®
Lift Trucks
Service Manual Chassis & Mast EC35N, EC40N, EC45N EC55N
For use with GE SX Control Service Manual.
A2EC4-60200-up A2EC5-60200-up
SENB8474-01
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
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
ii
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
TABLE OF CONTENTS CHAPTER 5: BRAKE SYSTEM (cont.) Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.13
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.13
Adjustment and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14
Automatic Adjuster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14
Procedure for Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14
Brake Fluid Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.15
Inspecting Reservoir Tank Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.15
Procedures for Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.17
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.15
Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.15
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.17
Placing Pump Back into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.20
Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.21
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.21
Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.25
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.26
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.26
Lift and Tilt Cylinders Removal Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.27
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.33
Disassembly Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.34
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.48
Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.51
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.51
Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.51
Inspection and Adjustment
iv
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.54
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.55
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.56
Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.56
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
GENERAL INFORMATION 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
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
GENERAL INFORMATION
Nameplate and Serial Number Locations
1.2
GENERAL INFORMATION
Dimensions
1.3
GENERAL INFORMATION
Dimensions Chart Ref#
Truck Model
EC35N
EC40N
EC45N
EC55N
4650 (183)
4650 (183)
5055 (199)
5320 (209)
150 (5.9)
150 (5.9)
160 (6.3)
160 (6.3)
1060 (41.5)
1060 (41.5)
1060 (41.5)
1060 (41.5)
1220 (48)
1220 (48)
1220 (48)
1220 (48)
6° / 8°
6° / 8°
6° / 8°
6° / 8°
A
Maximum Lift
B
Free Lift
C
Maximum Fork Spacing (outside to outside)
D
Fork Length
E
Tilt Angle (forward/backward)
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
GENERAL INFORMATION
General Information (Standard Models) Truck Model Units
EC35N
EC40N
meters
3.3
3.3
3.3
2.9
4581
4833
5677
6448
(10099)
(10656)
(12516)
(14215)
6849 (15099)
7101 (15656)
7945 (17516)
8716 (19215)
Standard Controller Standard Simplex Mast Size Service Weight
Battery With Max. Battery
Work Performance Traveling Performance
kg (lb)
Rated Capacity/
kg/mm
3500/500
4000/500
4500/600
5500/600
Load Center
(lb/in.)
(7000/24)
(8000/24)
(10,000/24)
(12,000/24)
mm (in.)
4650 (183)
4650 (183)
5055 (199)
5320 (209)
Maximum Fork Height
Power Train
EC55N
GE SX Controller
Without (standard axle)
EC45N
Lift Speed
36V
m/sec.
0.25 (50)
0.22 (43)
0.20 (39)
0.17 (33)
(Rated Load)
48V
(fpm)
0.31 (64)
0.34 (67))
0.25 (49)
0.21 (41)
Lowering Speed (rated load)
0.54 (106)
0.56 (110)
Tilt Angle (forward/backward) degrees Free Lift
6° / 8°
mm (in.)
150 (5.9)
160 (6.3)
Travel Speed
36V
km/h
14.0 (8.7)
13.8 (8.6)
13.7 (8.5)
13.6 (7.3)
(Without Load)
48V
(mph)
17.0 (10.6)
16.9 (10.5)
15.8 (10.3)
16.6 (10.3)
Minimum Turning
mm
2214
2258
2294
2468
Radius
(in.)
(87)
(89)
(90)
(97)
Traction Motor
36V
60min.
15.3 (11.4)
Output
48V
HP(kW)
20.9 (15.5)
Transfer
Type
Spur
Gear
Ratio
5.131
Reduction
Type
Spiral Bevel
Gear
Ratio
4.571
Axle Housing
Banjo
Differential
Gear Type/ Number
Gears
Straight Bevel/2
Pinions
Straight Bevel/2
1.5
GENERAL INFORMATION
Truck Model
Power Steering System
Units
EC35N thru EC55N
Type
Dynamic Load Sense Inside
82째 Degrees
Turning Angle Outside
59째
Steering Wheel Diameter
mm (in.)
328 (13)
2
Cylinder Minimum Test Pressure
kgf/cm (psi) [kPa] Type
120 (1706) [11,768] Self-Adjusting Duo-Servo
Inside Drum mm (in.) Diameter
317.5 (12.50)
Service Brake Lining Thickness
mm (in.)
10 (0.39)
Master Cylinder ID
mm (in.)
Primary 31.75 (1.25) Secondary 19.05 (0.75)
Traveling System
Brake System
Wheel Cylinder ID
1.6
31.75 (1.250)
Type Park Brake
Lever Operating Effort
Mechanical, Mounted on Front Wheels kgf (lbf) [N]
25 to 30 (55 to 66) [245 to 295]
Front Wheels
Fixed Type
Rear Wheels
Center Pivot Type
Mounting
Wheel Alignment
Oscillation Angle Camber
3째 Degrees 1째
GENERAL INFORMATION
Truck Model Units
EC35N
EC40N
EC45N
Type
Gear
Make
Haldex - Barnes
Model
W1500
Hydraulic Pump
Displacement cc (cu in.)
38 (2.32)
Make Control Valve
Hydraulic System
Valve
Husco International
Model
5000CC Sectional Valve
Relief
kgf /cm2
Aux
155 (2250) 15513
Pressure
(psi) [kPa]
Lift Tilt
197 (2850) 19650
Flow Regulator
Type Regulated Flow Rate
Lift Cylinders
Variable liter (cu.in.) / min
ID Stroke
100 (6100)
115 (7018)
60 (2.36)
70 (2.75) 1650 (64.96)
mm (in.)
ID
100 (3.937)
Stroke
120 (4.724)
Tilt Cylinders
Hydraulic Tank Capacity (Approx)
liter (US gal.)
Liter
Mast Model Outer
118x28x24x13 (4.6x1.1x0.9x0.5)
Inner, Middle
118x24x24x12 (4.6x0.9x0.9x0.47)
Bearing
Side Rollers
Bearing
118x32 (4.65x1.26)
Mast and Forks
130x26x26x13 (5.1x1.0x1.0x0.5)
130x34 (5.12x1.34)
Lubricating type needle roller bearing
Diameter x Width, mm (in.) Lift Chains
52x36 (2.05x1.42) BL834
Forks (length x width x thick), mm (in.)
BL1034
1220x150x50 (48x6x2)
Fork Spread (outer width), mm (in.)
1060 (41.5)
Voltage
36 / 48
Amp Hours (6 hr. rate)
36V
1760
48V
1540
Height
Dimensions
Battery
130x30x26x15 (5.1x1.2x1.0x0.6)
Ball Bearing
Diameter x Width, mm (in.)
Weight (Min/Max)
48 (12.7)
CJ type
Flange ID X flange back thickness X flange front thickness X web thickness Main Rollers
Compartment
EC55N
590 (23.22) mm (in.)
Length
1003 (39.5)
Width
1156 (45.5) kg (lb)
1500 / 2268 (3400 / 5000)
1650 / 2268 (3600 / 5000)
1800 / 2268 (3975 / 5000)
1.7
FRONT AXLE AND REDUCTION DIFFERENTIAL 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
FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications Truck Models
EC35N thru EC55N
Reduction
Gear type
Differential
Housing type
Running Gear
Items
Front axle type
Spiral bevel gear
Reduction ratio
4.571 Banjo type
Type and number of gears
Suspension
Large
Straight bevel gear x 2
Small
Straight bevel gear x2 Full-floating axle tube type
Front wheel
Frame fixing type
2.1
FRONT AXLE AND REDUCTION DIFFERENTIAL
Structure
5
1
6
7
8
• •
•• • • •
•
2
3
4
206653
Sequence 1 Front wheel hub drum 2 Front axle support 3 Axle shaft 4 Axle housing 5 Reduction bevel pinion 6 Reduction bevel gear 7 Differential case 8 Differential carrier
2.2
FRONT AXLE AND REDUCTION DIFFERENTIAL
Procedures and Key Points for Removal and Installation Front Tire Removal 1 Wheel nut Special tool needed
2
Front tire 2
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.
1
206654
(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.
(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.
206665
NOTE For both methods, place jack stands under the frame to prevent it from falling.
200227
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 8
NOTE Insure wheel nut mounting holes are free of paint and grease before torquing wheel nuts.
Wheel nut tightening torque N·m (kgf·m) [lbf·ft]
1
551±55 (56.2 ± 5.6) [406.5 ± 40.6]
5
3
4
7
6 2
206655
2.3
FRONT AXLE AND REDUCTION DIFFERENTIAL Front Axle Assembly Preparation (1) Pull the hand brake lever, and place wheel stoppers at the front and rear tires. (2) Remove the mast and the lift bracket assembly. (Refer to Mast and Fork section.) (3) Loosen the front tire nuts about two rotations, and jack up the vehicle. (4) Place jack stands under the frame on both sides at the front so that the vehicle becomes level. (5) Remove the front tires. (Refer to Front Tire Removal procedure.) (6) Drain differential oil. NOTE If replacing the front axle housing, carry out the above preparation. Removal 3 2
3
4
1
206666
Sequence 1 Axle shaft, Bolt, Spring washer 2 Bolt, Spring washer 3 Nuts, Spring washers, Bolts 4 Front axle assembly 2.4
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for removal (1) Removing axle support bolts (a) Place jack stands under the front of the transmission to support it.
← 206667
(b) 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. (c) To remove bolts, remove the bolts at the top on both sides, and insert a guide bar. Then remove the other bolts. Installation Follow the removal sequence in reverse. Be careful 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 axle shaft bolts N·m (kgf·m) [lbf·ft]
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.
128.3 ± 12.8 (13.1 ± 1.3) [94.7 ± 9.4]
(3) Tighten axle support bolts to the specified torque. Tightening torque of axle support bolts
EC35N thru EC55N
N-m (kgf•m) [lbf•ft]
693.8 (70.8) [512]
2.5
FRONT AXLE AND REDUCTION DIFFERENTIAL
Axle Shaft and Hub Disassembly
6
1 5 4 3 2
206656
Sequence 1 Front tire 2 Axle shaft, Bolt, Spring washer 3 Bolt, Lock washer, Lock nut 4 Taper roller bearing (inner) 5 Front hub drum assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal 6 Retainer, O-ring
Preparation (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
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for disassembly (1) Removing lock nut Use the special tool A to remove the lock nut. Special tool needed A
Socket wrench A
MCF-1102
200232
(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. 200233
(3) Using a bearing puller, remove the inner race of tapered roller bearing left on the axle housing, along with the seal retainer.
203651
2.7
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 0.07 to 0.17 Looseness of the A (0.0028 to 0.0067) axle shaft spline mm (in.) B 0.5 (0.020) (b) Measuring axle shaft bend (i) Attach a dial gauge to the center of the axle shaft, and rotate the axle shaft. Measure bend of the axle shaft.
200235
A: Standard value B: Repair limit Service limit Axle shaft bend A (1/2 of gauge reading) mm (in.) B
1.0 or less (0.039) 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 mm (in.)
A
0.04 (0.0015)
B
0.5 (0.020)
(2) Retainer 6 Check for wear or damage on the retainer circumference. (3) 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 of brake drum B mm (in.)
2.8
317.5 + 0.2 (12.5 + 0.078 ) 0 0 318.5 (12.539)
200276
FRONT AXLE AND REDUCTION DIFFERENTIAL Assembly
6
•
• 4
•• •
•
5
•
•
3 •
• • ••
•
5
2d
2
2a
2c
2b
1 206657
Sequence 1 Retainer, O-ring 2 Front hub drum assembly 2a Taper roller bearing (outer) 2b Spacer 2c Oil seal 2d Oil seal 3 Taper roller bearing (inner) 4 Lock nut, Lock washer, Bolt 5 Axle shaft, Bolt, Spring washer 6 Front tire, Wheel nut
2.9
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