CATERPILLAR CAT EC35N EC40N EC45N EC55N FORKLIFT LIFT TRUCKS Service Repair Manual Instant Download

1
Lift
Trucks
Service Manual
Chassis Mast EC35N, EC40N, EC45N EC55N
A2EC4-60200-up A2EC5-60200-up
SENB8474-01
For use with GE SX Control Service Manual.
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 AND REDUCTION
DIFFERENTIAL Specifications . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 2.1 Structure . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 2.2 Procedures
and Key Points for Removal and Installation . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 2.3 Front Tire . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 2.3 Front Axle Assembly
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 2.4 Reduction and
Differential . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 2.6 Axle Shaft and
Hub . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
. 2.6 Disassembly . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2.7 Inspection and Repair . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 2.8 Assembly . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 2.9 Adjustments . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 2.15 Troubleshooting . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 2.18 Service Data . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
. 2.19 CHAPTER 3 TRANSFER ASSEMBLY Structure
and Functions . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. 3.1 Disassembly and Reassembly . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. 3.2 Disassembly . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3.2 Inspection after Disassembly . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 3.4 Reassembly . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 3.5 Tightening Torque . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 3.8
i
3
TABLE OF CONTENTS CHAPTER 4 REAR
AXLE Specifications . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 4.1 Structure . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 4.2 Rear Axle . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 4.2 Steering
Cylinder . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. 4.3 Procedures and Key Points for Removal and
Installation . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 4.3 Rear
Tires . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. 4.4 Rear Axle . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 4.6 Rear Axle Assembly . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 4.8 Disassembly . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 4.9 Assembly . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 4.10 Steering Cylinder .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. 4.12 Disassembly . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 4.12 Inspection and Repair . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 4.13 Assembly . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 4.14 Adjustment . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 4.15 Adjustment of
Minimum Turning Radius . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 4.15 Troubleshooting . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 4.16 Service Data .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. 4.17 CHAPTER 5 BRAKE SYSTEM Specifications .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. 5.1 Structure . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 5.2 Brake System . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 5.2 Master Cylinder and
Reservoir Tank . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 5.3 Wheel Brake . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 5.4 Master Cylinder . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 5.5 Disassembly . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 5.5 Wheel
Cylinder . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. 5.6 Disassembly . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5.6 Inspection and Repair . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 5.7 Assembly . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 5.7 Wheel Brake . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 5.8 Disassembly . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 5.8 Inspection and Repair
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 5.9 Assembly . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 5.11
ii
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.ebo
oklibonline.com
5
TABLE OF CONTENTS
CHAPTER 5 BRAKE SYSTEM (cont.) Parking Brake
Lever . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . Inspection
and Repair . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . Installation .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . Adjustment
and Tests . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . Automatic
Adjuster Test . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . Procedure for
Manual Adjustment . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . Brake Fluid Line Bleeding .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Inspecting Reservoir Tank Level
Sensor . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. Procedures for Brake Pedal Adjustment . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . Service
Data . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
5.13 5.13 5.13 5.14 5.14 5.14 5.15 5.15 5.16 5.17
5.19
CHAPTER 6 STEERING SYSTEM Steering
System Description . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 6.1 Steering System . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 6.1 Oil Flow Sequence . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 6.1 General Information . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 6.1 Steering Gear Removal . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. 6.2 Installation . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 6.2 Steering Gear . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 6.3 Inspection after Removal
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 6.4 Disassembly . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 6.5 Working
Rules and Tips . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
. 6.6 Suggestions . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6.6 Inspection after Disassembly . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 6.6 Reassembly . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 6.6 Suggestions . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 6.6 Steer Pump Removal . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. 6.7 Installation . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 6.7
iii
6
TABLE OF CONTENTS CHAPTER 7 HYDRAULIC SYSTEM
Hydraulic System Description . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 7.1 Schematic . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 7.2 Hydraulic Tank
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 7.3 Hydraulic
Pump . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 7.4 Control
Valve . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. 7.5 Lift and Tilt Cylinders . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 7.6 Flow Regulator Valve . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 7.11 Down Safety Valve . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7.12 Removal and Installation Warning . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 7.12 Hydraulic Pump Removal . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . Installation . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. Disassembly . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Working Rules and Tips . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. Inspection after Disassembly . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. Reassembly . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Placing Pump Back into Service . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. Inspection after Reassembly . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. Trouble Shooting . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . Control Valve Removal . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . Installation . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. Suggestions . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Reassembly . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Lift and Tilt Cylinders Removal
7.13 7.13 7.15 7.15 7.16 7.17 7.20 7.21 7.21
7.22 7.23 7.25 7.26 7.26
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
7.27 7.33
Lift Cylinders Tilt Cylinders Disassembly Lift
Cylinders Tilt Cylinders
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
7.34 7.48 7.51 7.51 7.51
Flow Regulator Valve . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. Inspection after Disassembly . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. Precautions for Reassembly . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. Inspection and Adjustment Hydraulic Tank . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . Control Valve .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . Main
Relief Valve Adjustment . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . Auxiliary
Relief Valve Adjustment . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
7.54 7.55 7.56 7.56
iv
7
TABLE OF CONTENTS CHAPTER 8 MAST AND
FORKS Specifications . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 8.1 Description . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. 8.2 Dual-stage Panoramic Mast (Simplex Mast) .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. 8.5 Triple-stage Full Free Panoramic Mast
(Triplex Mast) . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. 8.9 Disassembly and Reassembly . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8.12 Dual-stage Panoramic Mast (Simplex
Mast) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8.12 Dual-stage Full Free Panoramic Mast
(Duplex Mast) . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. 8.16 Triple-stage Full Free Panoramic Mast
(Triplex Mast) . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 8.21 Inspection and Adjustment . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 8.25 Forks . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 8.25 Chain, Chain
Wheel Support and Chain Wheel . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 8.26 Chain Tension Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 8.27 Clearance Adjustment
on Lift Bracket . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 8.30 Mast Clearance
Adjustment . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 8.32 Main Roller
Shim Replacement (Simplex Mast) . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 8.34 Mast Strip Adjustment .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 8.34 Tilt Angle
Adjustment . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. 8.38 Lift Cylinder Stroke Adjustment . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 8.39 Troubleshooting . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 8.40 Service Data . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. 8.41 CHAPTER 9 SERVICE DATA Tightening
Torques for Standard Bolts and Nuts . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 9.1 Fine Thread with
Spring Washer . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 9.1 Fine Thread without
Spring Washer . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 9.2 Course Thread with Spring
Washer . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 9.3 Course Thread without Spring Washer
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. 9.4 Maintenance Chart . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 9.5 Periodic Replacement Parts . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 9.11 Lubrication Chart . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 9.12 Fuel and Lubricant
Specifications . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 9.13 Weight of Major
Components . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 9.14 Special Service
Tools . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 9.15 Special
Tool Illustrations . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. 9.16 Inspection Guide . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 9.19
v
8
GENERAL INFORMATION
CHAPTER 1 GENERAL INFORMATION Scope..............
..................................................
..................................................
............................................ 1.1 T
ruck Models Covered...............................
..................................................
..................................................
. 1.1 Nameplate and Serial Number Locations
..................................................
..................................................
.. 1.2 Dimensions ................................
..................................................
..................................................
................. 1.3 Dimensions Chart
..................................................
..................................................
....................................... 1.4 Genera
l Information (Standard Models)
..................................................
..................................................
..... 1.5
9
GENERAL INFORMATION Scope This service manual
deals with all components or systems of the Cat
Lift Trucks, except for the electrical system,
which is covered in a separate manual.
Truck Models Covered This service manual
furnishes service and maintenance information for
the following trucks.
Truck Model Serial Number
EC35N A2EC4-60200-up
EC40N A2EC4-60200-up
EC45N A2EC4-60200-up
EC55N A2EC5-60200-up
1.1
10
GENERAL INFORMATION Nameplate and Serial Number
Locations
1.2
11
GENERAL INFORMATION
Dimensions
1.3
12
GENERAL INFORMATION Dimensions Chart
Ref Truck Model EC35N EC40N EC45N EC55N
A Maximum Lift 4650 (183) 4650 (183) 5055 (199) 5320 (209)
B Free Lift 150 (5.9) 150 (5.9) 160 (6.3) 160 (6.3)
C Maximum Fork Spacing (outside to outside) 1060 (41.5) 1060 (41.5) 1060 (41.5) 1060 (41.5)
D Fork Length 1220 (48) 1220 (48) 1220 (48) 1220 (48)
E Tilt Angle (forward/backward) 6 / 8 6 / 8 6 / 8 6 / 8
F Overall Length 3640 (143.3) 3691 (145.3) 3746 (147.5) 3912 (154.0)
G Overall Width (outside of tires) 1270 (50.0) 1270 (50.0) 1315 (52.0) 1420 (55.9)
H Overall Height (to top of mast, lowered) 2270 (89.5) 2270 (89.5) 2350 (92.5) 2120 (83.5)
I Overall Height (to top of overhead guard) 2341 (92.2) 2341 (92.2) 2341 (92.2) 2341 (92.2)
J Overall Height (to top of mast, extended) 4550 (179.1) 4550 (179.1) 4115 (162.0) 4125 (162.4)
K Tread (front) 1040 (41.0) 1040 (41.0) 1065 (42.0) 1116 (44.0)
L Tread (rear) 965 (38.0) 965 (38.0) 965 (38.0) 965 (38.0)
M Wheelbase 1575 (62.0) 1575 (62.0) 1575 (62.0) 1720 (67.7)
N Front Overhang 450 (17.7) 450 (17.7) 465 (18.3) 480 (18.9)
O Rear Overhang 395 (16) 446 (18) 486 (19) 492 (19)
P Underclearance (at center of wheelbase) 106 (4.2) 106 (4.2) 106 (4.2) 106 (4.2)
Unit mm (in.)
1.4
13
GENERAL INFORMATION General Information (Standard
Models)
Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC35N EC40N EC45N EC55N
Standard Controller Standard 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 2.9
Service Weight (standard axle) Without Battery kg (lb) 4581 (10099) 4833 (10656) 5677 (12516) 6448 (14215)
Service Weight (standard axle) With Max. Battery kg (lb) 6849 (15099) 7101 (15656) 7945 (17516) 8716 (19215)
Work Performance Rated Capacity/ Load Center Rated Capacity/ Load Center kg/mm (lb/in.) 3500/500 (7000/24) 4000/500 (8000/24) 4500/600 (10,000/24) 5500/600 (12,000/24)
Work Performance Maximum Fork Height Maximum Fork Height mm (in.) 4650 (183) 4650 (183) 5055 (199) 5320 (209)
Work Performance Lift Speed (Rated Load) 36V m/sec. (fpm) 0.25 (50) 0.22 (43) 0.20 (39) 0.17 (33)
Work Performance Lift Speed (Rated Load) 48V m/sec. (fpm) 0.31 (64) 0.34 (67)) 0.25 (49) 0.21 (41)
Work Performance Lowering Speed (rated load) Lowering Speed (rated load) m/sec. (fpm) 0.54 (106) 0.54 (106) 0.56 (110) 0.56 (110)
Work Performance Tilt Angle (forward/backward) Tilt Angle (forward/backward) degrees 6 / 8 6 / 8 6 / 8 6 / 8
Work Performance Free Lift Free Lift mm (in.) 150 (5.9) 150 (5.9) 160 (6.3) 160 (6.3)
Traveling Performance Travel Speed (Without Load) 36V km/h (mph) 14.0 (8.7) 13.8 (8.6) 13.7 (8.5) 13.6 (7.3)
Traveling Performance Travel Speed (Without Load) 48V km/h (mph) 17.0 (10.6) 16.9 (10.5) 15.8 (10.3) 16.6 (10.3)
Traveling Performance Minimum Turning Radius Minimum Turning Radius mm (in.) 2214 (87) 2258 (89) 2294 (90) 2468 (97)
Power Train Traction Motor Output 36V 60min. HP(kW) 15.3 (11.4) 15.3 (11.4) 15.3 (11.4) 15.3 (11.4)
Power Train Traction Motor Output 48V 60min. HP(kW) 20.9 (15.5) 20.9 (15.5) 20.9 (15.5) 20.9 (15.5)
Power Train Transfer Gear Type Type Spur Spur Spur Spur
Power Train Transfer Gear Ratio Ratio 5.131 5.131 5.131 5.131
Power Train Reduction Gear Type Type Spiral Bevel Spiral Bevel Spiral Bevel Spiral Bevel
Power Train Reduction Gear Ratio Ratio 4.571 4.571 4.571 4.571
Power Train Differential Axle Housing Axle Housing Banjo Banjo Banjo Banjo
Power Train Differential Gear Type/ Number Gears 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
1.5
14
GENERAL INFORMATION
Truck Model Truck Model
Units EC35N thru EC55N
Power Steering System Type Type Type Dynamic Load Sense
Power Steering System Turning Angle Inside Degrees 82
Power Steering System Turning Angle Outside Degrees 59
Power Steering System Steering Wheel Diameter Steering Wheel Diameter mm (in.) 328 (13)
Power Steering System Cylinder Minimum Test Pressure Cylinder Minimum Test Pressure kgf/cm2 (psi) kPa 120 (1706) 11,768
Brake System Service Brake Type Type Self-Adjusting Duo-Servo
Brake System Service Brake Inside Drum Diameter mm (in.) 317.5 (12.50)
Brake System Service Brake Lining Thickness mm (in.) 10 (0.39)
Brake System Service Brake Master Cylinder ID mm (in.) Primary 31.75 (1.25) Secondary 19.05 (0.75)
Brake System Service Brake Wheel Cylinder ID 31.75 (1.250)
Brake System Park Brake Type Type Mechanical, Mounted on Front Wheels
Brake System Park Brake Lever Operating Effort kgf (lbf) N 25 to 30 (55 to 66) 245 to 295
Traveling System Mounting Front Wheels Front Wheels Fixed Type
Traveling System Mounting Rear Wheels Rear Wheels Center Pivot Type
Traveling System Wheel Alignment Oscillation Angle Degrees 3
Traveling System Wheel Alignment Camber Degrees 1
1.6
15
GENERAL INFORMATION
Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model Truck Model
Units EC35N EC35N EC40N EC45N EC45N EC55N
Hydraulic System Hydraulic Pump Hydraulic Pump Type Type Type Gear Gear Gear Gear Gear Gear
Hydraulic System Hydraulic Pump Hydraulic Pump Make Make Make Haldex - Barnes Haldex - Barnes Haldex - Barnes Haldex - Barnes Haldex - Barnes Haldex - Barnes
Hydraulic System Hydraulic Pump Hydraulic Pump Model Model Model W1500 W1500 W1500 W1500 W1500 W1500
Hydraulic System Hydraulic Pump Hydraulic Pump Displacement Displacement cc (cu in.) 38 (2.32) 38 (2.32) 38 (2.32) 38 (2.32) 38 (2.32) 38 (2.32)
Hydraulic System Hydraulic Pump Hydraulic Pump Make Make Make Husco International Husco International Husco International Husco International Husco International Husco International
Hydraulic System Control Valve Control Valve Model Model Model 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 Relief Pressure kgf /cm2 (psi) kPa Aux 155 (2250) 15513 Aux 155 (2250) 15513 Aux 155 (2250) 15513 Aux 155 (2250) 15513 Aux 155 (2250) 15513 Aux 155 (2250) 15513
Hydraulic System Control Valve Control Valve Relief Pressure Relief Pressure kgf /cm2 (psi) kPa Lift Tilt 197 (2850) 19650 Lift Tilt 197 (2850) 19650 Lift Tilt 197 (2850) 19650 Lift Tilt 197 (2850) 19650 Lift Tilt 197 (2850) 19650 Lift Tilt 197 (2850) 19650
Hydraulic System Flow Regulator Valve Flow Regulator Valve Type Type Type Variable Variable Variable Variable Variable Variable
Hydraulic System Flow Regulator Valve Flow Regulator Valve Regulated Flow Rate Regulated Flow Rate liter (cu.in.) / min 100 (6100) 100 (6100) 100 (6100) 115 (7018) 115 (7018) 115 (7018)
Hydraulic System Lift Cylinders Lift Cylinders ID ID mm (in.) 60 (2.36) 60 (2.36) 60 (2.36) 70 (2.75) 70 (2.75) 70 (2.75)
Hydraulic System Lift Cylinders Lift Cylinders Stroke Stroke mm (in.) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96) 1650 (64.96)
Hydraulic System Tilt Cylinders Tilt Cylinders ID ID mm (in.) 100 (3.937) 100 (3.937) 100 (3.937) 100 (3.937) 100 (3.937) 100 (3.937)
Hydraulic System Tilt Cylinders Tilt Cylinders Stroke Stroke mm (in.) 120 (4.724) 120 (4.724) 120 (4.724) 120 (4.724) 120 (4.724) 120 (4.724)
Hydraulic System Hydraulic Tank Capacity (Approx) Hydraulic Tank Capacity (Approx) Hydraulic Tank Capacity (Approx) Hydraulic Tank Capacity (Approx) liter (US gal.) Liter 48 (12.7) Liter 48 (12.7) Liter 48 (12.7) Liter 48 (12.7) Liter 48 (12.7) Liter 48 (12.7)
Mast and Forks Mast Model Mast Model Mast Model Mast Model Mast Model Mast Model CJ type CJ type CJ type CJ type CJ type
Mast and Forks Flange ID X flange back thickness X flange front thickness X web thickness Flange ID X flange back thickness X flange front thickness X web thickness Flange ID X flange back thickness X flange front thickness X web thickness Outer Outer Outer 118x28x24x13 (4.6x1.1x0.9x0.5) 118x28x24x13 (4.6x1.1x0.9x0.5) 118x28x24x13 (4.6x1.1x0.9x0.5) 130x30x26x15 (5.1x1.2x1.0x0.6) 130x30x26x15 (5.1x1.2x1.0x0.6)
Mast and Forks Flange ID X flange back thickness X flange front thickness X web thickness Flange ID X flange back thickness X flange front thickness X web thickness Flange ID X flange back thickness X flange front thickness X web thickness Inner, Middle Inner, Middle Inner, Middle 118x24x24x12 (4.6x0.9x0.9x0.47) 118x24x24x12 (4.6x0.9x0.9x0.47) 118x24x24x12 (4.6x0.9x0.9x0.47) 130x26x26x13 (5.1x1.0x1.0x0.5) 130x26x26x13 (5.1x1.0x1.0x0.5)
Mast and Forks Main Rollers Main Rollers Main Rollers Bearing Bearing Bearing Ball Bearing Ball Bearing Ball Bearing Ball Bearing Ball Bearing
Mast and Forks Main Rollers Main Rollers Main Rollers Diameter x Width, mm (in.) Diameter x Width, mm (in.) Diameter x Width, mm (in.) 118x32 (4.65x1.26) 118x32 (4.65x1.26) 118x32 (4.65x1.26) 130x34 (5.12x1.34) 130x34 (5.12x1.34)
Mast and Forks Side Rollers Side Rollers Side Rollers Bearing Bearing 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 Side Rollers Diameter x Width, mm (in.) Diameter x Width, mm (in.) Diameter x Width, mm (in.) 52x36 (2.05x1.42) 52x36 (2.05x1.42) 52x36 (2.05x1.42) 52x36 (2.05x1.42) 52x36 (2.05x1.42)
Mast and Forks Lift Chains Lift Chains Lift Chains Lift Chains Lift Chains Lift Chains BL834 BL834 BL834 BL1034 BL1034
Mast and Forks Forks (length x width x thick), mm (in.) Forks (length x width x thick), mm (in.) Forks (length x width x thick), mm (in.) Forks (length x width x thick), mm (in.) Forks (length x width x thick), mm (in.) Forks (length x width x thick), mm (in.) 1220x150x50 (48x6x2) 1220x150x50 (48x6x2) 1220x150x50 (48x6x2) 1220x150x50 (48x6x2) 1220x150x50 (48x6x2)
Mast and Forks Fork Spread (outer width), mm (in.) Fork Spread (outer width), mm (in.) Fork Spread (outer width), mm (in.) Fork Spread (outer width), mm (in.) Fork Spread (outer width), mm (in.) Fork Spread (outer width), mm (in.) 1060 (41.5) 1060 (41.5) 1060 (41.5) 1060 (41.5) 1060 (41.5)
Battery Voltage Voltage Voltage Voltage Voltage Voltage 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) Amp Hours (6 hr. rate) 36V 36V 1760 1760 1760 1760 1760
Battery Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) Amp Hours (6 hr. rate) 48V 48V 1540 1540 1540 1540 1540
Battery Compartment Dimensions Height Height Height mm (in.) mm (in.) 590 (23.22) 590 (23.22) 590 (23.22) 590 (23.22) 590 (23.22)
Battery Compartment Dimensions Length Length Length mm (in.) mm (in.) 1003 (39.5) 1003 (39.5) 1003 (39.5) 1003 (39.5) 1003 (39.5)
Battery Compartment Dimensions Width Width Width mm (in.) mm (in.) 1156 (45.5) 1156 (45.5) 1156 (45.5) 1156 (45.5) 1156 (45.5)
Battery Weight (Min/Max) Weight (Min/Max) Weight (Min/Max) Weight (Min/Max) kg (lb) kg (lb) 1500 / 2268 (3400 / 5000) 1500 / 2268 (3400 / 5000) 1650 / 2268 (3600 / 5000) 1650 / 2268 (3600 / 5000) 1800 / 2268 (3975 / 5000)
1.7
16
FRONT AXLE AND REDUCTION DIFFERENTIAL CHAPTER
2 FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications ...................................
..................................................
..................................................
......... 2.1 2.2 2.3 2.3 2.4 2.6 2.6 2.7 2.8 2.9
Structure ........................................
..................................................
..................................................
.......
Procedures and Key Points for Removal and
Installation......................................
........................................ Front
Tire .............................................
..................................................
..................................................
Front Axle Assembly .............................
..................................................
.................................................
Reduction and Differential .......................
..................................................
............................................. Axle
Shaft and Hub ...................................
..................................................
..................................................
Disassembly......................................
..................................................
..................................................
... Inspection and Repair.........................
..................................................
..................................................
. Assembly .......................................
..................................................
..................................................
......
Adjustments .....................................
..................................................
..................................................
... 2.15 Troubleshooting ........................
..................................................
..................................................
.................. 2.18 Service Data
..................................................
..................................................
..............................................
2.19
17
FRONT AXLE AND REDUCTION DIFFERENTIAL Specificati
ons
Truck Models Items Truck Models Items Truck Models Items Truck Models Items EC35N thru EC55N
Reduction Gear type Reduction ratio Gear type Reduction ratio Gear type Reduction ratio Spiral bevel gear 4.571
Differential Housing type Housing type Housing type Banjo type
Differential Type and number of gears Type and number of gears Large Small Straight bevel gear x 2 Straight bevel gear x2
Running Gear Front axle type Front axle type Front axle type Full-floating axle tube type
Running Gear Suspension Front wheel Front wheel Frame fixing type
2.1
18
FRONT AXLE AND REDUCTION DIFFERENTIAL Structure
5
6
7
8
1







4
2 3
206653

• Sequence
• Front wheel hub drum
• Front axle support
• Axle shaft
• Axle housing
• Reduction bevel pinion
• Reduction bevel gear
• Differential case
• Differential carrier

2.2
19
FRONT AXLE AND REDUCTION DIFFERENTIAL Procedures
and Key Points for Removal and Installation Front
Tire
Removal 1 Wheel nut Special tool needed
2 1 206654
2 Front tire
Wheel socket
MCF-1098
Preparation

1. Pull the hand brake lever, and place wheel
   stoppers at the rear tires.
2. Loosen the wheel nuts about two rotations, and
   lift the vehicle with a crane or a hydraulic
   unit.

(a) Lifting the vehicle with a crane, attach a
cable to the outer and inner mast crossmembers,
and lift the vehicle. Use protection cloth for
the cable.
206665
(b) Lifting the vehicle with the mast, tilt the
mast fully backward, place jack stands which
can bear the weight under the mast, and tilt the
mast forward until the front tires are off the
ground.
200227
NOTE
For both methods, place jack stands under the
frame to prevent it from falling.
Installation Follow the removal sequence in
reverse. Be careful with the following key
point. Tighten wheel nuts evenly to the specified
torque to prevent tire shimmy.
Tightening sequence
1
8
5
NOTE
Insure wheel nut mounting holes are free of paint
and grease before torquing wheel nuts.
3
4
7
6
Wheel nut tightening torque 55155
Nm (kgfm) lbfft (56.2 5.6)
406.5 40.6
2
206655
2.3
20

• FRONT AXLE AND REDUCTION DIFFERENTIAL
• Front Axle Assembly Preparation
• Pull the hand brake lever, and place wheel
  stoppers at the front and rear tires.
• Remove the mast and the lift bracket assem- bly.
  (Refer to Mast and Fork section.)
• Loosen the front tire nuts about two rotations,
  and jack up the vehicle.
• Place jack stands under the frame on both sides
  at the front so that the vehicle becomes level.
• Remove the front tires. (Refer to Front Tire
  Removal procedure.)
• Drain differential oil.
• NOTE
• If replacing the front axle housing, carry out
  the above preparation.
• Removal

3 2 3 4 1 206666

• Sequence
• Axle shaft, Bolt, Spring washer
• Bolt, Spring washer
• Nuts, Spring washers, Bolts
• Front axle assembly
• 2.4

21
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for removal (1) Removing axle support
bolts
206667
(a) Place jack stands under the front of the
transmission to support it.
?

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

Reduction and Differential When replacing the
reduction gear, replace the reduction pinion,
too. Tooth contact of the reduction gear and the
reduction pinion must be adjusted by mating the
transfer assembly on the pinion side and the
differential carrier on the gear side.
Therefore remove the transfer assembly and the
differential carrier from the frame before
adjusting the tooth contact. Dismount the
traction motor before removing or installing the
transfer assembly. (Refer to Power Line
section.) Place the transfer assembly on a stable
work bench, and remove the differential carrier.
Installation Follow the removal sequence in
reverse. Be care- ful with the following key
points.

1. Clean the mounting surface on the differential
   carrier completely, and apply liquid gasket
   before installation.
2. Apply liquid gasket to the mounting surface of
   the axle shaft, and tighten bolts.

Tightening torque of 128.3 12.8
axle shaft bolts (13.1 1.3)
Nm (kgfm) lbfft 94.7 9.4
(3) Tighten axle support bolts to the specified
torque.
Tightening torque of axle support bolts EC35N thru EC55N
N-m 693.8
(kgfm) (70.8)
lbfft 512
2.5
22
FRONT AXLE AND REDUCTION DIFFERENTIAL Axle Shaft
and Hub Disassembly
6
1
5 4 3 2
206656
Sequence
Preparation

• Front tire
• Axle shaft, Bolt, Spring washer
• Bolt, Lock washer, Lock nut
• Taper roller bearing (inner)
• Front hub drum assembly
• Taper roller bearing (outer), Oil seal, Taper
  roller bearing, Spacer and Oil seal
• Retainer, O-ring

1. Loosen front wheel nuts about two rotations, and
   jack up the vehicle.
2. Place stands or wood blocks under the frame on
   both sides at the front so that the vehicle is
   at the level position when viewed from the
   front.
3. Remove the front tires.
4. Drain differential oil.

NOTE Normally, disassemble the front axle while
the axle housing is installed to the frame.
2.6
23
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for disassembly (1) Removing lock
nut Use the special tool A to remove the lock nut.
A 200232
Special tool needed
Socket wrench A
MCF-1102
200233
(2) Removing front wheel hub Use a universal hub
puller or a gear puller to remove the front wheel
hub. If the interfit of the taper roller bearing
(inner race) is tight, the inner oil seal may
fall off and the taper roller bearing may remain
in the axle housing. In this case, insert a
wedge-shape tool between the taper roller
bearing (inner) and the retainer to take out the
taper roller bearing.
203651
(3) Using a bearing puller, remove the inner race
of tapered roller bearing left on the axle
housing, along with the seal retainer.
2.7
24
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
25
FRONT AXLE AND REDUCTION DIFFERENTIAL
Inspection and Repair
(1) Axle shaft 2 (a) Insert the differential
bevel gear to the axle shaft, and measure
looseness in the rotating direction with a dial
gauge. A Standard value B Repair limit Service
limit
200235
Looseness of the axle shaft spline A 0.07 to 0.17 (0.0028 to 0.0067)
mm (in.) B 0.5 (0.020)

• Measuring axle shaft bend
• Attach a dial gauge to the center of the axle
  shaft, and rotate the axle shaft. Measure bend
  of the axle shaft.
• A Standard value B Repair limit
• Service limit

200276
Axle shaft bend (1/2 of gauge reading) mm (in.) A 1.0 or less (0.039)
Axle shaft bend (1/2 of gauge reading) mm (in.) B 2.0 (0.079)
(ii) Attach a dial gauge to the edge of the
flange, and rotate the axle shaft. Measure
deflection of the flange. A Standard value B
Repair limit Service limit
Flange deflection A 0.04 (0.0015)
mm (in.) B 0.5 (0.020)

• Retainer 6
• Check for wear or damage on the retainer cir-
  cumference.
• Front hub drum 5
• If uneven wear or damage is found on the inner
  surface of the brake drum, grind and repair.
• A Standard value B Repair limit
• Service limit

Inner diameter A 317.5 0.2 (12.5 0.078 )
of brake drum A 0 0 )
of brake drum B 318.5 (12.539)
mm (in.) B 318.5 (12.539)
2.8
26
FRONT AXLE AND REDUCTION DIFFERENTIAL Assembly
6


4



5


3


5
1
2d
2 2a 2c 2b
206657

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

2.9
27
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.ebo
oklibonline.com