CATERPILLAR CAT EC15N EC18N EC20N EC25EN EC25LN EC25N EC30N FORKLIFT LIFT TRUCKS Service Repair Manual

1
Service Manual
Chassis Mast EC15N, EC18N A4EC1-10200-up A4EC1-
20200-up EC20N, EC25N A4EC2-10200-up A4EC2-20200-
up EC25EN, EC25LN, EC30N A4EC3-20200-up A4EC3-302
00-up A4EC3-40200-up
99759-6K110
2
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
Reduction Differential
Front Axle Description ................................................................................................................................... 2.1
General Information ................................................................................................................. 2.1
Removal ....................................................................................................................................... 2.2
Front Wheels ............................................................................................................................ 2.2
Method 1.............................................................................................................................. 2.3
Method 2.............................................................................................................................. 2.3
Method 3.............................................................................................................................. 2.3
Installation .................................................................................................................................... 2.4
Disassembly ................................................................................................................................. 2.5
Removing Front Wheel Hub ..................................................................................................... 2.6
Inspection after Disassembly ....................................................................................................... 2.7
Reassembly.................................................................................................................................. 2.8
Axle Housing ............................................................................................................................ 2.8
Front Wheel Hub ...................................................................................................................... 2.8
Hub Bearing Preload................................................................................................................ 2.10
Installation and Setting Preload........................................................................................... 2.10
Reduction Differential Description ................................................................................................................................... 2.11
Disassembly ................................................................................................................................. 2.12
Inspection after Disassembly ....................................................................................................... 2.13
Reduction Gear ........................................................................................................................ 2.13
Differential ................................................................................................................................ 2.13
Reassembly.................................................................................................................................. 2.14
Inspection and Adjustment........................................................................................................... 2.16
Side Bearing Preload ............................................................................................................... 2.16
Reduction Gear Backlash ........................................................................................................ 2.16
Reduction Gear Face Runout .................................................................................................. 2.17
Tooth Contact ........................................................................................................................... 2.17
Tooth Contact Adjustment ........................................................................................................ 2.18
i
3
TABLE OF CONTENTS Chapter 3 Transfer
Assembly Description .............................
..................................................
..................................................
.. 3.1 Disassembly .............................
..................................................
..................................................
3.2 Disassembly Sequence.......................
..................................................
.......................................
3.2 Inspection after Disassembly
..................................................
..................................................
... 3.4 Reassembly..............................
..................................................
..................................................
3.5 Chapter 4 Rear Axle Description
..................................................
..................................................
............................... 4.1 Rear
Wheels............................................
..................................................
................................... 4.2 Removal
..................................................
..................................................
...............................
4.2 Installation .................................
..................................................
.............................................
4.4 Rear Axle ....................................
..................................................
...............................................
4.7 Removal ......................................
..................................................
...........................................
4.7 Installation .................................
..................................................
.............................................
4.8 Disassembly ..................................
..................................................
.........................................
4.9 Inspection after Disassembly
..................................................
.................................................
4.11 Reassembly.................................
..................................................
...........................................
4.12 Inspection and Adjustment....................
..................................................
.....................................
4.17 Minimum Turning Radius Adjustment............
..................................................
......................... 4.17
Chapter 5 Brake System Description
..................................................
..................................................
............................... 5.1 Automatic
Adjusting Device .................................
..................................................
.................. 5.1 General Information
..................................................
..................................................
............. 5.1 Master Cylinder Disassembly
..................................................
..................................................
......................... 5.2 Inspection after
Disassembly ......................................
..................................................
........... 5.3 Reassembly......................
..................................................
..................................................
.... 5.3 Service Brakes Disassembly (EC15NEC18N)
.................................................
..................................................
.............. 5.4 (EC20NEC30N)
..................................................
..................................................
............. 5.5 Inspection after Disassembly
..................................................
.................................................
5.7 Reassembly (EC15NEC18N) ...................
..................................................
............................................
5.8 (EC20NEC30N) ................................
..................................................
............................... 5.9 Wheel
Cylinders Disassembly ............................
..................................................
............................................... In
spection after Disassembly .......................
..................................................
.......................... Reassembly.............
..................................................
..................................................
............. Inspection and Adjustment...........
..................................................
.......................................... ii
5.12 5.13 5.13 5.14
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com
5
TABLE OF CONTENTS Chapter 6 Steering
System Steering System Description
..................................................
..................................................
............................... 6.1 Steering
System ...........................................
..................................................
......................... 6.1 Oil Flow Sequence
..................................................
..................................................
.......... 6.1 General Information................
..................................................
...........................................
6.1 Steering Gear Steering Wheel 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..................................
..................................................
..............................................
6.7 Steer Pump Removal ...........................
..................................................
..................................................
........ 6.8 Installation ......................
..................................................
..................................................
.......... 6.9 Disassembly .....................
..................................................
..................................................
........ 6.10 Sequence .........................
..................................................
..................................................
.... 6.10 Working Rules and Tips
..................................................
..................................................
....... 6.11 Suggestions .......................
..................................................
..................................................
.. 6.11 Inspection after Disassembly
..................................................
.................................................
6.13 Reassembly.................................
..................................................
...............................................
6.14 Sequence ....................................
..................................................
...........................................
6.14 Suggestions .................................
..................................................
..........................................
6.15 Inspection after Reassembly..................
..................................................
................................ 6.17 Chapter 7
Hydraulic System Hydraulic System Description
..................................................
..................................................
............................... 7.1 Schematic
..................................................
..................................................
........................... 7.1 Hydraulic Tank
..................................................
..................................................
...................... 7.3 Hydraulic Pump
..................................................
..................................................
................... 7.4 Control Valve
..................................................
..................................................
........................ 7.6 Lift and Tilt
Cylinders.........................................
..................................................
..................... 7.7 Down Safety Valve
..................................................
..................................................
............... 7.8 Removal and Installation
Warning...........................................
..................................................
... 7.9
iii
6
TABLE OF CONTENTS
Hydraulic Pump Removal ...........................
..................................................
..................................................
........ Installation ............................
..................................................
..................................................
.... Disassembly .................................
..................................................
.............................................. Wor
king Rules and Tips ..............................
..................................................
........................... Suggestions
..................................................
..................................................
......................... Inspection after
Disassembly ......................................
..................................................
............... Body .............................
..................................................
..................................................
........ Mounting Flange Face ....................
..................................................
....................................... Bushes
and Balance Plate.................................
..................................................
.................... Gears .......................
..................................................
..................................................
............ Reassembly...........................
..................................................
..................................................
... Inspection after Reassembly...................
..................................................
................................... Control
Valve Removal ....................................
..................................................
.................................................
Installation .....................................
..................................................
............................................. Disa
ssembly ..........................................
..................................................
..................................... Suggestions
..................................................
..................................................
............................. Reassembly..........
..................................................
..................................................
.................... Lift and Tilt
Cylinders Removal Lift Cylinders
..................................................
..................................................
........................ Tilt Cylinders
..................................................
..................................................
........................ Disassembly Lift
Cylinders ........................................
..................................................
.................................. Tilt Cylinders
..................................................
..................................................
........................ Inspection after
Disassembly ......................................
..................................................
............... Precautions for Reassembly
..................................................
..................................................
.... Inspection and Adjustment Hydraulic Tank
..................................................
..................................................
.......................... Control Valve
..................................................
..................................................
............................ Lift and Tilt
Cylinders.........................................
..................................................
......................... Adjusting Method
..................................................
..................................................
................. Testing ........................
..................................................
..................................................
..........
7.10 7.11 7.12 7.12 7.14 7.16 7.16 7.16 7.16 7.16
7.17 7.21
7.22 7.23 7.24 7.25 7.25
7.26 7.29
7.31 7.32 7.33 7.33
7.34 7.35 7.38 7.39 7.40
Chapter 8 Mast and Forks Description
..................................................
..................................................
............................... 8.1 Removal and
Installation .....................................
..................................................
....................... 8.2 iv
7
TABLE OF CONTENTS Disassembly ...................
..................................................
..................................................
......... 8.4 Inspection after Disassembly
..................................................
..................................................
... 8.6 Reassembly..............................
..................................................
..................................................
8.7 Inspection and Adjustment....................
..................................................
..................................... 8.8 Forks
..................................................
..................................................
.................................... 8.8 Chain
Tension Adjustment ...............................
..................................................
...................... 8.9 Clearance Adjustment
on Lift Bracket...................................
..................................................
. 8.10 Mast Clearance Adjustment
..................................................
..................................................
. 8.13 Main Roller Shim Replacement
..................................................
.............................................
8.15 Mast Strip Adjustment .......................
..................................................
..................................... 8.15 Tilt
Angle Adjustment .................................
..................................................
............................ 8.16 Lift Cylinder
Stroke Adjustment.................................
..................................................
............. 8.17 Bleeding Lift Cylinders
..................................................
..................................................
......... 8.17 Service Data ....................
..................................................
..................................................
........ 8.18 Troubleshooting ....................
..................................................
..................................................
.... 8.20 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 Chapter 10 Maintenance Service Data
Maintenance Service Data........................................................................................................... 10.1
Front Axle and Reduction Differential ...................................................................................... 10.1
Transfer Case ........................................................................................................................... 10.3
Rear Axle ................................................................................................................................. 10.4
Brake System ........................................................................................................................... 10.6
Steering System,...................................................................................................................... 10.11
Hydraulic System ..................................................................................................................... 10.13
Mast and Forks (Simplex Mast) ............................................................................................... 10.16
Mast and Forks ........................................................................................................................ 10.17
Tightening Torques for Standard Bolts and Nuts ......................................................................... 10.18
Fine ThreadWith Spring Washer .......................................................................................... 10.18
Fine ThreadWithout Spring Washer ..................................................................................... 10.18
Coarse ThreadWith Spring Washer...................................................................................... 10.18
Coarse ThreadWith Spring Washer...................................................................................... 10.18
Tightening Torques for Standard Bolts and Nuts with Standard Threads .................................... 10.19
Coarse ThreadInches ........................................................................................................... 10.19
v
8
TABLE OF CONTENTS
Tightening Torques for Taperlock Studs
..................................................
..................................... Coarse
ThreadInches ....................................
..................................................
..................... Maintenance
Chart.............................................
..................................................
........................ Planned Replacement
Parts ............................................
..................................................
.......... Lubrication Information................
..................................................
............................................... Ch
art ..............................................
..................................................
........................................ Fuel
and Lubricant Specifications .....................
..................................................
..................... Recommended Brands of
Lubricants........................................
............................................... We
ight of Major Components (Approximate)
..................................................
............................. Special Service
Tools ............................................
..................................................
..................... Special Tool
Illustrations.....................................
..................................................
.................... Inspection Guide
..................................................
..................................................
......................
10.19 10.19 10.20 10.26 10.27 10.27 10.28 10.28 10
.29 10.30 10.31 10.34
vi
9
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
10
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
EC15N, EC18N A4EC1-10200-up
A4EC1-20200-up
EC20N, EC25N A4EC2-10200-up
A4EC2-20200-up
EC25EN, EC25LN, EC30N A4EC3-20200-up
A4EC3-30200-up
A4EC3-40200-up
1.1
11
GENERAL INFORMATION Nameplate and Serial Number
Locations
Mast serial number
Chassis serial number Power steering motor
serial number
Traction motor serial number Hydraulic motor
serial number
Nameplate
8609141
1.2
12
GENERAL INFORMATION
Dimensions
8609142
8609143
1.3
13
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)
C Maximum Fork Spacing (outside to outside) 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)
E Tilt Angle (forward/backward) 5/6 5/6 5/6 5/6 5/6
F Overall Length 3050 (120) 3155 (124) 3255 (128) 3255 (128) 3325 (131)
G Overall Width (outside of tires) 945 (37) 1055 (41.5) 1055 (41.5) 1103 (43.5) 1103 (43.5)
H Overall Height (to top of mast, lowered) 2105 (83) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5)
I Overall Height (to top of overhead guard) 2180 (86) 2210 (87) 2210 (87) 2210 (87) 2210 (87)
J Overall Height (to top of mast, extended) 4570 (180) 4570 (180) 4570 (180) 4570 (180) 4550 (179)
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)
P Underclearance (at center of wheelbase) 118 (4.6) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9)
Unit mm (in.)
1.4
14
GENERAL INFORMATION General Information
(Standard Models)
Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC15N EC18N EC20N EC25N EC25EN EC25LN EC30N
Standard Controller Standard Controller MHI SX Controller MHI SX Controller MHI SX Controller MHI SX Controller MHI SX Controller MHI SX Controller MHI SX Controller MHI 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
Service Weight (standard axle) Without Battery kg (lb) 2095 (4620) 2335 (5140) 2685 (5920) 2870 (6330) 2695 (5940) 2865 (6320) 3335 (7353)
Service Weight (standard axle) With Max. Battery kg (lb) 3295 (7270) 3535 (7790) 4285 (9470) 4420 (9880) 4495 (9940) 4665 (10320) 5135 (11353)
Work Performance Rated Capacity/ Load Center Rated Capacity/ Load Center kg/mm (lb/in.) 1350/600 (3000/24) 1600/600 (3500/24) 1800/600 (4000/24) 2275/600 (5000/24) 2275/600 (5500/24) 2500/600 (5000/24) 2725/600 (6000/24)
Work Performance Maximum Fork Height Maximum Fork Height mm (in.) 33235 (131) 33235 (131) 3340 (131) 3340 (131) 3340 (131) 3340 (131) 3315 (131)
Work Performance Lift Speed (Rated Load) 36V m/sec. (fph) .38 (75) .36 (71) .32 (63) .28 (55) .28 (55) .28 (55) .25 (49)
Work Performance Lift Speed (Rated Load) 48V m/sec. (fph) .53 (104) .49 (96) .45 (89) .38 (75) .38 (75) .38 (75) .36 (71)
Work Performance Lowering Speed (rated load) Lowering Speed (rated load) m/sec. (fph) .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
Work Performance Free Lift Free Lift mm (in.) 115 (4.5) 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3)
Traveling Performance Travel Speed (Without Load) 36V km/h (mph) 18 (11.2) 17.3 (10.8) 17.4 (10.8) 17.4 (10.8) 17.4 (10.8) 17.0 (10.6) 17.1 (10.6)
Traveling Performance Travel Speed (Without Load) 48V km/h (mph) 18.2 (11.3) 18.2 (11.3) 18.2 (11.3) 18.2 (11.3) 18.2 (11.3) 18.2 (11.3) 18.2 (11.3)
Traveling Performance Minimum Turning Radius Minimum Turning Radius mm (in.) 1790 (70.5) 1790 (70.5) 1840 (72.5) 1840 (72.5) 1990 (78.5) 1990 (78.5) 2045 (80.5)
Power Train Traction Motor Output 36V 60min. HP(kW) 8.3 (6.2) 8.3 (6.2) 12.1 (9.0) 12.1 (9.0) 12.1 (9.0) 12.1 (9.0) 13.7 (10.2)
Power Train Traction Motor Output 48V 60min. HP(kW) 9.2 (6.8) 9.2 (6.8) 14.2 (10.6) 14.2 (10.6) 14.2 (10.6) 14.2 (10.6) 17.2 (12.8)
Power Train Transfer Gear Type Type Spur Spur Spur Spur Spur Spur Spur
Power Train Transfer Gear Ratio Ratio 3.538 3.538 3.067 3.067 3.067 3.067 3.067
Power Train Reduction Gear Type Type Bevel Bevel Bevel Bevel Bevel Bevel Bevel
Power Train Reduction Gear Ratio Ratio 4.571 4.571 5.0 5.0 5.0 5.0 5.0
Power Train Differential Axle Housing Axle Housing 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
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
1.5
15
GENERAL INFORMATION
Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC15N EC18N EC20N EC25N EC25EN EC25LN EC30N
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
Power Steering System Turning Angle Inside Degrees 83 83 83 83 83 83 83
Power Steering System Turning Angle Outside Degrees 54 54 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)
Power Steering System Cylinder Minimum Test Pressure Cylinder Minimum Test Pressure kgf/cm2 (psi) kPa 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
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
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)
Brake System Service Brake Lining Thickness mm (in.) 4.87 (0.19) 4.87 (0.19) 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)
Brake System Service Brake Wheel Cylinder ID 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)
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
Brake System Park Brake Lever Operating Effort kgf (lbf) N 25 to 30 (55 to 66) 245 to 295 25 to 30 (55 to 66) 245 to 295 25 to 30 (55 to 66) 245 to 295 25 to 30 (55 to 66) 245 to 295 25 to 30 (55 to 66) 245 to 295 25 to 30 (55 to 66) 245 to 295 25 to 30 (55 to 66) 245 to 295
Traveling System Mounting Front Wheels Front Wheels 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
Traveling System Wheel Alignment Oscillation Angle Degrees 3 3 3 3 3 3 3
Traveling System Wheel Alignment Camber Degrees 1 1 1 1 1 1 1
1.6
16
GENERAL INFORMATION
Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC15N EC18N EC20N EC25N EC25EN EC25EN EC25LN EC30N
Hydraulic System Hydraulic Pump Hydraulic Pump Type Type Gear Gear Gear Gear Gear Gear Gear Gear
Hydraulic System Hydraulic Pump Hydraulic Pump Make Make Casappa Casappa 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 KP2024.5 KP2024.5 25R029 25R029 25R029 25R029 25R029 25R029
Hydraulic System Hydraulic Pump Hydraulic Pump Displacement cc (cu in.) 25 (1.526) 25 (1.526) 29 (1.77) 29 (1.77) 29 (1.77) 29 (1.77) 29 (1.77) 29 (1.77)
Hydraulic System Control Valve Interval Flow Regulator Valve Control Valve Interval Flow Regulator Valve Make Make Husco International Husco International Husco International Husco International Husco International Husco International Husco International Husco International
Hydraulic System Control Valve Interval Flow Regulator Valve Control Valve Interval Flow Regulator Valve Model Model 9510 Sectional Valve 9510 Sectional Valve 9510 Sectional Valve 9510 Sectional Valve 9510 Sectional Valve 9510 Sectional Valve 9510 Sectional Valve 9510 Sectional Valve
Hydraulic System Control Valve Interval Flow Regulator Valve Control Valve Interval Flow Regulator Valve Relief Pressure kgf /cm2 (psi) kPa AUX 158 (2250) 15513 AUX 158 (2250) 15513 AUX 158 (2250) 15513 AUX 158 (2250) 15513 AUX 158 (2250) 15513 AUX 158 (2250) 15513 AUX 158 (2250) 15513 AUX 158 (2250) 15513
Hydraulic System Control Valve Interval Flow Regulator Valve Control Valve Interval Flow Regulator Valve Relief Pressure kgf /cm2 (psi) kPa Lift Tilt 185 (2630) 18133 Lift Tilt 185 (2630) 18133 Lift Tilt 185 (2630) 18133 Lift Tilt 185 (2630) 18133 Lift Tilt 185 (2630) 18133 Lift Tilt 185 (2630) 18133 Lift Tilt 185 (2630) 18133 Lift Tilt 185 (2630) 18133
Hydraulic System Control Valve Interval Flow Regulator Valve Control Valve Interval Flow Regulator Valve Type Type Variable Variable Variable Variable Variable Variable Variable Variable
Hydraulic System Control Valve Interval Flow Regulator Valve Control Valve Interval Flow Regulator Valve Regulated Flow Rate liter (cu.in.) / min 45 (2746) 45 (2746) 60 (3661) 60 (3661) 60 (3661) 60 (3661) 60 (3661) 60 (3661)
Hydraulic System Lift Cylinders Lift Cylinders ID mm (in.) 45 (1.77) 45 (1.77) 50 (1.97) 50 (1.97) 50 (1.97) 50 (1.97) 55 (2.17) 55 (2.17)
Hydraulic System Tilt Cylinders Tilt Cylinders ID mm (in.) 63 (2.48) 63 (2.48) 70 (2.75) 70 (2.75) 70 (2.75) 70 (2.75) 80 (3.15) 80 (3.15)
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) 24 (6.3) 24 (6.3) 24 (6.3) 24 (6.3) 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
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 42 x 11 (3.94 x 0.59 x 0.47) 100 x 42 x 11 (3.94 x 0.59 x 0.47) 115 x 46 x 12 4.53 x 0.79 x 0.51) 115 x 46 x 12 4.53 x 0.79 x 0.51) 115 x 46 x 12 4.53 x 0.79 x 0.51) 115 x 46 x 12 4.53 x 0.79 x 0.51) 115 x 46 x 12 4.53 x 0.79 x 0.51) 115 x 46 x 12 4.53 x 0.79 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 60 x 10 (3.94 x 0.67 x 0.47) 100 x 60 x 10 (3.94 x 0.67 x 0.47) 115 x 45 x 11 (4.53 x 0.83 x 0.51) 115 x 45 x 11 (4.53 x 0.83 x 0.51) 115 x 45 x 11 (4.53 x 0.83 x 0.51) 115 x 45 x 11 (4.53 x 0.83 x 0.51) 115 x 45 x 11 (4.53 x 0.83 x 0.51) 115 x 45 x 11 (4.53 x 0.83 x 0.51)
Mast and Forks Main Rollers Main Rollers Type Type 6308 Ball Bearing 6308 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 27 (3.94 x 1.18) 100 x 27 (3.94 x 1.18) 115 x 30 (4.53 x 1.58) 115 x 30 (4.53 x 1.58) 115 x 30 (4.53 x 1.58) 115 x 30 (4.53 x 1.58) 115 x 30 (3.94 x 1.18) 115 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
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)
Mast and Forks Lift Chains Lift Chains Lift Chains Lift Chains BL534 BL534 BL634 BL634 BL634 BL634 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) 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)
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 / 920 240 / 920 240 / 920 240 / 920 285 / 960 285 / 960
Battery Voltage Voltage Voltage Voltage 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 1400 1400 1400 1400 1400 1400
Battery Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) 48V 700 700 1100 1100 1100 1100 1100 1100
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)
Battery Compartment Dimensions Height-Edges Height-Edges mm (in.) 589 (23.2) 589 (23.2) 589 (23.2) 589 (23.2) 589 (23.2) 589 (23.2) 589 (23.2) 589 (23.2)
Battery Compartment Dimensions Length Length mm (in.) 705 (27.8) 705 (27.8) 772 (30.4) 772 (30.4) 772 (30.4) 872 (34.3) 872 (34.3) 872 (34.3)
Battery Compartment Dimensions Width Width mm (in.) 903 (35.5) 903 (35.5) 1000 (39.4) 1000 (39.4) 1000 (39.4) 1000 (39.4) 1000 (39.4) 1000 (39.4)
Battery Weight (Min/Max) Weight (Min/Max) Weight (Min/Max) kg (lb) 750/1200 (1650/2650) 750/1200 (1650/2650) 1000/1600 (2200/3550) 1315/1600 (2900/3550) 1315/1600 (2900/3550) 1400/1800 (3100/4000) 1400/1800 (3100/4000) 1400/1800 (3100/4000)
1.7
17
TABLE OF CONTENTS
Chapter 2 Front Axle Reduction
Differential Front Axle Description
..................................................
..................................................
............................... 2.1 General
Information ......................................
..................................................
......................... 2.1 Removal
..................................................
..................................................
................................... 2.2 Front
Wheels ...........................................
..................................................
............................... 2.2 Method
1.................................................
..................................................
........................... 2.3 Method
2.................................................
..................................................
........................... 2.3 Method
3.................................................
..................................................
........................... 2.3 Installation
..................................................
..................................................
................................
2.4 Disassembly ..................................
..................................................
.............................................
2.5 Removing Front Wheel Hub .....................
..................................................
.............................. 2.6 Inspection
after Disassembly ................................
..................................................
..................... 2.7 Reassembly............
..................................................
..................................................
.................. 2.8 Axle Housing
..................................................
..................................................
........................ 2.8 Front Wheel Hub
..................................................
..................................................
.................. 2.8 Hub Bearing
Preload...........................................
..................................................
................... 2.10 Installation and Setting
Preload...........................................
................................................
2.10 Reduction Differential Description
..................................................
..................................................
............................... Disassembly
..................................................
..................................................
............................. Inspection after
Disassembly ......................................
..................................................
............... Reduction Gear ...................
..................................................
..................................................
. Differential ...................................
..................................................
........................................... Reasse
mbly..............................................
..................................................
.................................. Inspection and
Adjustment........................................
..................................................
................. Side Bearing Preload
..................................................
..................................................
........... Reduction Gear Backlash
..................................................
..................................................
.... Reduction Gear Face Runout
..................................................
................................................ T
ooth Contact .....................................
..................................................
.................................... Tooth
Contact Adjustment ...............................
..................................................
.......................
2.11 2.12 2.13 2.13 2.13 2.14 2.16 2.16 2.16 2.17
2.17 2.18
18
FRONT AXLE REDUCTION DIFFERENTIAL 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
19
FRONT AXLE REDUCTION DIFFERENTIAL
Removal Front Wheels
Suggestions

1. Park the truck on level floor with the parking
   brake applied, the direction lever in neutral,
   the forks lowered, and the key switch off.
2. Prepare tools, jacks, and wheel blocks.
3. Block the rear wheels.
4. 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
20
FRONT AXLE REDUCTION DIFFERENTIAL
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.)
EC15NEC18N 3000 kgf (6700 lbf)
EC20NEC30N 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
21
FRONT AXLE REDUCTION DIFFERENTIAL
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.
Tightening Torque For Wheel Nuts Tightening Torque For Wheel Nuts
EC15NEC18N EC20NEC30N
16 kgfm 38.5 kgfm
(116 lbfft) (278 lbfft)
157 Nm 378 Nm
Wheel Nut Counterbore 100835A
2.4
22
FRONT AXLE REDUCTION DIFFERENTIAL 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 differen-
  tial, 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
23
FRONT AXLE REDUCTION DIFFERENTIAL
Removing Front Wheel Hub Use a wheel hub puller
(Special Tool).
Suggestions Removing the Lock Nut Use a lock nut
wrench (Special Tool).
Tool EC15NEC18N EC20NEC30N
Wheel Hub Puller 64309-40100 MH061017
(Puller seat) (64309-10601)
Tool EC15NEC18N EC20NEC30N
Lock Nut Wrench 91268-00800 03703-59001
NOTE
Special Tool 200232
It is not necessary to remove the oil seal from
the hub or to disassemble the oil deflector
unless the seal is defective.
Any wear or grooves in oil seal deflector would
require replacement. It has been standard
practice to replace the oil seal every time the
hub is removed to reduce the possibility of oil
leaks.
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
24
FRONT AXLE REDUCTION DIFFERENTIAL
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
EC15NEC18N EC20NEC30N
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
25
FRONT AXLE REDUCTION DIFFERENTIAL
Front Wheel Hub 1. Fill the front wheel hub,
especially the roller holder and oil seal lip
groove, with grease. Pack both bearings with
grease.
Reassembly To reassemble, reverse the steps of
the disassem- bly 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.

205954a
Frame support
O-ring
A
NOTE
Be careful not to apply grease to the brake drum.
200237
Check for excessive movement between frame
support and axle housing.
200238
2.8
26
FRONT AXLE REDUCTION DIFFERENTIAL 2. Install
the inner race and oil seal retainer of the
wheel hub bearing with an installer (Special
Tool).
Special tool 203569
Tool EC15NEC18N EC20N EC30N
Installer 64309-12300 91468-00300
3. Apply retaining compound to the flange sur-
faces of the axle shafts.
2.9
27
FRONT AXLE REDUCTION DIFFERENTIAL
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 still 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 tan-
  gential 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
2.10
28
FRONT AXLE REDUCTION DIFFERENTIAL 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
   differential case)
2. Tapered roller bearings

• Start By
• Remove the differential carrier from the trans-
  mission case.
• 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
29
FRONT AXLE REDUCTION DIFFERENTIAL
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
2.12
30
FRONT AXLE REDUCTION DIFFERENTIAL
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
2.13
31
FRONT AXLE REDUCTION DIFFERENTIAL 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
   bear- ing caps, side bearing nuts, and lock
   washers

2.14
32
FRONT AXLE REDUCTION DIFFERENTIAL
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 mak- ing 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