Caterpillar Cat EC25EN Forklift Lift Trucks Service Repair Manual SN:A4EC3-20200 and up

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  Service Manual Chassis & Mast EC15N, EC18N A4EC1-10200-up A4EC1-20200-upEC20N, EC25N A4EC2-10200-up A4EC2-20200-upEC25EN, EC25LN, EC30N A4EC3-20200-up…
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Service Manual Chassis & Mast EC15N, EC18N A4EC1-10200-up A4EC1-20200-upEC20N, EC25N A4EC2-10200-up A4EC2-20200-upEC25EN, EC25LN, EC30N A4EC3-20200-up A4EC3-30200-up A4EC3-40200-up99759-6K110TABLE 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)....................................................................................... 1.5Chapter 2: Front Axle & Reduction Differential Front Axle Description ................................................................................................................................... 2.1 General Information ................................................................................................................. 2.1 Removal ....................................................................................................................................... Front Wheels ............................................................................................................................ Method 1.............................................................................................................................. Method 2.............................................................................................................................. Method 3..............................................................................................................................2.2 2.2 2.3 2.3 2.3Installation .................................................................................................................................... 2.4 Disassembly ................................................................................................................................. 2.5 Removing Front Wheel Hub ..................................................................................................... 2.6 Inspection after Disassembly ....................................................................................................... 2.7 Reassembly.................................................................................................................................. Axle Housing ............................................................................................................................ Front Wheel Hub ...................................................................................................................... Hub Bearing Preload................................................................................................................ Installation and Setting Preload...........................................................................................2.8 2.8 2.8 2.10 2.10Reduction 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........................................................................................................... Side Bearing Preload ............................................................................................................... Reduction Gear Backlash ........................................................................................................ Reduction Gear Face Runout .................................................................................................. Tooth Contact ........................................................................................................................... Tooth Contact Adjustment ........................................................................................................2.16 2.16 2.16 2.17 2.17 2.18iTABLE OF CONTENTS Chapter 3: Transfer Assembly Description ................................................................................................................................... 3.1 Disassembly ................................................................................................................................. 3.2 Disassembly Sequence................................................................................................................ 3.2 Inspection after Disassembly ....................................................................................................... 3.4 Reassembly.................................................................................................................................. 3.5Chapter 4: Rear Axle Description ................................................................................................................................... 4.1 Rear Wheels................................................................................................................................. 4.2 Removal ................................................................................................................................... 4.2 Installation ................................................................................................................................ 4.4 Rear Axle ..................................................................................................................................... Removal ................................................................................................................................... Installation ................................................................................................................................ Disassembly ............................................................................................................................. Inspection after Disassembly ................................................................................................... Reassembly..............................................................................................................................4.7 4.7 4.8 4.9 4.11 4.12Inspection and Adjustment........................................................................................................... 4.17 Minimum Turning Radius Adjustment....................................................................................... 4.17Chapter 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 (EC15N–EC18N) ................................................................................................................. (EC20N–EC30N) ................................................................................................................. Inspection after Disassembly ................................................................................................... Reassembly (EC15N–EC18N) ................................................................................................................. (EC20N–EC30N) ................................................................................................................. Wheel Cylinders Disassembly ............................................................................................................................. Inspection after Disassembly ................................................................................................... Reassembly.............................................................................................................................. Inspection and Adjustment....................................................................................................... ii5.4 5.5 5.7 5.8 5.9 5.12 5.13 5.13 5.14TABLE OF CONTENTS Chapter 6: Steering System Steering System Description ................................................................................................................................... Steering System ...................................................................................................................... Oil Flow Sequence .............................................................................................................. General Information.............................................................................................................6.1 6.1 6.1 6.1Steering Gear Steering Wheel Removal ................................................................................................................................... 6.2 Installation ................................................................................................................................ 6.2 Steering Gear............................................................................................................................... 6.3 Inspection after Removal ............................................................................................................. 6.4 Disassembly ................................................................................................................................. Working Rules and Tips ........................................................................................................... Suggestions ............................................................................................................................. Inspection after Disassembly ...................................................................................................6.5 6.6 6.6 6.6Reassembly.................................................................................................................................. 6.7 Steer Pump Removal ....................................................................................................................................... 6.8 Installation .................................................................................................................................... 6.9 Disassembly ................................................................................................................................. Sequence ................................................................................................................................. Working Rules and Tips ........................................................................................................... Suggestions ............................................................................................................................. Inspection after Disassembly ...................................................................................................6.10 6.10 6.11 6.11 6.13Reassembly.................................................................................................................................. Sequence ................................................................................................................................. Suggestions ............................................................................................................................. Inspection after Reassembly....................................................................................................6.14 6.14 6.15 6.17Chapter 7: Hydraulic System Hydraulic System Description ................................................................................................................................... Schematic ............................................................................................................................... Hydraulic Tank.......................................................................................................................... Hydraulic Pump ....................................................................................................................... Control Valve ............................................................................................................................ Lift and Tilt Cylinders................................................................................................................ Down Safety Valve ...................................................................................................................7.1 7.1 7.3 7.4 7.6 7.7 7.8Removal and Installation Warning................................................................................................ 7.9iiiTABLE OF CONTENTS Hydraulic Pump Removal ....................................................................................................................................... 7.10 Installation .................................................................................................................................... 7.11 Disassembly ................................................................................................................................. 7.12 Working Rules and Tips ........................................................................................................... 7.12 Suggestions ............................................................................................................................. 7.14 Inspection after Disassembly ....................................................................................................... Body ......................................................................................................................................... Mounting Flange Face ............................................................................................................. Bushes and Balance Plate....................................................................................................... Gears .......................................................................................................................................7.16 7.16 7.16 7.16 7.16Reassembly.................................................................................................................................. 7.17 Inspection after Reassembly........................................................................................................ 7.21 Control Valve Removal ....................................................................................................................................... 7.22 Installation .................................................................................................................................... 7.23 Disassembly ................................................................................................................................. 7.24 Suggestions ................................................................................................................................. 7.25 Reassembly.................................................................................................................................. 7.25 Lift and Tilt Cylinders Removal Lift Cylinders ............................................................................................................................ 7.26 Tilt Cylinders ............................................................................................................................ 7.29 Disassembly Lift Cylinders ............................................................................................................................ 7.31 Tilt Cylinders ............................................................................................................................ 7.32 Inspection after Disassembly ....................................................................................................... 7.33 Precautions for Reassembly ........................................................................................................ 7.33 Inspection and Adjustment Hydraulic Tank.............................................................................................................................. 7.34 Control Valve ................................................................................................................................ 7.35 Lift and Tilt Cylinders.................................................................................................................... 7.38 Adjusting Method ..................................................................................................................... 7.39 Testing ...................................................................................................................................... 7.40Chapter 8: Mast and Forks Description ................................................................................................................................... 8.1 Removal and Installation.............................................................................................................. 8.2 ivTABLE OF CONTENTS Disassembly ................................................................................................................................ 8.4 Inspection after Disassembly ....................................................................................................... 8.6 Reassembly.................................................................................................................................. 8.7 Inspection and Adjustment........................................................................................................... Forks ........................................................................................................................................ Chain Tension Adjustment ....................................................................................................... Clearance Adjustment on Lift Bracket...................................................................................... Mast Clearance Adjustment ..................................................................................................... Main Roller Shim Replacement ......................................
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