Caterpillar Cat EC35N EC40N EC45N Forklift Lift Trucks Service Repair Manual SNA2EC4-60200 and up

®

Lift Trucks

Service Manual Chassis & Mast EC35N, EC40N, EC45N EC55N

For use with GE SX Control Service Manual.

A2EC4-60200-up A2EC5-60200-up

SENB8474-01

TABLE OF CONTENTS CHAPTER 1: GENERAL INFORMATION Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Truck Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Nameplate and Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Dimensions Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

General Information (Standard Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

CHAPTER 2: FRONT AXLE AND REDUCTION DIFFERENTIAL Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Procedures and Key Points for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Reduction and Differential

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2.6

Axle Shaft and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.18

Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.19

CHAPTER 3: TRANSFER ASSEMBLY Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Reassembly

....................................................................

3.5

Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

i

TABLE OF CONTENTS CHAPTER 4: REAR AXLE Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Procedures and Key Points for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6

Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10

Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15

Adjustment of Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16

Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17

CHAPTER 5: BRAKE SYSTEM

ii

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

Master Cylinder and Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7

Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11

TABLE OF CONTENTS CHAPTER 5: BRAKE SYSTEM (cont.)

Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13

Adjustment and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14

Automatic Adjuster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14

Procedure for Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14

Brake Fluid Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15

Inspecting Reservoir Tank Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15

Procedures for Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.17

Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.19

CHAPTER 6: STEERING SYSTEM Steering System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

Oil Flow Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

Steering Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2

Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Inspection after Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5

Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Steer Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

iii

TABLE OF CONTENTS CHAPTER 7: HYDRAULIC SYSTEM Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Hydraulic Pump

.................................................................

7.4

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5

Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6

Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11

Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12

Removal and Installation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12

Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15

Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15

Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.16

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.17

Placing Pump Back into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.20

Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.21

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.21

Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.22

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.23

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.25

Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.26

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.26

Lift and Tilt Cylinders Removal Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.27

Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.33

Disassembly Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.34

Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.48

Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.51

Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.51

Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.51

Inspection and Adjustment

iv

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.54

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.55

Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.56

Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.56

TABLE OF CONTENTS

CHAPTER 8: MAST AND FORKS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2

Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5

Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9

Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12

Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12

Dual-stage Full Free Panoramic Mast (Duplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.16

Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.21

Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.25

Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.25

Chain, Chain Wheel Support and Chain Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.26

Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.27

Clearance Adjustment on Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.30

Mast Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.32

Main Roller Shim Replacement (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.34

Mast Strip Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.34

Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.38

Lift Cylinder Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.39

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.40

Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.41

CHAPTER 9: SERVICE DATA Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1

Fine Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1

Fine Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2

Course Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3

Course Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4

Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5

Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.11

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.12

Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.13

Weight of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.14

Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.15

Special Tool Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.16

Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.19

v

GENERAL INFORMATION CHAPTER 1: GENERAL INFORMATION Scope..............................................................................................................................................................

1.1

Truck Models Covered....................................................................................................................................

1.1

Nameplate and Serial Number Locations ......................................................................................................

1.2

Dimensions .....................................................................................................................................................

1.3

Dimensions Chart ...........................................................................................................................................

1.4

General Information (Standard Models) .........................................................................................................

1.5

GENERAL INFORMATION

Scope This service manual deals with all components or systems of the Cat Lift Trucks, except for the electrical system, which is covered in a separate manual.

Truck Models Covered This service manual furnishes service and maintenance information for the following trucks.

Truck Model

Serial Number

EC35N

A2EC4-60200-up

EC40N

A2EC4-60200-up

EC45N

A2EC4-60200-up

EC55N

A2EC5-60200-up

1.1

GENERAL INFORMATION

Nameplate and Serial Number Locations

1.2

GENERAL INFORMATION

Dimensions

1.3

GENERAL INFORMATION

Dimensions Chart Ref#

Truck Model

EC35N

EC40N

EC45N

EC55N

4650 (183)

4650 (183)

5055 (199)

5320 (209)

150 (5.9)

150 (5.9)

160 (6.3)

160 (6.3)

1060 (41.5)

1060 (41.5)

1060 (41.5)

1060 (41.5)

1220 (48)

1220 (48)

1220 (48)

1220 (48)

6° / 8°

6° / 8°

6° / 8°

6° / 8°

A

Maximum Lift

B

Free Lift

C

Maximum Fork Spacing (outside to outside)

D

Fork Length

E

Tilt Angle (forward/backward)

F

Overall Length

3640 (143.3)

3691 (145.3)

3746 (147.5)

3912 (154.0)

G

Overall Width (outside of tires)

1270 (50.0)

1270 (50.0)

1315 (52.0)

1420 (55.9)

H

Overall Height (to top of mast, lowered)

2270 (89.5)

2270 (89.5)

2350 (92.5)

2120 (83.5)

I

Overall Height (to top of overhead guard)

2341 (92.2)

2341 (92.2)

2341 (92.2)

2341 (92.2)

J

Overall Height (to top of mast, extended)

4550 (179.1)

4550 (179.1)

4115 (162.0)

4125 (162.4)

K

Tread (front)

1040 (41.0)

1040 (41.0)

1065 (42.0)

1116 (44.0)

L

Tread (rear)

965 (38.0)

965 (38.0)

965 (38.0)

965 (38.0)

M

Wheelbase

1575 (62.0)

1575 (62.0)

1575 (62.0)

1720 (67.7)

N

Front Overhang

450 (17.7)

450 (17.7)

465 (18.3)

480 (18.9)

O

Rear Overhang

395 (16)

446 (18)

486 (19)

492 (19)

P

Underclearance (at center of wheelbase)

106 (4.2)

106 (4.2)

106 (4.2)

106 (4.2)

Unit: mm (in.)

1.4

GENERAL INFORMATION

General Information (Standard Models) Truck Model Units

EC35N

EC40N

meters

3.3

3.3

3.3

2.9

4581

4833

5677

6448

(10099)

(10656)

(12516)

(14215)

6849 (15099)

7101 (15656)

7945 (17516)

8716 (19215)

Standard Controller Standard Simplex Mast Size Service Weight

Battery With Max. Battery

Work Performance Traveling Performance

kg (lb)

Rated Capacity/

kg/mm

3500/500

4000/500

4500/600

5500/600

Load Center

(lb/in.)

(7000/24)

(8000/24)

(10,000/24)

(12,000/24)

mm (in.)

4650 (183)

4650 (183)

5055 (199)

5320 (209)

Maximum Fork Height

Power Train

EC55N

GE SX Controller

Without (standard axle)

EC45N

Lift Speed

36V

m/sec.

0.25 (50)

0.22 (43)

0.20 (39)

0.17 (33)

(Rated Load)

48V

(fpm)

0.31 (64)

0.34 (67))

0.25 (49)

0.21 (41)

Lowering Speed (rated load)

0.54 (106)

0.56 (110)

Tilt Angle (forward/backward) degrees Free Lift

6° / 8°

mm (in.)

150 (5.9)

160 (6.3)

Travel Speed

36V

km/h

14.0 (8.7)

13.8 (8.6)

13.7 (8.5)

13.6 (7.3)

(Without Load)

48V

(mph)

17.0 (10.6)

16.9 (10.5)

15.8 (10.3)

16.6 (10.3)

Minimum Turning

mm

2214

2258

2294

2468

Radius

(in.)

(87)

(89)

(90)

(97)

Traction Motor

36V

60min.

15.3 (11.4)

Output

48V

HP(kW)

20.9 (15.5)

Transfer

Type

Spur

Gear

Ratio

5.131

Reduction

Type

Spiral Bevel

Gear

Ratio

4.571

Axle Housing

Banjo

Differential

Gear Type/ Number

Gears

Straight Bevel/2

Pinions

Straight Bevel/2

1.5

GENERAL INFORMATION

Truck Model

Power Steering System

Units

EC35N thru EC55N

Type

Dynamic Load Sense Inside

82째 Degrees

Turning Angle Outside

59째

Steering Wheel Diameter

mm (in.)

328 (13)

2

Cylinder Minimum Test Pressure

kgf/cm (psi) [kPa] Type

120 (1706) [11,768] Self-Adjusting Duo-Servo

Inside Drum mm (in.)

Diameter

317.5 (12.50)

Service Brake Lining Thickness

mm (in.)

10 (0.39)

Master Cylinder ID

mm (in.)

Primary 31.75 (1.25) Secondary 19.05 (0.75)

Traveling System

Brake System

Wheel Cylinder ID

1.6

31.75 (1.250)

Type Park Brake

Lever Operating Effort

Mechanical, Mounted on Front Wheels kgf (lbf) [N]

25 to 30 (55 to 66) [245 to 295]

Front Wheels

Fixed Type

Rear Wheels

Center Pivot Type

Mounting

Wheel Alignment

Oscillation Angle Camber

3째 Degrees 1째

GENERAL INFORMATION

Truck Model Units

EC35N

EC40N

EC45N

Type

Gear

Make

Haldex - Barnes

Model

W1500

Hydraulic Pump

Displacement cc (cu in.)

38 (2.32)

Make Control Valve

Hydraulic System

Valve

Husco International

Model

5000CC Sectional Valve

Relief

kgf /cm2

Aux

155 (2250) 15513

Pressure

(psi) [kPa]

Lift Tilt

197 (2850) 19650

Flow Regulator

Type Regulated Flow Rate

Lift Cylinders

Variable liter (cu.in.) / min

ID Stroke

100 (6100)

115 (7018)

60 (2.36)

70 (2.75) 1650 (64.96)

mm (in.)

ID

100 (3.937)

Stroke

120 (4.724)

Tilt Cylinders

Hydraulic Tank Capacity (Approx)

liter (US gal.)

Liter

Mast Model Outer

118x28x24x13 (4.6x1.1x0.9x0.5)

Inner, Middle

118x24x24x12 (4.6x0.9x0.9x0.47)

Bearing

Side Rollers

Bearing

118x32 (4.65x1.26)

Mast and Forks

130x26x26x13 (5.1x1.0x1.0x0.5)

130x34 (5.12x1.34)

Lubricating type needle roller bearing

Diameter x Width, mm (in.)

Lift Chains

52x36 (2.05x1.42) BL834

Forks (length x width x thick), mm (in.)

BL1034

1220x150x50 (48x6x2)

Fork Spread (outer width), mm (in.)

1060 (41.5)

Voltage

36 / 48

Amp Hours (6 hr. rate)

36V

1760

48V

1540

Height

Dimensions

Battery

130x30x26x15 (5.1x1.2x1.0x0.6)

Ball Bearing

Diameter x Width, mm (in.)

Weight (Min/Max)

48 (12.7)

CJ type

Flange ID X flange back thickness X flange front thickness X web thickness Main Rollers

Compartment

EC55N

590 (23.22) mm (in.)

Length

1003 (39.5)

Width

1156 (45.5) kg (lb)

1500 / 2268 (3400 / 5000)

1650 / 2268 (3600 / 5000)

1800 / 2268 (3975 / 5000)

1.7

FRONT AXLE AND REDUCTION DIFFERENTIAL CHAPTER 2: FRONT AXLE AND REDUCTION DIFFERENTIAL Specifications ................................................................................................................................................

2.1

Structure

...................................................................................................................................................

2.2

Procedures and Key Points for Removal and Installation..............................................................................

2.3

Front Tire .................................................................................................................................................

2.3

Front Axle Assembly................................................................................................................................

2.4

Reduction and Differential ......................................................................................................................

2.6

Axle Shaft and Hub .......................................................................................................................................

2.6

Disassembly.............................................................................................................................................

2.7

Inspection and Repair..............................................................................................................................

2.8

Assembly .................................................................................................................................................

2.9

Adjustments ............................................................................................................................................ 2.15 Troubleshooting .............................................................................................................................................. 2.18 Service Data .................................................................................................................................................. 2.19

FRONT AXLE AND REDUCTION DIFFERENTIAL

Specifications Truck Models

EC35N thru EC55N

Reduction

Gear type

Differential

Housing type

Running Gear

Items

Front axle type

Spiral bevel gear

Reduction ratio

4.571 Banjo type

Type and number of gears

Suspension

Large

Straight bevel gear x 2

Small

Straight bevel gear x2 Full-floating axle tube type

Front wheel

Frame fixing type

2.1

FRONT AXLE AND REDUCTION DIFFERENTIAL

Structure

5

1

6

7

8

• •

•• • • •

•

2

3

4

206653

Sequence 1 Front wheel hub drum 2 Front axle support 3 Axle shaft 4 Axle housing 5 Reduction bevel pinion 6 Reduction bevel gear 7 Differential case 8 Differential carrier

2.2

FRONT AXLE AND REDUCTION DIFFERENTIAL

Procedures and Key Points for Removal and Installation Front Tire Removal 1 Wheel nut Special tool needed

2

Front tire 2

Wheel socket

MCF-1098

Preparation (1) Pull the hand brake lever, and place wheel stoppers at the rear tires.

(2) Loosen the wheel nuts about two rotations, and lift the vehicle with a crane or a hydraulic unit.

1

206654

(a) Lifting the vehicle with a crane, attach a cable to the outer and inner mast crossmembers, and lift the vehicle.

Use protection cloth for the cable.

(b) Lifting the vehicle with the mast, tilt the mast fully backward, place jack stands which can bear the weight under the mast, and tilt the mast forward until the front tires are off the ground.

206665

NOTE For both methods, place jack stands under the frame to prevent it from falling.

200227

Installation Follow the removal sequence in reverse. Be careful with the following key point.

Tighten wheel nuts evenly to the specified torque to prevent tire shimmy.

Tightening sequence 8

NOTE Insure wheel nut mounting holes are free of paint and grease before torquing wheel nuts.

Wheel nut tightening torque N·m (kgf·m) [lbf·ft]

1

551±55 (56.2 ± 5.6) [406.5 ± 40.6]

5

3

4

7

6 2

206655

2.3

FRONT AXLE AND REDUCTION DIFFERENTIAL Front Axle Assembly Preparation (1) Pull the hand brake lever, and place wheel stoppers at the front and rear tires.

(2) Remove the mast and the lift bracket assembly. (Refer to Mast and Fork section.)

(3) Loosen the front tire nuts about two rotations, and jack up the vehicle.

(4) Place jack stands under the frame on both sides at the front so that the vehicle becomes level.

(5) Remove the front tires. (Refer to Front Tire Removal procedure.)

(6) Drain differential oil.

NOTE If replacing the front axle housing, carry out the above preparation.

Removal 3 2

3

4

1

206666

Sequence 1 Axle shaft, Bolt, Spring washer 2 Bolt, Spring washer 3 Nuts, Spring washers, Bolts 4 Front axle assembly 2.4

FRONT AXLE AND REDUCTION DIFFERENTIAL

Key points for removal (1) Removing axle support bolts (a) Place jack stands under the front of the transmission to support it.

← 206667

(b) Attach a cable with protection cloth to the mast fitting on the front axle assembly, and lift the assembly until the cable is taught. Wind the cable rope twice firmly. (c) To remove bolts, remove the bolts at the top on both sides, and insert a guide bar.

Then remove the other bolts.

Installation Follow the removal sequence in reverse. Be careful with the following key points.

(1) Clean the mounting surface on the differential carrier completely, and apply liquid gasket before installation.

(2) Apply liquid gasket to the mounting surface of the axle shaft, and tighten bolts.

Tightening torque of axle shaft bolts N·m (kgf·m) [lbf·ft]

Reduction and Differential When replacing the reduction gear, replace the reduction pinion, too.

Tooth contact of the reduction gear and the reduction pinion must be adjusted by mating the transfer assembly on the pinion side and the differential carrier on the gear side.

Therefore remove the transfer assembly and the differential carrier from the frame before adjusting the tooth contact.

Dismount the traction motor before removing or installing the transfer assembly. (Refer to Power Line section.)

Place the transfer assembly on a stable work bench, and remove the differential carrier.

128.3 ± 12.8 (13.1 ± 1.3) [94.7 ± 9.4]

(3) Tighten axle support bolts to the specified torque.

Tightening torque of axle support bolts

EC35N thru EC55N

N-m (kgf•m) [lbf•ft]

693.8 (70.8) [512]

2.5

FRONT AXLE AND REDUCTION DIFFERENTIAL

Axle Shaft and Hub Disassembly

6

1 5 4 3 2

206656

Sequence 1 Front tire 2 Axle shaft, Bolt, Spring washer 3 Bolt, Lock washer, Lock nut 4 Taper roller bearing (inner) 5 Front hub drum assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal 6 Retainer, O-ring

Preparation (1) Loosen front wheel nuts about two rotations, and jack up the vehicle.

(2) Place stands or wood blocks under the frame on both sides at the front so that the vehicle is at the level position when viewed from the front.

(3) Remove the front tires.

(4) Drain differential oil.

NOTE Normally, disassemble the front axle while the axle housing is installed to the frame.

2.6

FRONT AXLE AND REDUCTION DIFFERENTIAL

Key points for disassembly (1) Removing lock nut Use the special tool A to remove the lock nut.

Special tool needed A

Socket wrench A

MCF-1102

200232

(2) Removing front wheel hub Use a universal hub puller or a gear puller to remove the front wheel hub.

If the interfit of the taper roller bearing (inner race) is tight, the inner oil seal may fall off and the taper roller bearing may remain in the axle housing.

In this case, insert a wedge-shape tool between the taper roller bearing (inner) and the retainer to take out the taper roller bearing.

200233

(3) Using a bearing puller, remove the inner race of tapered roller bearing left on the axle housing, along with the seal retainer.

203651

2.7

FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection and Repair (1) Axle shaft 2 (a) Insert the differential bevel gear to the axle shaft, and measure looseness in the rotating direction with a dial gauge.

A: Standard value B: Repair limit Service limit 0.07 to 0.17 Looseness of the A (0.0028 to 0.0067) axle shaft spline mm (in.)

B 0.5 (0.020) (b) Measuring axle shaft bend (i) Attach a dial gauge to the center of the axle shaft, and rotate the axle shaft.

Measure bend of the axle shaft.

200235

A: Standard value B: Repair limit Service limit Axle shaft bend A (1/2 of gauge reading) mm (in.)

B

1.0 or less (0.039) 2.0 (0.079)

(ii) Attach a dial gauge to the edge of the flange, and rotate the axle shaft.

Measure deflection of the flange.

A: Standard value B: Repair limit Service limit Flange deflection mm (in.)

A

0.04 (0.0015)

B

0.5 (0.020)

(2) Retainer 6 Check for wear or damage on the retainer circumference.

(3) Front hub drum 5 If uneven wear or damage is found on the inner surface of the brake drum, grind and repair.

A: Standard value B: Repair limit Service limit Inner diameter A of brake drum B mm (in.)

2.8

317.5 + 0.2 (12.5 + 0.078 ) 0 0 318.5 (12.539)

200276

FRONT AXLE AND REDUCTION DIFFERENTIAL Assembly

6

•

• 4

•• •

•

5

•

•

3 •

• • ••

•

5

2d

2

2a

2c

2b

1 206657

Sequence 1 Retainer, O-ring 2 Front hub drum assembly 2a Taper roller bearing (outer) 2b Spacer 2c Oil seal 2d Oil seal 3 Taper roller bearing (inner) 4 Lock nut, Lock washer, Bolt 5 Axle shaft, Bolt, Spring washer 6 Front tire, Wheel nut

2.9

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