CATERPILLAR CAT EC15K EC18K EC20K EC25K EC25KE EC25KL EC30K FORKLIFT LIFT TRUCKS Service Repair Manual

1
Service Manual

• Chassis Mast
• EC15K, EC18K, EC18KL
• A3EC1-10200-up
• A3EC1-20200-up A3EC1-30200-up A3EC2-40200-up
• EC20K, EC25K
• A3EC2-10200-up
• A3EC2-20200-up A3EC2-30200-up A3EC2-40200-up
  A3EC2-80200-up
• EC25KE, EC25KL, EC30K
• A3EC3-10200-up
• A3EC3-20200-up A3EC3-30200-up A3EC3-40200-up
  A3EC3-80200-up
• EC30KL
• A3EC4-40200-up

99759-83110
2
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.
8609141A
Truck Models Covered This service manual
furnishes service and maintenance information for
the following trucks.
Truck Model Serial Number
EC15K, EC18K, EC18KL A3EC1-10200-up
A3EC1-20200-up
A3EC1-30200-up
A3EC2-40200-up
EC20K, EC25K A3EC2-10200-up
A3EC2-20200-up
A3EC2-30200-up
A3EC2-40200-up
A3EC2-80200-up
EC25KE, EC25KL, EC30K A3EC3-10200-up
A3EC3-20200-up
A3EC3-30200-up
A3EC3-40200-up
A3EC3-80200-up
EC30KL A3EC4-40200-up
1.1
3
GENERAL INFORMATION Nameplate and Serial Number
Locations
Mast serial number
Power steering motor serial number
Traction motor serial number Hydraulic motor
serial number
Chassis serial number
Nameplate
8609141
1.2
4
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5
GENERAL INFORMATION
Dimensions
8609142
8609143
1.3
6
GENERAL INFORMATION Dimensions Chart
Ref Truck Model EC15K, EC18K EC18KL EC20K, EC25K EC25KE EC25KL EC30K EC30KL
A Maximum Lift 3320 (130) 3320 (130) 3340 (131) 3340 (131) 3340 (131) 3310 (130) 3215 (126)
B Free Lift 115 (4.5) 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3) 135 (5.3)
C Maximum Fork Spacing (outside to outside)1070 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0)
D Fork Length 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42)
E Tilt Angle (forward/backward) 5/6 5/6 5/6 5/6 5/6 5/6 5/6
F Overall Length 3050 (120) 3123 (122.8) 3152 (124) 3252 (127.9) 3252 (127.9) 3325 (130.8) 3325 (130.8)
G Overall Width (outside of tires) 945 (37.2) 970 (38.2) 1054 (41.5) 1054 (41.5) 1103 (43.4) 1103 (43.4) 1103 (43.4)
H Overall Height (to top of mast, lowered) 2105 (83) 2105 (83) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5)
I Overall Height (to top of overhead guard) 2180 (85.8) 2180 (85.8) 2207 (86.9) 2207 (86.9) 2207 (86.9) 2207 (86.9) 2207 (86.9)
J Overall Height (to top of mast, extended) 4560 (180) 4560 (180) 4570 (180) 4570 (180) 4570 (180) 4540 (179) 4540 (179)
K Tread (front) 793 (31.2) 818 (32.2) 875 (34.4) 875 (34.4) 900 (35.4) 900 (35.4) 900 (35.4)
L Tread (rear) 826 (32.5) 826 (32.5) 897 (35.3) 897 (35.3) 897 (35.3) 897 (35.3) 897 (35.3)
M Wheelbase 1170 (46.1) 1170 (46.1) 1280 (50.4) 1380 (54.3) 1380 (54.3) 1380 (54.3) 1380 (54.3)
N Front Overhang 376 (14.8) 376 (14.8) 394 (15.5) 394 (15.5) 394 (15.5) 406 (15.9) 406 (15.9)
O Rear Overhang 434 (17) 507 (19) 408 (16) 408 (16) 408 (16) 469 (18.4) 469 (18.4)
P Underclearance (at center of wheelbase) 118 (4.6) 118 (4.6) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9)
Unit mm (in.)
1.4
7
GENERAL INFORMATION General Information (Standard
Models)
Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC15K EC18K EC18KL EC20K EC25K EC25K EC25KE EC25KL EC30K EC30KL
Standard Controller Standard Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller GE SX Controller
Standard Simplex Mast Size Standard Simplex Mast Size meters 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Service Weight (standard axle) Without Battery kg (lb) 2095 (4620) 2335 (5140) 2595 (5720) 2685 (5920) 2870 (6330) 2870 (6330) 2695 (5940) 2865 (6320) 3335 (7353) 3502 (7721)
Service Weight (standard axle) With Max. Battery kg (lb) 3298 (7270) 3534 (7790) 3797 (8370) 4296 (9470) 4482 (9880) 4482 (9880) 4509 (9940) 4681 (10320) 5150 (11353) 5317 (11722)
Work Performance Rated Capacity/ Load Center Rated Capacity/ Load Center kg/mm (lb/in.) 1500/500 (3000/24) 1800/500 (3500/24) 1800/500 (4000/24) 2000/500 (4000/24) 2500/500 (5000/24) 2500/500 (5000/24) 2500/500 (5000/24) 2500/600 (5000/24) 3000/500 (6000/24) 3500/500 (6500/29)
Work Performance Maximum Fork Height Maximum Fork Height mm (in.) 3320 (130) 3320 (130) 3320 (130) 3340 (131) 3340 (131) 3340 (131) 3340 (131) 3340 (131) 3310 (130) 3215 (126)
Work Performance Lift Speed (Rated Load) 36V m/sec. (fph) .24 (48) .23 (45) .34 (67) .31 (61) .31 (61) .28 (56) .28 (56) .28 (56) .26 (51) .23 (45)
Work Performance Lift Speed (Rated Load) 48V m/sec. (fph) .34 (67) .32 (64) .47 (93) .40 (78) .40 (78) .38 (74) .38 (74) .38 (74) .36 (70) .31 (62)
Work Performance Lowering Speed (rated load) Lowering Speed (rated load) m/sec. (fph) .50 (99) .50 (99) .50 (99) .50 (98) .50 (98) .50 (98) .50 (98) .50 (98) .50 (98) .50 (98)
Work Performance Tilt Angle (forward/backward) Tilt Angle (forward/backward) degrees 5 / 6 5 / 6 5 / 6 5 / 6 5 / 6 5 / 6 5 / 6 5 / 6 5 / 6 5 / 6
Work Performance Free Lift Free Lift mm (in.) 115 (4.5) 115 (4.5) 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3) 135 (5.3)
Traveling Performance Travel Speed (Without Load) 36V km/h (mph) 12.9 (8.0) 12.9 (8.0) 14.3 (8.9) 11.6 (7.2) 11.6 (7.2) 11.6 (7.2) 11.6 (7.2) 11.1 (6.9) 10.8 (6.7) 13.2 (8.2)
Traveling Performance Travel Speed (Without Load) 48V km/h (mph) DNA DNA 17.9 (11.1) 14.8 (9.2) 14.8 (9.2) 14.8 (9.2) 14.8 (9.2) 14.5 (9.0) 14.2 (8.8) 16.4 (10.2)
Traveling Performance Minimum Turning Radius Minimum Turning Radius mm (in.) 1790 (70.5) 1790 (70.5) 1840 (72.5) 1890 (74.5) 1890 (74.5) 1890 (74.5) 1990 (78.5) 1990 (78.5) 2045 (80.5) 2045 (80.5)
Power Train Traction Motor Output 36V 60min. HP(kW) 8.2 (6.1) 8.2 (6.1) 9.6 (7.1) 8.3 (6.1) 8.3 (6.1) 8.3 (6.1) 8.3 (6.1) 8.3 (6.1) 8.3 (6.1) 8.3 (6.1)
Power Train Traction Motor Output 48V 60min. HP(kW) DNA DNA 13.4 (10.0) 11.7 (8.7) 11.7 (8.7) 11.7 (8.7) 11.7 (8.7) 11.7 (8.7) 11.7 (8.7) 11.7 (8.7)
Power Train Transfer Gear Type Type Spur Spur Spur Spur Spur Spur Spur Spur Spur Spur
Power Train Transfer Gear Ratio Ratio 3.538 3.538 3.538 3.067 3.067 3.067 3.067 3.067 3.067 3.067
Power Train Reduction Gear Type Type Bevel Bevel Bevel Bevel Bevel Bevel Bevel Bevel Bevel Bevel
Power Train Reduction Gear Ratio Ratio 4.571 4.571 4.571 5.0 5.0 5.0 5.0 5.0 5.0 5.0
Power Train Differential Axle Housing Axle Housing Banjo Banjo Banjo Banjo Banjo Banjo Banjo Banjo Banjo Banjo
Power Train Differential Gear Type/ Number Gears Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2
Power Train Differential Gear Type/ Number Pinions Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2 Straight Bevel/2
1.5
8
GENERAL INFORMATION
Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC15K EC18K EC18KL EC20K EC25K EC25KE EC25KL EC30K EC30KL
Power Steering System Type Type Type Dynamic Load Sense Dynamic Load Sense Dynamic Load Sense Dynamic Load Sense Dynamic Load Sense Dynamic Load Sense Dynamic Load Sense Dynamic Load Sense Dynamic Load Sense
Power Steering System Turning Angle Inside Degrees 83 83 83 83 83 83 83 83 83
Power Steering System Turning Angle Outside Degrees 54 54 54 56 56 56 56 56 56
Power Steering System Steering Wheel Diameter Steering Wheel Diameter mm (in.) 328 (13) 328 (13) 328 (13) 328 (13) 328 (13) 328 (13) 328 (13) 328 (13) 328 (13)
Power Steering System Cylinder Minimum Test Pressure Cylinder Minimum Test Pressure kgf/cm2 (psi) kPa 107 (1522) 10,500 107 (1522) 10,500 107 (1522) 10,500 163 (2320) 16,000 163 (2320) 16,000 163 (2320) 16,000 163 (2320) 16,000 163 (2320) 16,000 163 (2320) 16,000
Brake System Service Brake Type Type Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo Self-Adjusting Duo-Servo
Brake System Service Brake Inside Drum Diameter mm (in.) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051) 254 0 0.13(10.00 0 0.0051)
Brake System Service Brake Lining Thickness mm (in.) 4.87 (0.19) 4.87 (0.19) 4.87 (0.19) 6 (0.24) 6 (0.24) 6 (0.24) 6 (0.24) 6 (0.24) 6 (0.24)
Brake System Service Brake Master Cylinder ID mm (in.) 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748)
Brake System Service Brake Wheel Cylinder ID 22.22 (0.8748) 22.22 (0.8748) 22.22 (0.8748) 28.58 (1.1252) 28.58 (1.1252) 28.58 (1.1252) 28.58 (1.1252) 28.58 (1.1252) 28.58 (1.1252)
Brake System Park Brake Type Type Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels Mechanical, Mounted on Front Wheels
Brake System Park Brake Lever Operating Effort kgf (lbf) N 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294 25 to 30 (55 to 66) 245 to 294
Traveling System Mounting Front Wheels Front Wheels Fixed Type Fixed Type Fixed Type Fixed Type Fixed Type Fixed Type Fixed Type Fixed Type Fixed Type
Traveling System Mounting Rear Wheels Rear Wheels Center Pivot Type Center Pivot Type Center Pivot Type Center Pivot Type Center Pivot Type Center Pivot Type Center Pivot Type Center Pivot Type Center Pivot Type
Traveling System Wheel Alignment Oscillation Angle Degrees 3 3 3 3 3 3 3 3 3
Traveling System Wheel Alignment Camber Degrees 1 1 1 1 1 1 1 1 1
1.6
9
GENERAL INFORMATION
Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC15K EC18K EC18K EC18KL EC20K EC25K EC25K EC25KE EC25KL EC25KL EC30K EC30K EC30KL
Hydraulic System Hydraulic Pump Hydraulic Pump Type Type Gear Gear Gear Gear Gear Gear Gear Gear Gear Gear Gear Gear Gear
Hydraulic System Hydraulic Pump Hydraulic Pump Make Make Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc. Parker Hydraulics, Inc.
Hydraulic System Hydraulic Pump Hydraulic Pump Model Model 1PX230 1PX230 1PX230 1SX250 1PX290 1PX290 1PX290 1PX290 1SX250 1SX250 1SX250 1SX250 1SX250
Hydraulic System Hydraulic Pump Hydraulic Pump Displacement cc (cu in.) 23.0 (1.403)/rev. 23.0 (1.403)/rev. 23.0 (1.403)/rev. 25.(1.526) 29(1.77) 29(1.77) 29(1.77) 29(1.77) 25(1.526) 25(1.526) 25(1.526) 25(1.526) 25(1.526)
Hydraulic System Hydraulic Pump Hydraulic Pump Make Make Husco International Husco International Husco International Husco International Husco International Husco International Husco International Husco International Husco International Husco International Husco International Husco International Husco International
Hydraulic System Control Valve Control Valve Model Model 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve 5000CC Sectional Valve
Hydraulic System Control Valve Control Valve Relief Pressure kgf /cm2 (psi) kPa 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855 263 (3750) 25855
Hydraulic System Flow Regulator Valve Flow Regulator Valve Type Type Variable Variable Variable Variable Variable Variable Variable Variable Variable Variable Variable Variable Variable
Hydraulic System Flow Regulator Valve Flow Regulator Valve Regulated Flow Rate liter (cu.in.) / min 48(2929) 48(2929) 48(2929) 48(2929) 59 (3600) 59 (3600) 59 (3600) 59 (3600) 59 (3600) 59 (3600) 59 (3600) 71(4332) 71(4332)
Hydraulic System Lift Cylinders Lift Cylinders ID mm (in.) 45 (1.77) 45 (1.77) 45 (1.77) 45 (1.77) 50 (1.97) 50 (1.97) 50 (1.97) 50 (1.97) 50 (1.97) 55 (2.17) 55 (2.17) 55 (2.17) 55 (2.17)
Hydraulic System Lift Cylinders Lift Cylinders Stroke mm (in.) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1600 (62.99) 1600 (62.99) 1600 (62.99) 1600 (62.99)
Hydraulic System Tilt Cylinders Tilt Cylinders ID mm (in.) 63 (2.48) 63 (2.48) 63 (2.48) 63 (2.48) 70 (2.75) 70 (2.75) 70 (2.75) 70 (2.75) 70 (2.75) 80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15)
Hydraulic System Tilt Cylinders Tilt Cylinders Stroke mm (in.) 79 (3.11) 79 (3.11) 79 (3.11) 79 (3.11) 81 (3.19) 81 (3.19) 81 (3.19) 81 (3.19) 81 (3.19) 81 (3.19) 81 (3.19) 81 (3.19) 81 (3.19)
Hydraulic System Hydraulic Tank Capacity liter (Approx) Hydraulic Tank Capacity liter (Approx) Hydraulic Tank Capacity liter (Approx) 1 (US gal.) 8 (4.8) 8 (4.8) 8 (4.8) 8 (4.8) 24 (6.3) 24 (6.3) 24 (6.3) 24 (6.3) 24 (6.3) 30 (7.9) 30 (7.9) 30 (7.9) 30 (7.9)
Mast and Forks Mast Mast Mast Mast Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL Roller type CL
Mast and Forks Mast Dimensions (Flange Inside Width x THK x WEB THK) Mast Dimensions (Flange Inside Width x THK x WEB THK) Outer mm (in.) 100 x 15 x 12 (3.94 x 0.59 x 0.47) 100 x 15 x 12 (3.94 x 0.59 x 0.47) 100 x 15 x 12 (3.94 x 0.59 x 0.47) 100 x 15 x 12 (3.94 x 0.59 x 0.47) 115 x 20 x 13 4.53 x 0.79 x 0.51) 115 x 20 x 13 4.53 x 0.79 x 0.51) 115 x 20 x 13 4.53 x 0.79 x 0.51) 115 x 20 x 13 4.53 x 0.79 x 0.51) 115 x 20 x 13 4.53 x 0.79 x 0.51) 115 x 21 x 13 (4.53 x 0.83 x 0.51) 115 x 21 x 13 (4.53 x 0.83 x 0.51) 115 x 21 x 13 (4.53 x 0.83 x 0.51) 115 x 21 x 13 (4.53 x 0.83 x 0.51)
Mast and Forks Mast Dimensions (Flange Inside Width x THK x WEB THK) Mast Dimensions (Flange Inside Width x THK x WEB THK) Inner mm (in.) 100 x 17 x 12 (3.94 x 0.67 x 0.47) 100 x 17 x 12 (3.94 x 0.67 x 0.47) 100 x 17 x 12 (3.94 x 0.67 x 0.47) 100 x 17 x 12 (3.94 x 0.67 x 0.47) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51) 115 x 20 x 13 (4.53 x 0.83 x 0.51)
Mast and Forks Main Rollers Main Rollers Type Type 6308 Ball Bearing 6308 Ball Bearing 6308 Ball Bearing 6308 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing 6309 Ball Bearing
Mast and Forks Main Rollers Main Rollers Diameter x Width Diameter x Width 100 x 30 (3.94 x 1.18) 100 x 30 (3.94 x 1.18) 100 x 30 (3.94 x 1.18) 100 x 30 (3.94 x 1.18) 115 x 35 (4.53 x 1.58) 115 x 35 (4.53 x 1.58) 115 x 35 (4.53 x 1.58) 115 x 35 (4.53 x 1.58) 115 x 35 (4.53 x 1.58) 100 x 30 (3.94 x 1.18) 100 x 30 (3.94 x 1.18) 100 x 30 (3.94 x 1.18) 100 x 30 (3.94 x 1.18)
Mast and Forks Side Rollers Side Rollers Type Type Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing Lubricating type needle roller bearing
Mast and Forks Side Rollers Side Rollers Diameter x Width mm (in.) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42) 42 x 36 (1.65 x 1.42)
Mast and Forks Lift Chains Lift Chains Lift Chains Lift Chains BL534 BL534 BL534 BL534 BL634 BL634 BL634 BL634 BL634 BL834 BL834 BL834 BL834
Mast and Forks Forks (Lgth x Wdth x Thk) Forks (Lgth x Wdth x Thk) Forks (Lgth x Wdth x Thk) mm (in.) 1070x100x35 (36x4x1.3) 1070x100x35 (36x4x1.3) 1070x100x35 (36x4x1.3) 1070x100x35 (36x4x1.3) 1070 x100 x40 (42 x 3.9 x 1.6) 1070 x100 x40 (42 x 3.9 x 1.6) 1070 x100 x40 (42 x 3.9 x 1.6) 1070 x100 x40 (42 x 3.9 x 1.6) 1070 x100 x40 (42 x 3.9 x 1.6) 1070 x 125 x 45 (42 x 5 x 1.8) 1070 x 125 x 45 (42 x 5 x 1.8) 1070 x 125 x 45 (42 x 5 x 1.8) 1070 x 125 x 45 (42 x 5 x 1.8)
Mast and Forks Fork Spacing (out to out) min/max Fork Spacing (out to out) min/max Fork Spacing (out to out) min/max mm (in.) 240 / 818 (9.4/32) 240 / 818 (9.4/32) 240 / 818 (9.4/32) 240 / 818 (9.4/32) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7) 284 / 958 (11.2/37.7)
Battery Voltage Voltage Voltage Voltage 36/48 36/48 36/48 36/48 36/48 36/48 36/48 36/48 36/48 36/48 36/48 36/48 36/48
Battery Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) 36V 900 900 900 900 1300 1300 1300 1300 1300 1300 1300 1300 1300
Battery Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) 48V 700 700 700 700 800 800 800 800 800 1000 1000 1000 1000
Battery Compartment Dimensions Height-Center Height-Center mm (in.) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6) 598 (23.6)
Battery Compartment Dimensions Height-Edges Height-Edges mm (in.) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3) 592 (23.3)
Battery Compartment Dimensions Length Length mm (in.) 708 (27.9) 708 (27.9) 708 (27.9) 708 (27.9) 775 (30.5) 775 (30.5) 775 (30.5) 775 (30.5) 775 (30.5) 875 (34.4) 875 (34.4) 875 (34.4) 875 (34.4)
Battery Compartment Dimensions Width Width mm (in.) 906 (35.6) 906 (35.6) 906 (35.6) 906 (35.6) 1003 (39.5 1003 (39.5 1003 (39.5 1003 (39.5 1003 (39.5 1003 (39.5 1003 (39.5 1003 (39.5 1003 (39.5
Battery Weight (Min/Max) Weight (Min/Max) Weight (Min/Max) kg (lb) 750/1200 (1650/2650) 750/1200 (1650/2650) 750/1200 (1650/2650) 750/1200 (1650/2650) 1000/1600 (2200/3550) 1000/1600 (2200/3550) 1315/1600 (2900/3550) 1315/1600 (2900/3550) 1315/1600 (2900/3550) 1400/1800 (3100/4000) 1400/1800 (3100/4000) 1400/1800 (3100/4000) 1400/1800 (3100/4000)
1.7
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FRONT AXLE DESCRIPTION
Front Axle Description
6
8
5
7
1
4
3
2
203658

1. Front wheel hub
2. Frame support
3. Axle shaft
4. Axle housing

1. Reduction pinion
2. Reduction gear
3. Differential case
4. Differential carrier

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
11
FRONT AXLE REMOVAL INSTALLATION Removal
Front Wheels

• Suggestions
• Park the truck on level floor with the parking
  brake applied, the direction lever in neutral,
  the forks lowered, and the key switch off.
• Prepare tools, jacks, and wheel blocks.
• Block the rear wheels.
• Loosen the wheel nuts about two turns.

!
WARNING
Be sure to use the same size and brand tire for
replacement.
Removal Sequence
Wheel nut 100902B
2 1 205952

1. Wheel Nuts
2. Front Wheel

NOTE Loosen, but do not remove, the wheel nuts.
5. Raise the front end of the truck. Use one of
the methods shown.
!
WARNING
To prevent possible injury, do not replace the
tire when the truck is loaded. Dismount the truck
before raising the front tire. To prevent
possible personal injury, raise the truck only
until the tire just clears the ground. Do not put
any portion of your body under the truck.
Securely support the truck on blocks after
raising it.
2.2
12
FRONT AXLE REMOVAL INSTALLATION
Method 1 Position the jack under the frame and
raise the truck until the tire clears the floor.
Method 3 Fasten a hoist to the mast and lift the
front end of the truck as shown.
100828
202778A
Jack Capacities
6. Remove the wheel nuts (loosened in Step 4.)
EC15K - 18KL 3000 kgf (6700 lbf)
EC20K - 30KL 5000 kgf (12,000 lbf)
!
CAUTION
Be careful not to damage the bolt threads when
removing the wheel.
Method 2 Tilt the mast all the way back, place
wood blocks under the mast, and tilt the mast
forward.
7. Remove the wheel.
!
CAUTION
NOTE 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.
After raising the front end, securely support it
by blocks.
200227
25.4 mm (1 inch) 100880
2.3
13
FRONT AXLE REMOVAL INSTALLATION Installation
To install, reverse the removal sequence and do
the following steps.
2. Lower the truck until the tire touches the
floor. Then tighten the wheel nuts in numbered
sequence shown below, in two or three steps, to
the specified torque.
!
CAUTION
1 6 3 4 5 2 205953
Use the same size and brand of tire. Make sure
the clamping surfaces of the wheel nuts and
counterbores in the rim are free of dirt.
1. Install the tire and tighten the wheel nuts.
Tighten each nut until its tapered portion is in
full-face contact with the counterbore in the rim.
Wheel Nut Counterbore 100835A
Tightening Torque For Wheel Nuts Tightening Torque For Wheel Nuts
EC15K - 18KL EC20K - 30KL
16 kgfm 38.5 kgfm
(116 lbfft) (278 lbfft)
157 Nm 378 Nm
2.4
14
FRONT AXLE DISASSEMBLY
Disassembly
6
7
1
2
3 4
5
205954

• Sequence
• Axle shaft
• Lock nut, lock washer, oil seal, and tapered
  roller bearing (inner bearing)
• Hub drum assembly Front wheel hub, brake
  drum, wheel bolts, drum nuts, and tapered roller
  bearing (outer bearing)

1. Tapered roller bearing (outer bearing), oil
   seal, and oil deflector
2. Tapered roller bearing (inner bearing), and seal
   retainer
3. Brake assembly
4. Frame support and axle housing

• Start By
• Remove the mast. (For replacement of the front
  axle housing and disassembly of the dif-
  ferential, refer to section, MAST AND FORKS.)
• Jack up the truck.

1. Support the front end of the truck at both sides
   with blocks or stands to keep the truck in a
   horizontal position.
2. Remove the front wheels.

NOTE It is not necessary to remove the axle
housing or drain the oil for removal of the shaft
only.
2.5
15
FRONT AXLE DISASSEMBLY Suggestions
Removing the Lock Nut Use a lock nut wrench
(Special Tool).
Removing Bearings The inner race of the tapered
roller bearing re- mains in the axle housing when
the hub is drawn out. Remove this race together
with the seal retainer with a bearing puller.
Tool EC15K - 18KL EC20K - 30KL
Lock Nut Wrench 91268-00800 03703-59001
203651
Special Tool 200232
Removing Front Wheel Hub Use a wheel hub puller
(Special Tool).
Tool EC15K - 18KL EC20K - 30KL
Wheel Hub Puller 64309-40100 MH061017
(Puller seat) (64309-10601)
NOTE It is not necessary to remove the oil seal
from the hub or to disassemble the oil deflector
unless the seal is defective.
Special Tool 200233
2.6
16
FRONT AXLE DISASSEMBLY
Inspection after Disassembly Axle
Shafts Looseness of Mating Splines Mount the
differential bevel gear on the splined end of the
shaft and set a dial indicator as shown below.
Turn the bevel gear and read the indicator.
Runout Set a dial indicator at the middle part of
the axle shaft. Turn the shaft and read the
indicator to find runout.
200235
Runout of shaft
Face runout of flange
200236
EC15K -18KL EC20K - 30KL
Runout of axle shaft (1/2 of dial indicator reading A 0.5 (0.020) maximum 1.0 (0.039) maximum
Runout of axle shaft (1/2 of dial indicator reading B 1.0 (0.039) 2.0 (0.079)
Free movement (looseness of splines) A 0.07 to 0.17 (0.0028 to 0.0067)
Free movement (looseness of splines) B 0.5 (0.020)
Unit mm (in.) A Assembly Standard B Repair
or Service Limit
Unit mm (in.) A Assembly Standard B Repair
or Service Limit

• Axle Housing
• Check the surfaces of axle housing in contact
  with the mast bearing for damage.
• Check the entire axle housing for distortion,
  dents, and other defects, paying particular
  attention to the welds to see if any weld is
  cracked.

Set a dial indicator against the flange of the
axle shaft as shown. Turn the shaft and read the
indi- cator to find face runout.
Face runout of axle shaft flange A 0.05 (0.0020)
Face runout of axle shaft flange B 0.5 (0.020)

• Oil Seals and Retainers
• Check the outer surface of the oil seal retainer
  for wear or damage.
• Check the outer and inner oil seals for wear and
  damage.

Unit mm (in.) A Assembly Standard B Repair
or Service Limit
2.7
17
FRONT AXLE REASSEMBLY Reassembly

• To reassemble, reverse the steps of the disas-
  sembly sequence and do the following steps.
• Axle Housing
• Install the O-ring in the outer groove (of the
  two grooves in the bore of each frame sup-
  port).
• Apply grease to the surfaces A of the support
  and axle housing.

2. Install the inner race and oil seal retainer
of the wheel hub bearing with an installer
(Special Tool).
Special tool 203569
Frame support
O-ring
A
Tool EC15K - 18KL EC20K- 30KL
Installer 64309-12300 91468-00300
200237
3. Apply retaining compound to the flange sur-
faces of the axle shafts.
Front Wheel Hub 1. Fill the front wheel hub,
especially the roller holder and oil seal lip
groove, with grease.
NOTE Be careful not to apply grease to the brake
drum.
200238
2.8
18
FRONT AXLE REASSEMBLY
Hub Bearing Preload Tighten the inner nut to
produce the required pre- load. Tighten the outer
nut to the specified torque and check the
preload. Be sure that the preload noted after
tightening the outer nut meets the specification.
This step is for new bearings. Where the bearings
removed in disassembly are reused, try to produce
the preload at the lower side of the range.

• Installation and Setting Preload
• Fill the hub with the recommended grease as
  listed in the service manual.
• Pack the inner and outer bearing with the
  recommended grease.
• Install the inner bearing to the back side of
  the hub.
• Install the inner seal.
• Clean the lining surface of the drum.
• Install the hub onto the axle.
• Install the outer bearing, grease seal and pre-
  load nut.
• If the bearings are being reused, try to pro-
  duce the lower side of the applied force in
  tangential direction.
• For new bearings, tighten the preload nut to 14
  kgfm (101 lbfft) 137 Nm. Slowly rotate the
  hub slightly more than 3 turns, back the nut off
  80, and set the applied force in tan- gential
  direction.
• For models with an outer lock nut, torque the
  nut to 20 kgfcm (145 lbfft) 196 Nm. After
  torquing the lock nut, check the force applied
  in tangential direction again to insure the pre-
  load did not change.

Preload for hub bearing 5 to 50 kgfcm (0.4 to 3.6 lbfft) 0.5 to 4.9 Nm
Tightening torque for lock nuts 20 kgfm (145 lbfft) 196 Nm
Inner nut Outer nut
200468
Bar Spring balancer 101653
2.9
19
REDUCTION DIFFERENTIAL DESCRIPTION Reduction
Differential Description
3
1
4
5 2
200240

• Sequence
• Lock plates
• Side bearing nuts
• Differential carrier assembly (lock washers,
  side bearing caps, and differential carrier)

1. Reduction gear and differential gear assembly
   (spring pins, pinion shafts, differential
   pinions, differential bevel gear, washers, and
   differen- tial case)
2. Tapered roller bearings

Start By Remove the differential carrier from
the transmis- sion case.
2.10
20
REDUCTION DIFFERENTIAL DISASSEMBLY Disassembly
Suggestions 1. Before removing the differential
carrier from the transmission case, measure the
gear backlash to aid in obtaining correct
backlash at the time of reassembly.
Removing Bearing Inner Races Use a bearing puller
to remove the inner races from the differential
case.
200242
Backlash between reduction gear and pinion
0.15 to 0.25 (0.0059 to 0.0098)
Unit mm (in.)
200247
2. Put a mark across the bearing cap, adjusting
screw and carrier on each side. The caps are not
interchangeable.
200241
2.11
21
REDUCTION DIFFERENTIAL DISASSEMBLY Inspection
after Disassembly
Reduction Gear Check the teeth for wear, pitting,
flaking, or chip- ping. Minor flaws on the tooth
surface can be repaired by grinding with an oil
stone or a hand grinder. Check the teeth for
contact. If the gear is badly damaged and
requires replacement, replace the pinion too.
Reduction gear and pinion are a matched set and
must be changed at the same time.

• Differential
• Check the differential cases for damage. Check
  in particular the seat formed of each case for
  carrying the side bearing inner race to see
  whether the seat surface is galled or not.
• Check the sliding surfaces of the thrust wash-
  ers and gears for wear or damage.
• Check the teeth of the differential pinions and
  bevel gears for wear, pitting, chipping, or
  galling.
• Check the fit of each pinion on the spider.

Fit of differential pinions on spider A 0.02 to 0.07 (0.0008 to 0.0028)
Fit of differential pinions on spider B 0.35 (0.0138)
Unit mm (in.) A Assembly Standard B Repair
or service limit
2.12
22
REDUCTION DIFFERENTIAL REASSEMBLY Reassembly
1
4
5
3 2
200243

• Sequence
• Tapered roller bearings
• Differential gear assembly differential case,
  thrust washers, bevel gears, pinions, and pin-
  ion shaft

1. Spring pin
2. Reduction gear
3. Differential carrier assembly carrier, side
   bearing caps, side bearing nuts, and lock
   washers

2.13
23
REDUCTION DIFFERENTIAL REASSEMBLY Suggestions
Reassembling Differential Pinions The thrust
washers of the differential gears are to be used
for adjusting the backlash between the
differential gears and pinions. Measure the back-
lash and, if it exceeds the limit, replace the
thrust washers.
Reassembling Differential Case After putting the
case assembly in place on the carrier, install
the bearing caps tentatively by making the cap
bolts snug tight. The caps are to be secured
tight after the bearing preload has been
adjusted. Installing Bearing Caps Be sure to know
which are the left and right caps and to put each
cap in place correctly.
Backlash between differential gears and pinions A 0.18 to 0.23 (0.0071 to 0.0091)
Backlash between differential gears and pinions B 0.5 (0.020)
Unit mm (in.) A Assembly Standard B Repair
or service limit
Tightening torque for bearing cap bolts
12.8 kgfm (93 lbfft) 126 Nm
200244
200241
Installing Reduction Gear Apply LOCTITE No. 271
to the bolts for holding the reduction gear to
the case. Be sure to tighten these bolts evenly
so as not to strain the gear.
Tightening torque for reduction gear bolts
12.0 kgfm (87 lbfft) 118 Nm
2.14
24
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25
REDUCTION DIFFERENTIAL REASSEMBLY Inspection
and Adjustment
Side Bearing Preload Tie a wire on the reduction
gear tooth and hook a spring scale to the wire.
Tighten the side bearing nuts while reading the
spring scale until the speci- fied preload is
obtained.
Reduction Gear Backlash Adjust the backlash
between the reduction gear and pinion after
installing the differential carrier assembly to
the transmission case. To measure the backlash,
set a dial indicator with its spindle pointing
squarely to the tooth face of the reduc- tion
gear. With the pinion held, move the gear back
and forth to read the indicator. Adjust the
backlash using the left and right side bearing
nuts and pinion shims.
NOTE Before measuring the preload, tap the back
of the reduction gear with a copper hammer while
rotating the gear to center between bearing.
Backlash between reduction gear and pinion
0.15 to 0.25 (0.0059 to 0.0098)
Unit mm (in.)
15 to 30 kgf Min. (1.1 to 2.2 lbf) 1.5 to 2.9 N
Preload for differential case side bearings 1.32 to 2.5 kgfcm Max. (2.9 to 5.5 lbfft) 13 to 25 Nm
As force applied to reduction gear in tangential direction.
200247
200246
Backlash
Increase
Decrease
Decrease Increase
Increase Backlash
Decrease
200248
2.15
26
REDUCTION DIFFERENTIAL INSPECTION
Reduction Gear Face Runout Using a dial
indicator, check the reduction gear for face
runout at the maximum radius position in back of
the gear. If the runout exceeds the limit, check
the reduction gear bolts for tightness retighten
if necessary. Check the tapered roller bearings
for condition. Readjust or replace them if
necessary.
Tooth Contact Check the gear reduction tooth
contact. To check, apply a thin coat of bluing to
several gear teeth on both drive and coast sides.
Press forward on the reduction pinion and rotate
the reduction gear back and forth until a contact
pattern is noted on both concave and convex faces
of the gear teeth. To adjust the tooth contact,
refer to the chart.
Face runout of reduction gear A 0.05 (0.0020) maximum
Face runout of reduction gear B 0.05 (0.0020) maximum
200250
Unit mm (in.) A Assembly Standard B Repair
or Service Limit
200249
2.16
27
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