) for selective use. Select
the size that will provide a longitudinal clearances Mast cap
Bushing
of 1 mm (0.04 in.) and less.

Inner mast Outer mast

Clearance
Apply grease
Side with
wider cut
203712
Lift
bracket Clearance
2. Install mast support bushings and caps with
beveling toward the center of truck respec-
tively. Greasing will be facilitated if the mast is
203529
lifted by placing wooden blocks under it.

Roller Sizes Precautions for Installing Chain Anchor Kit

Diameter of 2EC15/18 2EC20/25/ Be careful not to install the center plate in the posi-
main roller 25E/30 tion for link plate.
S 99 (3.90) 114 (4.49)
M 100 (3.94) 115 (4.53) 2
L 101 (3.98) 116 (4.57) 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 1
clearance between the outer mast and cylinder. 4 Stamped mark
Reduce the clearance, if any, to zero by shimming. 200383

1. Link plate (marked)

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

204879

8.9
MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Inspection and Adjustment

Forks
1. Carefully inspect the forks for cracks. Special 3. Check the fork blade D. The fork should be
attention should be given to the heel section withdrawn from service if the thickness is
A, all weld areas and B mounting brackets. reduced to less than the tolerant thickness.
Forks with cracks should be removed from Check the heel of fork. Fork blade length may
service. also be reduced by wear, especially on
“Wet Test” magnetic particle inspection is gen- tapered forks and platens. Remove the forks
erally preferred due to its sensitivity and the from service when the blade length is no
ease of interpreting the results. 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 34 (1.3) 32 (1.3)
uneven support of the load and cause prob-
2EC18 37 (1.5) 35 (1.4)
lems when entering loads.
2EC20 / 25 / 25E 42 (1.7) 40 (1.6)
The maximum allowable difference in fork tip
elevation C is 5 mm (0.20 in.) for pallet forks. 2EC30 50 (2.0) 45 (1.8)

Replace one or both forks when the difference Unit: mm (in.)

in fork tip height exceeds the maximum allow-
able difference.

101629

8.10
 MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Chain Tension Adjustment

4. After adjusting the chains by means of the

! WARNING
lock nuts, tighten the anchor nuts to the spec-
ified torque. Check each chain for twist.
Personal injury can be caused by sudden
movement of the mast and lift bracket.
Blocks must be used to prevent the mast Lock nuts
and lift bracket from any movement while
the adjustments are made. Keep hands and
feet clear of any parts that can move.

1. Have the truck standing on a level floor, with

the mast vertical and the forks lowered to the
floor. Check to be sure that the lift cylinders
are fully retracted.
204880
2. Set the anchor bolts with lock nut.
3. Raise the forks a little and push the chains
2EC15/18/20/25/25E 2EC30
inward midway between the chain wheel and
anchor alternately to check the tension. When Min Max Min Max
adjusting the chains by means of the anchor Tightening 10 15 15 20
bolt lock nuts, tilt the mast forward to slacken torque for (72) (108) (108) (144)
the chains to facilitate adjustment. anchor bolt
lock nut [98] [147] [147] [196]

Unit: kgf•m (lbf•ft) [N•m]

5. Make sure that the chain tension is correct

with the mast in vertical (0°) position.

8.11
MAST AND FORKS/EARLIER 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. 3. If the clearance F is out of specification, use
2. Insert a bar between the upper part of lift oversize rollers.
bracket and the inner mast, and push the inner
mast to one side. Using a feeler gauge, meas-
ure the clearance F between the main roller F
and inner mast on the opposite side.

F
F

Upper/middle roller Lower roller

204883

Roller Sizes
Diameter of 2EC15/18 2EC20/25/
F 204882
main roller 25E/30
S 99 (3.90) 114 (4.49)

0.1 to 1.0 mm M 100 (3.94) 115 (4.53)

Clearance F
(0.004 to 0.039 in.) L 101 (3.98) 116 (4.57)
Unit: mm (in.)

8.12
 MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Lateral Clearance Adjustment on

Lift Bracket Main Rollers and Side Rollers
1. Raise the mast all the way. 5. Read the indicator.
2. Set a dial indicator on the inner mast with its 6. If the clearance G is out of specification, use
contact point rested on the side of the lift oversize rollers. Adjust the side roller clear-
bracket. ance by adding shims under the roller 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. G

4. Insert a bar between the inner mast and lift G

bracket on the indicator side, and push the lift
bracket to the opposite side. G

G
Upper/middle
roller Side roller

204884

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

203818 7. After adjusting the clearance, move the mast

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

8.13
MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Mast Clearance Adjustment

Longitudinal Clearance Adjustment on
Mast Main Rollers
1. Tilt the mast all the way backward. 3. If the clearance H is out of specification, use
2. Using a feeler gauge, measure the clearance oversize rollers.
H between the inner mast lower roller and the
outer mast. Roller Sizes
Diameter of 2EC15/18 2EC20/25/
0.1 to 1.0 mm main roller 25E/30
Clearance H
(0.004 to 0.039 in.)
S 99 (3.90) 114 (4.49)
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
Unit: mm (in.)

204885

8.14
 MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Lateral Clearance Adjustment on

Inner Mast Main Rollers
1. Raise the mast all the way. 5. Read the indicator.
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 indicator side, and push the inner mast
to the opposite side.

J
204887

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

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

it by using shims.
J
204886

Shims A

Shims B

204888

NOTE

Refer to Main Roller Shim Replacement.

8.15
MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Lateral Clearance Adjustment on

Outer Mast Main Rollers
1. Raise the mast all the way. 5. Read the indicator.
2. Set a dial indicator on the outer mast with its
contact point rested on the inner mast. 0.1 to 0.5 mm
Clearance K
3. Go over to the opposite side of the mast, and (0.004 to 0.020 in.)
push the outer mast against the inner mast
with a bar. Set the indicator to zero.
6. If the clearance K is out of specification, adjust
4. Insert a bar between the outer and inner
it by means of shims.
masts, and push the inner mast to the oppo-
site side.

K
204890

204889

NOTE

Refer to Main Roller Shim Replacement.

8.16
 MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Main Roller Shim Replacement

1. Remove the lift bracket from the mast. Mast Strip Adjustment
1. Check the clearance L with the clearance
NOTE between the outer mast rollers and inner mast
set to zero (0) in maximum lift position.
Refer to REMOVAL AND INSTALLATION, Lift
Bracket Removal.
L

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
cylinders, and lift the inner mast with a hoist.
Remove the hose guard. 200391
c. Remove the clamps from the lift cylinders.
Pull the bottom ends of the cylinders from
the outer mast, tilt the cylinders to the center 0.1 to 0.5 mm
Clearance L
of the mast, and tie them to the crossmem- (0.004 to 0.020 in.)
ber of outer mast with rope.
d. Slowly lower the inner mast until it comes in
contact with the lift cylinders. 2. If the clearance L is out of specification,
adjust it by means of shims.
e. Now the main rollers can be removed from
the inner and outer masts. Remove the mast
strips and shims in advance because they NOTE
are apt to come off under this condition.
Refer to Main Roller Shim Replacement.

202961

8.17
MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Tilt Angle Adjustment Lift Cylinder Stroke Adjustment

1. Adjust the tire pressure correctly and keep the 1. Slowly raise the inner mast, and check how
truck level. the piston rods, left and right, stop at the
2. Tilt the mast all the way backward and turn off moment the inner mast reaches its maximum
the truck. height.
3. Measure the backward tilt angle of the mast at 2. If the top of the inner mast rocks at that
both sides. moment, make a shim adjustment. Abnormal
condition can be told by a little time lag in
3. To adjust the tilt angle, loosen the lock nut of
stopping between the piston rods, left and
tilt cylinder socket, and adjust the cylinder
right, and rocking of the rod with a longer
stroke by turning the rod on either cylinder so
cylinder stroke.
that there is no difference in stroke between
the left and right cylinders.

204698

204893

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)

5. After adjusting the tilt angle, tighten the lock

nuts to the specified torque.

2EC15/18/ 2EC25E/30
20/25
Tightening torque 28 40
for tilt cylinder (203) (289)
lock nuts [275] [392]
Unit: kgf•m (lbf•ft) [N•m]

8.18
 MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Adjusting Method
1. Raise the inner mast, place blocks under the 3. Extend the piston rod, and tighten the cylin-
left and right sides of the inner mast, and der set bolt. Remove the blocks from under
lower the mast until it rests on the blocks. the inner mast.

Stopper bolt

Shims

202983 200365

2. Remove the set bolt at the top of lift cylinder 4. Slowly lower the inner mast all the way to
which stopped first, retract the piston rod, make sure that the piston rods move smooth-
and insert shims at the top of piston rod end. ly and that the left and right lift cylinders
come to the end of stroke simultaneously.

8.19
MAST AND FORKS/EARLIER VERSION: INSPECTION & ADJUSTMENT

Mast Adjustment Chart

F
C

C
E
L
D
Lift Bracket

G1
B
G2
Inner mast
F
A
K
H
J

Outer mast
204894A

2EC15/18 2EC20/25/25E/30

Distance between outer mast main rollers (inside to inside) A 511 (20.12) 559 (22.01)

Distance between inner mast main rollers (outside to outside) B 581 (22.87) 639 (25.16)

Distance between lift bracket main rollers (outside to outside) C, D 477 (18.78) 523 (20.59)

Distance between lift bracket side rollers (outside to outside) E 482 (18.98) 528 (20.79)
Longitudinal clearance of lift bracket main rollers (with forks slightly lifted) F 0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of lift bracket main rollers (fully raised) G1 0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket side rollers (fully raised) G2 0.1 to 0.5 (0.004 to 0.020)

Longitudinal clearance of mast main rollers (in the whole lift range) H 0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of inner mast main rollers (fully raised) J 0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of outer mast main rollers (fully raised) K 0.1 to 0.5 (0.004 to 0.020)

Mast strip clearance (fully raised) L 0.1 to 0.5 (0.004 to 0.020)

Unit: mm (in.)

8.20