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Caterpillar Cat EC25EN Forklift Lift Trucks Service Repair Manual SN A4EC3-20200 and Up PDF
Caterpillar Cat EC25EN Forklift Lift Trucks Service Repair Manual SN A4EC3-20200 and Up PDF
EC20N, EC25N
A4EC2-10200-up
A4EC2-20200-up
99759-6K110
TABLE OF CONTENTS
i
TABLE OF CONTENTS
iii
TABLE OF CONTENTS
Hydraulic Pump
Removal ....................................................................................................................................... 7.10
Installation .................................................................................................................................... 7.11
Disassembly ................................................................................................................................. 7.12
Working Rules and Tips ........................................................................................................... 7.12
Suggestions ............................................................................................................................. 7.14
Inspection after Disassembly ....................................................................................................... 7.16
Body ......................................................................................................................................... 7.16
Mounting Flange Face ............................................................................................................. 7.16
Bushes and Balance Plate....................................................................................................... 7.16
Gears ....................................................................................................................................... 7.16
Reassembly.................................................................................................................................. 7.17
Inspection after Reassembly........................................................................................................ 7.21
Control Valve
Removal ....................................................................................................................................... 7.22
Installation .................................................................................................................................... 7.23
Disassembly ................................................................................................................................. 7.24
Suggestions ................................................................................................................................. 7.25
Reassembly.................................................................................................................................. 7.25
Lift and Tilt Cylinders
Removal
Lift Cylinders ............................................................................................................................ 7.26
Tilt Cylinders ............................................................................................................................ 7.29
Disassembly
Lift Cylinders ............................................................................................................................ 7.31
Tilt Cylinders ............................................................................................................................ 7.32
Inspection after Disassembly ....................................................................................................... 7.33
Precautions for Reassembly ........................................................................................................ 7.33
Inspection and Adjustment
Hydraulic Tank.............................................................................................................................. 7.34
Control Valve ................................................................................................................................ 7.35
Lift and Tilt Cylinders.................................................................................................................... 7.38
Adjusting Method ..................................................................................................................... 7.39
Testing ...................................................................................................................................... 7.40
Chapter 9: Troubleshooting
Front Axle and Reduction Differential .......................................................................................... 9.1
Brake System ............................................................................................................................... 9.2
Steering System........................................................................................................................... 9.4
Hydraulic System ......................................................................................................................... 9.6
Rear Axle ..................................................................................................................................... 9.8
Mast and Forks ............................................................................................................................ 9.9
v
TABLE OF CONTENTS
vi
TABLE OF CONTENTS
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.
8609141A
1.1
GENERAL INFORMATION
Mast
serial number
Chassis
serial number
Power steering
motor serial number
Traction motor
serial number
Hydraulic motor Nameplate
serial number
8609141
1.2
GENERAL INFORMATION
Dimensions
8609142
8609143
1.3
GENERAL INFORMATION
Dimensions Chart
Ref# Truck Model EC15N, EC18N EC20N, EC25N EC25EN EC25LN EC30N
A Maximum Lift 3320 (130) 3340 (131) 3340 (131) 3340 (131) 3310 (130)
B Free Lift 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3)
D Fork Length 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42)
Tilt Angle
E 5°/6° 5°/6° 5°/6° 5°/6° 5°/6°
(forward/backward)
F Overall Length 3050 (120) 3155 (124) 3255 (128) 3255 (128) 3325 (131)
Overall Width
G 945 (37) 1055 (41.5) 1055 (41.5) 1103 (43.5) 1103 (43.5)
(outside of tires)
K Tread (front) 793 (31) 875 (34.5) 875 (34.5) 900 (35.5) 900 (35.5)
L Tread (rear) 826 (32.5) 900 (35.5) 900 (35.5) 900 (35.5) 900 (35.5)
M Wheelbase 1170 (46) 1280 (50.5) 1380 (54.5) 1380 (54.5) 1380 (54.5)
N Front Overhang 376 (14.8) 394 (15.5) 394 (15.5) 394 (15.5) 406 (16)
O Rear Overhang 434 (17.2) 411 (16) 411 (16) 411 (16) 469 (18.5)
Underclearance
P 118 (4.6) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9)
(at center of wheelbase)
Unit: mm (in.)
1.4
GENERAL INFORMATION
Rated Capacity/ kg/mm 1350/600 1600/600 1800/600 2275/600 2275/600 2500/600 2725/600
Load Center (lb/in.) (3000/24) (3500/24) (4000/24) (5000/24) (5500/24) (5000/24) (6000/24)
Maximum Fork Height mm (in.) 33235 (131) 3340 (131) 3315 (131)
Performance
36V .38 (75) .36 (71) .32 (63) .28 (55) .25 (49)
Work
Travel Speed 36V km/h 18 (11.2) 17.3 (10.8) 17.4 (10.8) 17.0 (10.6) 17.1 (10.6)
Traveling
Traction Motor 36V 60min. 8.3 (6.2) 12.1 (9.0) 13.7 (10.2)
Output 48V HP(kW) 9.2 (6.8) 14.2 (10.6) 17.2 (12.8)
1.5
GENERAL INFORMATION
Truck Model
Master
mm (in.) 22.22 (0.8748)
Cylinder ID
Wheel
22.22 (0.8748) 28.58 (1.1252)
Cylinder ID
Mounting
Rear Wheels Center Pivot Type
Wheel Oscillation 3°
Alignment Angle Degrees
Camber 1°
1.6
GENERAL INFORMATION
Truck Model
Units EC15N EC18N EC20N EC25N EC25EN EC25LN EC30N
Type Gear
Hydraulic Pump Make Casappa Parker Hydraulics, Inc.
Model KP20–24.5 25R029
1.7
TABLE OF CONTENTS
Front Axle
Description
6 8
5
7
4 3 1
2
203658
General Information
The frame supports hold the front axle housing in
such a manner as to allow a limited amount of
rotary motion of the housing, the rotary sliding
surfaces being lubricated with grease.
The cushion tire is press-fitted to the outer ring of
the wheel hub.
2.1
FRONT AXLE & REDUCTION DIFFERENTIAL
Removal
Front Wheels Suggestions
1. Park the truck on level floor with the parking
! WARNING brake applied, the direction lever in neutral,
Be sure to use the same size and brand the forks lowered, and the key switch off.
tire for replacement. 2. Prepare tools, jacks, and wheel blocks.
3. Block the rear wheels.
4. Loosen the wheel nuts about two turns.
Removal Sequence
2
Wheel nut
1
205952 100902B
1. Wheel Nuts
NOTE
2. Front Wheel
Loosen, but do not remove, the wheel
nuts.
! WARNING
2.2
FRONT AXLE & REDUCTION DIFFERENTIAL
Method 1 Method 3
Position the jack under the frame and raise the Fasten a hoist to the mast and lift the front end of
truck until the tire clears the floor. the truck as shown.
100828 202778A
! CAUTION
After raising the front end, securely support NOTE
it by blocks.
Service Limit For Cushion Tires
Replace the tire if the height of the solid
rubber portion is 25.4 mm (1 in. or less). For
tire replacement, consult your Cat lift dealer.
25.4 mm
200227 (1 inch)
100880
2.3
FRONT AXLE & REDUCTION DIFFERENTIAL
Installation
To install, reverse the removal sequence and do 2. Lower the truck until the tire touches the
the following steps. floor. Then tighten the wheel nuts in numbered
sequence shown below, in two or three steps,
to the specified torque.
! CAUTION
1
Use the same size and brand of tire.
6
3
Make sure the clamping surfaces of the
wheel nuts and counterbores in the rim
are free of dirt.
4
5
1. Install the tire and tighten the wheel nuts.
2
Tighten each nut until its tapered portion is
in full-face contact with the counterbore in 205953
the rim.
Tightening Torque For Wheel Nuts
EC15N–EC18N EC20N–EC30N
Wheel Nut
16 kgf•m 38.5 kgf•m
Counterbore
(116 lbf•ft) (278 lbf•ft)
[157 N•m] [378 N•m]
100835A
2.4
FRONT AXLE & REDUCTION DIFFERENTIAL
Disassembly
6 7
5 205954
Sequence
1. Axle shaft 4. Tapered roller bearing (outer bearing), oil seal,
2. Lock nut, lock washer, oil seal, and tapered and oil deflector
roller bearing (inner bearing) 5. Tapered roller bearing (inner bearing), and
3. Hub & drum assembly [Front wheel hub, brake seal retainer
drum, wheel bolts, drum nuts, and tapered 6. Brake assembly
roller bearing (outer bearing)] 7. Frame support and axle housing
Start By:
1. Remove the mast. (For replacement of the front 3. Support the front end of the truck at both sides
axle housing and disassembly of the differen- with blocks or stands to keep the truck in a
tial, refer to section, MAST AND FORKS.) horizontal position.
2. Jack up the truck. 4. Remove the front wheels.
NOTE
2.5
FRONT AXLE & REDUCTION DIFFERENTIAL
NOTE
Special Tool
200233
Removing Bearings
The inner race of the tapered roller bearing
remains in the axle housing when the hub is
drawn out. Remove this race together with the
seal retainer with a bearing puller.
203651
2.6
FRONT AXLE & REDUCTION DIFFERENTIAL
Runout of shaft
2.7
FRONT AXLE & REDUCTION DIFFERENTIAL
Frame support
O-ring A
205954a
NOTE
200238
2.8
FRONT AXLE & REDUCTION DIFFERENTIAL
Special tool
203569
EC20N–
Tool EC15N–EC18N
EC30N
2.9
FRONT AXLE & REDUCTION DIFFERENTIAL
Bar
Spring
balancer
101653
2.10
FRONT AXLE & REDUCTION DIFFERENTIAL
Reduction Differential
Description
3
4 5 2 1
200240
Sequence
1. Lock plates 4. Reduction gear and differential gear assembly
(spring pins, pinion shafts, differential pinions,
2. Side bearing nuts
differential bevel gear, washers, and differential
3. Differential carrier assembly (lock washers, case)
side bearing caps, and differential carrier)
5. Tapered roller bearings
Start By:
1. Remove the differential carrier from the trans-
mission case.
2. Check the pattern of gears at time of removal.
This step is important when assembly has
been completed and checking pattern of gears
to match.
2.11
FRONT AXLE & REDUCTION DIFFERENTIAL
Disassembly
Suggestions Removing Bearing Inner Races
1. Before removing the differential carrier from Use a bearing puller to remove the inner races
the transmission case, measure the gear from the differential case.
backlash to aid in obtaining correct backlash
at the time of reassembly.
200242
200247
200241
2.12
FRONT AXLE & REDUCTION DIFFERENTIAL
A 0.02 to 0.07
Fit of differential (0.0008 to 0.0028)
pinions on spider
B 0.35 (0.0138)
Unit: mm (in.)
A = Assembly Standard B = Repair or service limit
2.13
FRONT AXLE & REDUCTION DIFFERENTIAL
Reassembly
4 1
3 2
200243
Sequence
1. Tapered roller bearings 3. Spring pin
2.14
FRONT AXLE & REDUCTION DIFFERENTIAL
Suggestions
Reassembling Differential Pinions Reassembling Differential Case
The thrust washers of the differential gears are to After putting the case assembly in place on the
be used for adjusting the backlash between the carrier, install the bearing caps tentatively by mak-
differential gears and pinions. Measure the back- ing the cap bolts snug tight. The caps are to be
lash and, if it exceeds the limit, replace the thrust secured tight after the bearing preload has been
washers. adjusted.
Unit: mm (in.)
12.8 kgf•m
A = Assembly Standard B = Repair or service limit Tightening torque for
(93 lbf•ft)
bearing cap bolts
[126 N•m]
200244
200241
2.15
FRONT AXLE & REDUCTION DIFFERENTIAL
200247
Backlash
Increase
Decrease
Decrease
Increase
200246
Increase
Backlash
Decrease
200248
2.16
FRONT AXLE & REDUCTION DIFFERENTIAL
200250
200249
2.17
FRONT AXLE & REDUCTION DIFFERENTIAL
203669-2 203669-2A
203669-3 203669-3A
203669-4 203670-4A
203669-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
2.18
FRONT AXLE & REDUCTION DIFFERENTIAL
203670-2 203670-2A
203670-3 203670-3A
203670-4 203670-4A
203670-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
2.19
TABLE OF CONTENTS
Description
6 Traction motor
5 9 4 6 209002
Main component
1 Transfer case 6 Taper roller bearing
2 Transfer cover 7 Lock nut
3 Input gear (13T) 8 Ball bearing
4 Output gear (48T) 9 Plug (standard) or pulse generator (option)
5 Bevel gear set
3.1
TRANSFER ASSEMBLY
Disassembly
Start by:
(1) Remove the drain plug on the front axle hous- (3) Remove the traction motor, reduction and dif-
ing to let the oil drain out. ferential assembly and transfer assembly as
(2) Disconnect the connectors of the traction one unit, from the front axle housing.
motor harnesses and pulse generator har- (4) Separate the three assemblies removed in
ness. step (3) from each other.
3 15 Liquid gasket
2
18 1
14
17
Plug (standard)
or 16
Pluse generator (option)
Staked
7
4
6
8 9
13 11 10 12
209002A
Disassembly sequence
1 Bolt 10 Output gear
2 Transfer cover 11 Spacer
3 Side cover with pulse generator, or plug 12 Bearing cup
4 Nut 13 Bearing cup
5 Shim 14 Snap ring
Remove parts 6 and 8 as a unit. Remove parts 15 to 17 as a unit.
6 Bevel pinion shaft 15 Input gear
7 Shim 16 Ball bearing
8 Bearing cone 17 Ball bearing
9 Bearing cone 18 Transfer case
3.2
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