Caterpillar Cat EC25LN Forklift Lift Trucks Service Repair Manual SN A4EC3-30200 and Up PDF

Service Manual
Chassis & Mast

EC15N, EC18N
A4EC1-10200-up
A4EC1-20200-up
EC20N, EC25N
A4EC2-10200-up
A4EC2-20200-up
EC25EN, EC25LN, EC30N

A4EC3-20200-up
A4EC3-30200-up
A4EC3-40200-up
99759-6K110
TABLE OF CONTENTS
Chapter 1: General Information

Scope ........................................................................................................................................... 1.1
Truck Models Covered ................................................................................................................. 1.1
Nameplate and Serial Number Locations .................................................................................... 1.2
Dimensions................................................................................................................................... 1.3
Dimensions Chart .................................................................................................................... 1.4
General Information (Standard Models)....................................................................................... 1.5
Chapter 2: Front Axle & Reduction Differential

Front Axle
Description ................................................................................................................................... 2.1
General Information ................................................................................................................. 2.1
Removal ....................................................................................................................................... 2.2
Front Wheels ............................................................................................................................ 2.2
Method 1.............................................................................................................................. 2.3
Method 2.............................................................................................................................. 2.3
Method 3.............................................................................................................................. 2.3
Installation .................................................................................................................................... 2.4
Disassembly ................................................................................................................................. 2.5
Removing Front Wheel Hub ..................................................................................................... 2.6
Inspection after Disassembly ....................................................................................................... 2.7
Reassembly.................................................................................................................................. 2.8
Axle Housing ............................................................................................................................ 2.8
Front Wheel Hub ...................................................................................................................... 2.8
Hub Bearing Preload................................................................................................................ 2.10
Installation and Setting Preload........................................................................................... 2.10
Reduction Differential
Description ................................................................................................................................... 2.11
Disassembly ................................................................................................................................. 2.12
Reduction Gear ........................................................................................................................ 2.13
Differential ................................................................................................................................ 2.13
Reassembly.................................................................................................................................. 2.14
Inspection and Adjustment........................................................................................................... 2.16
Side Bearing Preload ............................................................................................................... 2.16
Reduction Gear Backlash ........................................................................................................ 2.16
Reduction Gear Face Runout .................................................................................................. 2.17
Tooth Contact ........................................................................................................................... 2.17
Tooth Contact Adjustment ........................................................................................................ 2.18
i
TABLE OF CONTENTS
Chapter 3: Transfer Assembly

Description ................................................................................................................................... 3.1
Disassembly ................................................................................................................................. 3.2
Disassembly Sequence................................................................................................................ 3.2
Reassembly.................................................................................................................................. 3.5
Chapter 4: Rear Axle

Description ................................................................................................................................... 4.1
Rear Wheels................................................................................................................................. 4.2
Removal ................................................................................................................................... 4.2
Installation ................................................................................................................................ 4.4
Rear Axle ..................................................................................................................................... 4.7
Removal ................................................................................................................................... 4.7
Installation ................................................................................................................................ 4.8
Disassembly ............................................................................................................................. 4.9
Inspection after Disassembly ................................................................................................... 4.11
Reassembly.............................................................................................................................. 4.12
Minimum Turning Radius Adjustment....................................................................................... 4.17
Chapter 5: Brake System

Description ................................................................................................................................... 5.1
Automatic Adjusting Device ..................................................................................................... 5.1
Master Cylinder
Disassembly ............................................................................................................................. 5.2
Reassembly.............................................................................................................................. 5.3
Service Brakes
Disassembly
(EC15N–EC18N) ................................................................................................................. 5.4
(EC20N–EC30N) ................................................................................................................. 5.5
Reassembly
(EC15N–EC18N) ................................................................................................................. 5.8
(EC20N–EC30N) ................................................................................................................. 5.9
Wheel Cylinders
Disassembly ............................................................................................................................. 5.12
Reassembly.............................................................................................................................. 5.13
Inspection and Adjustment....................................................................................................... 5.14
ii
TABLE OF CONTENTS
Chapter 6: Steering System

Steering System
Description ................................................................................................................................... 6.1
Steering System ...................................................................................................................... 6.1
Oil Flow Sequence .............................................................................................................. 6.1
General Information............................................................................................................. 6.1
Steering Gear
Steering Wheel
Removal ................................................................................................................................... 6.2
Installation ................................................................................................................................ 6.2
Steering Gear............................................................................................................................... 6.3
Inspection after Removal ............................................................................................................. 6.4
Disassembly ................................................................................................................................. 6.5
Working Rules and Tips ........................................................................................................... 6.6
Suggestions ............................................................................................................................. 6.6
Reassembly.................................................................................................................................. 6.7
Steer Pump
Removal ....................................................................................................................................... 6.8
Installation .................................................................................................................................... 6.9
Disassembly ................................................................................................................................. 6.10
Sequence ................................................................................................................................. 6.10
Suggestions ............................................................................................................................. 6.11
Reassembly.................................................................................................................................. 6.14
Sequence ................................................................................................................................. 6.14
Suggestions ............................................................................................................................. 6.15
Inspection after Reassembly.................................................................................................... 6.17
Chapter 7: Hydraulic System

Hydraulic System
Description ................................................................................................................................... 7.1
Schematic ............................................................................................................................... 7.1
Hydraulic Tank.......................................................................................................................... 7.3
Hydraulic Pump ....................................................................................................................... 7.4
Control Valve ............................................................................................................................ 7.6
Lift and Tilt Cylinders................................................................................................................ 7.7
Down Safety Valve ................................................................................................................... 7.8
Removal and Installation Warning................................................................................................ 7.9
iii
TABLE OF CONTENTS
Hydraulic Pump
Removal ....................................................................................................................................... 7.10
Installation .................................................................................................................................... 7.11
Disassembly ................................................................................................................................. 7.12
Suggestions ............................................................................................................................. 7.14
Body ......................................................................................................................................... 7.16
Mounting Flange Face ............................................................................................................. 7.16
Bushes and Balance Plate....................................................................................................... 7.16
Gears ....................................................................................................................................... 7.16
Reassembly.................................................................................................................................. 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
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 ...................................................................................................................................... 7.40
Chapter 8: Mast and Forks

Description ................................................................................................................................... 8.1
Removal and Installation.............................................................................................................. 8.2
iv
TABLE OF CONTENTS
Disassembly ................................................................................................................................ 8.4

Reassembly.................................................................................................................................. 8.7
Forks ........................................................................................................................................ 8.8
Chain Tension Adjustment ....................................................................................................... 8.9
Clearance Adjustment on Lift Bracket...................................................................................... 8.10
Mast Clearance Adjustment ..................................................................................................... 8.13
Main Roller Shim Replacement ............................................................................................... 8.15
Mast Strip Adjustment.............................................................................................................. 8.15
Tilt Angle Adjustment ............................................................................................................... 8.16
Lift Cylinder Stroke Adjustment................................................................................................ 8.17
Bleeding Lift Cylinders ............................................................................................................. 8.17
Service Data ................................................................................................................................ 8.18
Troubleshooting ............................................................................................................................ 8.20
Chapter 9: Troubleshooting
Front Axle and Reduction Differential .......................................................................................... 9.1
Brake System ............................................................................................................................... 9.2
Steering System........................................................................................................................... 9.4
Hydraulic System ......................................................................................................................... 9.6
Rear Axle ..................................................................................................................................... 9.8
Mast and Forks ............................................................................................................................ 9.9
Chapter 10: Maintenance Service Data

Maintenance Service Data........................................................................................................... 10.1
Front Axle and Reduction Differential ...................................................................................... 10.1
Transfer Case ........................................................................................................................... 10.3
Rear Axle ................................................................................................................................. 10.4
Brake System ........................................................................................................................... 10.6
Steering System,...................................................................................................................... 10.11
Hydraulic System ..................................................................................................................... 10.13
Mast and Forks (Simplex Mast) ............................................................................................... 10.16
Mast and Forks ........................................................................................................................ 10.17
Tightening Torques for Standard Bolts and Nuts ......................................................................... 10.18
Fine Thread—With Spring Washer .......................................................................................... 10.18
Fine Thread—Without Spring Washer ..................................................................................... 10.18
Coarse Thread—With Spring Washer...................................................................................... 10.18
Coarse Thread—With Spring Washer...................................................................................... 10.18
Tightening Torques for Standard Bolts and Nuts with Standard Threads .................................... 10.19
Coarse Thread—Inches ........................................................................................................... 10.19
v
TABLE OF CONTENTS
Tightening Torques for Taperlock Studs ....................................................................................... 10.19

Coarse Thread—Inches ........................................................................................................... 10.19
Maintenance Chart....................................................................................................................... 10.20
Planned Replacement Parts ........................................................................................................ 10.26
Lubrication Information................................................................................................................. 10.27
Chart ........................................................................................................................................ 10.27
Fuel and Lubricant Specifications ............................................................................................ 10.28
Recommended Brands of Lubricants....................................................................................... 10.28
Weight of Major Components (Approximate) ............................................................................... 10.29
Special Service Tools ................................................................................................................... 10.30
Special Tool Illustrations........................................................................................................... 10.31
Inspection Guide .......................................................................................................................... 10.34
vi
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
GENERAL INFORMATION
Scope
This service manual deals with all components or systems of the Cat lift trucks, except for the electrical
system, which is covered in a separate manual.
8609141A
Truck Models Covered

This service manual furnishes service and maintenance information for the following trucks.
Truck Model Serial Number

EC15N, EC18N A4EC1-10200-up
A4EC1-20200-up
EC20N, EC25N A4EC2-10200-up
A4EC2-20200-up
EC25EN, EC25LN, EC30N A4EC3-20200-up
A4EC3-30200-up
A4EC3-40200-up
1.1
GENERAL INFORMATION
Nameplate and Serial Number Locations
Mast
serial number
Chassis
serial number
Power steering
motor serial number
Traction motor
serial number
Hydraulic motor Nameplate
serial number
8609141
1.2
GENERAL INFORMATION
Dimensions
8609142
8609143
1.3
GENERAL INFORMATION
Dimensions Chart
Ref# Truck Model EC15N, EC18N EC20N, EC25N EC25EN EC25LN EC30N
A Maximum Lift 3320 (130) 3340 (131) 3340 (131) 3340 (131) 3310 (130)
B Free Lift 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3)
Maximum Fork Spacing

C 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0)
(outside to outside)
D Fork Length 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42)
Tilt Angle
E 5°/6° 5°/6° 5°/6° 5°/6° 5°/6°
(forward/backward)
F Overall Length 3050 (120) 3155 (124) 3255 (128) 3255 (128) 3325 (131)
Overall Width
G 945 (37) 1055 (41.5) 1055 (41.5) 1103 (43.5) 1103 (43.5)
(outside of tires)
Overall Height (to top of

H 2105 (83) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5)
mast, lowered)

I 2180 (86) 2210 (87) 2210 (87) 2210 (87) 2210 (87)
overhead guard)

J 4570 (180) 4570 (180) 4570 (180) 4570 (180) 4550 (179)
mast, extended)
K Tread (front) 793 (31) 875 (34.5) 875 (34.5) 900 (35.5) 900 (35.5)
L Tread (rear) 826 (32.5) 900 (35.5) 900 (35.5) 900 (35.5) 900 (35.5)
M Wheelbase 1170 (46) 1280 (50.5) 1380 (54.5) 1380 (54.5) 1380 (54.5)
N Front Overhang 376 (14.8) 394 (15.5) 394 (15.5) 394 (15.5) 406 (16)
O Rear Overhang 434 (17.2) 411 (16) 411 (16) 411 (16) 469 (18.5)
Underclearance
P 118 (4.6) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9)
(at center of wheelbase)
Unit: mm (in.)
1.4
GENERAL INFORMATION
General Information (Standard Models)

Truck Model
Units EC15N EC18N EC20N EC25N EC25EN EC25LN EC30N
Standard Controller MHI SX Controller

Standard Simplex Mast Size meters 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Without 2095 2335 2685 2870 2695 2865 3335
Service Weight Battery (4620) (5140) (5920) (6330) (5940) (6320) (7353)
kg (lb)
(standard axle) With Max. 3295 3535 4285 4420 4495 4665 5135
Battery (7270) (7790) (9470) (9880) (9940) (10320) (11353)
Rated Capacity/ kg/mm 1350/600 1600/600 1800/600 2275/600 2275/600 2500/600 2725/600
Load Center (lb/in.) (3000/24) (3500/24) (4000/24) (5000/24) (5500/24) (5000/24) (6000/24)
Maximum Fork Height mm (in.) 33235 (131) 3340 (131) 3315 (131)
Performance
36V .38 (75) .36 (71) .32 (63) .28 (55) .25 (49)
Work
Lift Speed m/sec.

(Rated Load) 48V (fph) .53 (104) .49 (96) .45 (89) .38 (75) .36 (71)
Lowering Speed (rated load) .50 (98)
Tilt Angle (forward/backward) degrees 5° / 6°
Free Lift mm (in.) 115 (4.5) 130 (5.1) 135 (5.3)

Performance
Travel Speed 36V km/h 18 (11.2) 17.3 (10.8) 17.4 (10.8) 17.0 (10.6) 17.1 (10.6)
Traveling
(Without Load) 48V (mph) 18.2 (11.3)
Minimum Turning mm 1790 1840 1990 2045

Radius (in.) (70.5) (72.5) (78.5) (80.5)
Traction Motor 36V 60min. 8.3 (6.2) 12.1 (9.0) 13.7 (10.2)
Output 48V HP(kW) 9.2 (6.8) 14.2 (10.6) 17.2 (12.8)
Transfer Type Spur

Power Train
Gear Ratio 3.538 3.067
Reduction Type Bevel

Gear Ratio 4.571 5.0
Axle Housing Banjo
Differential Gear Type/ Gears Straight Bevel/2
Number Pinions Straight Bevel/2
1.5
GENERAL INFORMATION
Truck Model
Type Dynamic Load Sense

Power Steering System
Inside 83° 83°

Turning Angle Degrees
Outside 54° 56°
Steering Wheel Diameter mm (in.) 328 (13)
Cylinder Minimum kgf/cm2

107 (1522) [10,500] 163 (2320) [16,000]
Test Pressure (psi) [kPa]
Type Self-Adjusting Duo-Servo
Inside Drum +0 0.13(10.00 +0 0.0051)

mm (in.) 254
Diameter
Service Brake
Lining
mm (in.) 4.87 (0.19) 6 (0.24)
Thickness
Brake System
Master
mm (in.) 22.22 (0.8748)
Cylinder ID
Wheel
22.22 (0.8748) 28.58 (1.1252)
Cylinder ID
Type Mechanical, Mounted on Front Wheels
Park Brake Lever kgf 25 to 30

Operating (lbf) (55 to 66)
Effort [N] [245 to 295]
Front Wheels Fixed Type

Traveling System
Mounting
Rear Wheels Center Pivot Type
Wheel Oscillation 3°
Alignment Angle Degrees
Camber 1°
1.6
GENERAL INFORMATION
Truck Model
Type Gear
Hydraulic Pump Make Casappa Parker Hydraulics, Inc.
Model KP20–24.5 25R029
Displacement cc (cu in.) 25 (1.526) 29 (1.77)

Make Husco International
Control Valve Model 9510 Sectional Valve
Hydraulic System
Relief kgf /cm2 AUX 158 (2250) [15513]
Interval Pressure (psi) [kPa] Lift Tilt 185 (2630) [18133}

Flow Regulator Type Variable
Valve Regulated liter
45 (2746) 60 (3661)
Flow Rate (cu.in.) / min
Lift Cylinders
ID 45 (1.77) 50 (1.97) 55 (2.17)
mm (in.)
Tilt Cylinders ID 63 (2.48) 70 (2.75) 80 (3.15)
Hydraulic Tank Capacity liter 1 8 (4.8) 24 (6.3) 30 (7.9)

(Approx) (US gal.)
Mast Roller type CL
Mast 100 x 42 x 11 115 x 46 x 12
Outer
Dimensions (3.94 x 0.59 x 0.47) 4.53 x 0.79 x 0.51)
(Flange Inside mm (in.)
Width x THK x 100 x 60 x 10 115 x 45 x 11
Inner
WEB THK) (3.94 x 0.67 x 0.47) (4.53 x 0.83 x 0.51)
Mast and Forks
Main Rollers Type #6308 Ball Bearing #6309 Ball Bearing

Diameter x Width 100 x 27 (3.94 x 1.18) 115 x 30 (4.53 x 1.58) 115 x 30 (3.94 x 1.18)
Side Rollers Type Lubricating type needle roller bearing
Diameter x
mm (in.) 42 x 36 (1.65 x 1.42)
Width
Lift Chains BL534 BL634 BL834
Forks (Lgth x Wdth x Thk) 1070x100x35 1070 x100 x40 1070 x 125 x 45
(36x4x1.3) (42 x 3.9 x 1.6) (42 x 5 x 1.8)
mm (in.)
Fork Spacing 240 / 818 (9.4/32) 240 / 920 285 / 960
(out to out) min/max
Voltage 36/48
Amp Hours (6 hr. rate) 36V 900 1400
48V 700 1100
Compartment Height-Center 598 (23.6)
Battery
Dimensions Height-Edges 589 (23.2)

mm (in.)
Length 705 (27.8) 772 (30.4) 872 (34.3)
Width 903 (35.5) 1000 (39.4)
Weight (Min/Max) kg (lb) 750/1200 1000/1600 1315/1600 1400/1800
(1650/2650) (2200/3550) (2900/3550) (3100/4000)
1.7
TABLE OF CONTENTS
Chapter 2: Front Axle & Reduction Differential

Front Axle
Description ................................................................................................................................... 2.1
Removal ....................................................................................................................................... 2.2
Front Wheels ............................................................................................................................ 2.2
Method 1.............................................................................................................................. 2.3
Method 2.............................................................................................................................. 2.3
Method 3.............................................................................................................................. 2.3
Installation .................................................................................................................................... 2.4
Disassembly ................................................................................................................................. 2.5
Removing Front Wheel Hub ..................................................................................................... 2.6
Reassembly.................................................................................................................................. 2.8
Axle Housing ............................................................................................................................ 2.8
Front Wheel Hub ...................................................................................................................... 2.8
Hub Bearing Preload................................................................................................................ 2.10
Installation and Setting Preload........................................................................................... 2.10
Description ................................................................................................................................... 2.11
Disassembly ................................................................................................................................. 2.12
Reduction Gear ........................................................................................................................ 2.13
Differential ................................................................................................................................ 2.13
Reassembly.................................................................................................................................. 2.14
Side Bearing Preload ............................................................................................................... 2.16
Reduction Gear Backlash ........................................................................................................ 2.16
Reduction Gear Face Runout .................................................................................................. 2.17
Tooth Contact ........................................................................................................................... 2.17
Tooth Contact Adjustment ........................................................................................................ 2.18
FRONT AXLE & REDUCTION DIFFERENTIAL
Front Axle
Description
6 8
5
7
4 3 1
2
203658
1. Front wheel hub 5. Reduction pinion

2. Frame support 6. Reduction gear
3. Axle shaft 7. Differential case
4. Axle housing 8. Differential carrier
General Information
The frame supports hold the front axle housing in
such a manner as to allow a limited amount of
rotary motion of the housing, the rotary sliding
surfaces being lubricated with grease.
The cushion tire is press-fitted to the outer ring of
the wheel hub.
2.1
Removal
Front Wheels Suggestions
1. Park the truck on level floor with the parking
! WARNING brake applied, the direction lever in neutral,
Be sure to use the same size and brand the forks lowered, and the key switch off.
tire for replacement. 2. Prepare tools, jacks, and wheel blocks.
3. Block the rear wheels.
4. Loosen the wheel nuts about two turns.
Removal Sequence
2
Wheel nut
1
205952 100902B
1. Wheel Nuts
NOTE
2. Front Wheel
Loosen, but do not remove, the wheel
nuts.
5. Raise the front end of the truck. Use one of

the methods shown.
! WARNING
To prevent possible injury, do not replace

the tire when the truck is loaded.
Dismount the truck before raising the front

tire.
To prevent possible personal injury, raise

the truck only until the tire just clears the
ground.
Do not put any portion of your body under

the truck. Securely support the truck on
blocks after raising it.
2.2
Method 1 Method 3
Position the jack under the frame and raise the Fasten a hoist to the mast and lift the front end of
truck until the tire clears the floor. the truck as shown.
100828 202778A
Jack Capacities 6. Remove the wheel nuts (loosened in Step 4.)
EC15N–EC18N 3000 kgf (6700 lbf)

EC20N–EC30N 5000 kgf (12,000 lbf) ! CAUTION
Be careful not to damage the bolt threads
when removing the wheel.
Method 2
Tilt the mast all the way back, place wood blocks
under the mast, and tilt the mast forward.
7. Remove the wheel.
! CAUTION
After raising the front end, securely support NOTE
it by blocks.
Service Limit For Cushion Tires
Replace the tire if the height of the solid
rubber portion is 25.4 mm (1 in. or less). For
tire replacement, consult your Cat lift dealer.
25.4 mm
200227 (1 inch)
100880
2.3
Installation
To install, reverse the removal sequence and do 2. Lower the truck until the tire touches the
the following steps. floor. Then tighten the wheel nuts in numbered
sequence shown below, in two or three steps,
to the specified torque.
! CAUTION
1
Use the same size and brand of tire.
6
3
Make sure the clamping surfaces of the
wheel nuts and counterbores in the rim
are free of dirt.
4
5
1. Install the tire and tighten the wheel nuts.
2
Tighten each nut until its tapered portion is
in full-face contact with the counterbore in 205953
the rim.
Tightening Torque For Wheel Nuts
EC15N–EC18N EC20N–EC30N
Wheel Nut
16 kgf•m 38.5 kgf•m
Counterbore
(116 lbf•ft) (278 lbf•ft)
[157 N•m] [378 N•m]
100835A
2.4
Disassembly
6 7
5 205954
Sequence
1. Axle shaft 4. Tapered roller bearing (outer bearing), oil seal,
2. Lock nut, lock washer, oil seal, and tapered and oil deflector
roller bearing (inner bearing) 5. Tapered roller bearing (inner bearing), and
3. Hub & drum assembly [Front wheel hub, brake seal retainer
drum, wheel bolts, drum nuts, and tapered 6. Brake assembly
roller bearing (outer bearing)] 7. Frame support and axle housing
Start By:
1. Remove the mast. (For replacement of the front 3. Support the front end of the truck at both sides
axle housing and disassembly of the differen- with blocks or stands to keep the truck in a
tial, refer to section, MAST AND FORKS.) horizontal position.
2. Jack up the truck. 4. Remove the front wheels.
NOTE
It is not necessary to remove the axle

housing or drain the oil for removal of the
shaft only.
2.5
Suggestions Removing Front Wheel Hub

Removing the Lock Nut Use a wheel hub puller (Special Tool).
Use a lock nut wrench (Special Tool).
Tool EC15N–EC18N EC20N–EC30N
Tool EC15N–EC18N EC20N–EC30N

Wheel Hub Puller 64309-40100 MH061017
Lock Nut Wrench 91268-00800 03703-59001 (Puller seat) (64309-10601)
NOTE
It is not necessary to remove the oil seal

from the hub or to disassemble the oil
deflector unless the seal is defective.
Special Tool
Any wear or grooves in oil seal deflector would

require replacement.
It has been standard practice to replace the oil
seal every time the hub is removed to reduce the
200232 possibility of oil leaks.
Special Tool
200233
Removing Bearings
The inner race of the tapered roller bearing
remains in the axle housing when the hub is
drawn out. Remove this race together with the
seal retainer with a bearing puller.
203651
2.6
Inspection after Disassembly

Axle Shafts
Looseness of Mating Splines Runout
Mount the differential bevel gear on the splined Set a dial indicator at the middle part of the axle
end of the shaft and set a dial indicator as shown shaft. Turn the shaft and read the indicator to find
below. Turn the bevel gear and read the indicator. runout.
Runout of shaft
Face runout of flange

200235 200236
Free movement A 0.07 to 0.17

(0.0028 to 0.0067) EC15N–EC18N EC20N–EC30N
(looseness of
splines) B 0.5 (0.020) Runout of axle A 0.5 (0.020) 1.0 (0.039)
shaft (1/2 of dial maximum maximum
Unit: mm (in.) indicator reading B 1.0 (0.039) 2.0 (0.079)
A = Assembly Standard B = Repair or Service Limit
Unit: mm (in.)
Axle Housing A = Assembly Standard B = Repair or Service Limit
1. Check the surfaces of axle housing in contact
Set a dial indicator against the flange of the axle
with the mast bearing for damage.
shaft as shown. Turn the shaft and read the indi-
2. Check the entire axle housing for distortion, cator to find face runout.
dents, and other defects, paying particular
attention to the welds to see if any weld is A 0.05 (0.0020)
Face runout of axle
cracked. shaft flange B 0.5 (0.020)
Oil Seals and Retainers Unit: mm (in.)
1. Check the outer surface of the oil seal retainer A = Assembly Standard B = Repair or Service Limit
for wear or damage.
2. Check the outer and inner oil seals for wear
and damage.
2.7
Reassembly Front Wheel Hub

1. Fill the front wheel hub, especially the roller
To reassemble, reverse the steps of the disassem-
holder and oil seal lip groove, with grease.
bly sequence and do the following steps.
Pack both bearings with grease.
Axle Housing
1. Install the O-ring in the outer groove (of the
two grooves in the bore of each frame sup-
port).
2. Apply grease to the surfaces A of the support
and axle housing.
Frame support
O-ring A
205954a
NOTE
Be careful not to apply grease to the brake

200237 drum.
Check for excessive movement between frame

support and axle housing.
200238
2.8
2. Install the inner race and oil seal retainer of

the wheel hub bearing with an installer
(Special Tool).
Special tool
203569
EC20N–
Tool EC15N–EC18N
EC30N
Installer 64309-12300 91468-00300
3. Apply retaining compound to the flange sur-

faces of the axle shafts.
2.9
Hub Bearing Preload Installation and Setting Preload

Tighten the inner nut to produce the required pre- 1. Fill the hub with the recommended grease as
load. Tighten the outer nut to the specified torque listed in the service manual.
and check the preload. Be sure that the preload 2. Pack the inner and outer bearing with the
noted after tightening the outer nut still meets the recommended grease.
specification. This step is for new bearings. Where
3. Install the inner bearing to the back side of the
the bearings removed in disassembly are reused,
hub.
try to produce the preload at the lower side of the
range. 4. Install the inner seal.
5. Clean the lining surface of the drum.
5 to 50 kgf•cm
Preload for hub bearing (0.4 to 3.6 lbf•ft) 6. Install the hub onto the axle.
[0.5 to 4.9 N•m] 7. Install the outer bearing, grease seal and pre-
Tightening torque 20 kgf•m
load nut.
for (145 lbf•ft)
lock nuts [196 N•m] 8. If the bearings are being reused, try to pro-
duce the lower side of the applied force in tan-
gential direction.
9. For new bearings, tighten the preload nut to
14 kgf•m (101 lbf•ft) [137 N•m]. Slowly rotate
the hub slightly more than 3 turns, back the
nut off 80°, and set the applied force in tan-
gential direction.
10. For models with an outer lock nut, torque the
nut to 20 kgf•cm (145 lbf•ft) [196 N•m]. After
torquing the lock nut, check the force applied
in tangential direction again to insure the pre-
Inner nut Outer nut 200468 load did not change.
Bar
Spring
balancer
101653
2.10
Description
3
4 5 2 1
200240
Sequence
1. Lock plates 4. Reduction gear and differential gear assembly
(spring pins, pinion shafts, differential pinions,
2. Side bearing nuts
differential bevel gear, washers, and differential
3. Differential carrier assembly (lock washers, case)
side bearing caps, and differential carrier)
5. Tapered roller bearings
Start By:
1. Remove the differential carrier from the trans-
mission case.
2. Check the pattern of gears at time of removal.
This step is important when assembly has
been completed and checking pattern of gears
to match.
2.11
Disassembly
Suggestions Removing Bearing Inner Races
1. Before removing the differential carrier from Use a bearing puller to remove the inner races
the transmission case, measure the gear from the differential case.
backlash to aid in obtaining correct backlash
at the time of reassembly.
Backlash between reduction gear 0.15 to 0.25

and pinion (0.0059 to 0.0098)
Unit: mm (in.)
200242
200247
2. Put a mark across the bearing cap, adjusting

screw and carrier on each side.
The caps are not interchangeable.
200241
2.12
Inspection after Disassembly

Reduction Gear Differential
Check the teeth for wear, pitting, flaking, or chip- 1. Check the differential cases for damage.
ping. Minor flaws on the tooth surface can be Check in particular the seat formed of each
repaired by grinding with an oil stone or a hand case for carrying the side bearing inner race
grinder. Check the teeth for contact. If the gear is to see whether the seat surface is galled or
badly damaged and requires replacement, replace not.
the pinion too. Reduction gear and pinion are a 2. Check the sliding surfaces of the thrust wash-
matched set and must be changed at the same ers and gears for wear or damage.
time.
3. Check the teeth of the differential pinions and
bevel gears for wear, pitting, chipping, or
galling.
4. Check the fit of each pinion on the spider.
A 0.02 to 0.07
Fit of differential (0.0008 to 0.0028)
pinions on spider
B 0.35 (0.0138)
Unit: mm (in.)
A = Assembly Standard B = Repair or service limit
2.13
Reassembly
4 1
3 2
200243
Sequence
1. Tapered roller bearings 3. Spring pin
2. Differential gear assembly [differential case, 4. Reduction gear

thrust washers, bevel gears, pinions, and pin-
5. Differential carrier assembly [carrier, side bear-
ion shaft]
ing caps, side bearing nuts, and lock washers]
2.14
Suggestions
Reassembling Differential Pinions Reassembling Differential Case
The thrust washers of the differential gears are to After putting the case assembly in place on the
be used for adjusting the backlash between the carrier, install the bearing caps tentatively by mak-
differential gears and pinions. Measure the back- ing the cap bolts snug tight. The caps are to be
lash and, if it exceeds the limit, replace the thrust secured tight after the bearing preload has been
washers. adjusted.
Installing Bearing Caps

Backlash between A 0.18 to 0.23
differential gears (0.0071 to 0.0091) Be sure to know which are the left and right caps
and pinions B 0.5 (0.020) and to put each cap in place correctly.
Unit: mm (in.)
12.8 kgf•m
A = Assembly Standard B = Repair or service limit Tightening torque for
(93 lbf•ft)
bearing cap bolts
[126 N•m]
200244
200241
Installing Reduction Gear

Apply LOCTITE No. 271 to the bolts for holding
the reduction gear to the case. Be sure to tighten
these bolts evenly so as not to strain the gear.
12.0 kgf•m
Tightening torque for
(87 lbf•ft)
reduction gear bolts
[118 N•m]
2.15
Inspection and Adjustment

Side Bearing Preload Reduction Gear Backlash
Tie a wire on the reduction gear tooth and hook a Adjust the backlash between the reduction gear
spring scale to the wire. Tighten the side bearing and pinion after installing the differential carrier
nuts while reading the spring scale until the speci- assembly to the transmission case. To measure
fied preload is obtained. the backlash, set a dial indicator with its spindle
pointing squarely to the tooth face of the reduction
NOTE gear. With the pinion held, move the gear back
and forth to read the indicator. Adjust the backlash
Before measuring the preload, tap the using the left and right side bearing nuts and pin-
back of the reduction gear with a copper ion shims.
hammer while rotating the gear to center
between bearing. 0.15 to 0.25
Backlash between
(0.0059 to
reduction gear and pinion
0.0098)
15 to 30 kgf Unit: mm (in.)

Min. (1.1 to 2.2 lbf)
[1.5 to 2.9 N]
Preload for differential 1.32 to 2.5 kgf•cm

case side bearings Max. (2.9 to 5.5 lbf•ft)
[13 to 25 N•m]
As force applied to
reduction gear in
tangential direction.
200247
Backlash
Increase
Decrease
Decrease
Increase
200246
Increase
Backlash
Decrease
200248
2.16
Reduction Gear Face Runout Tooth Contact

Using a dial indicator, check the reduction gear for Check the gear reduction tooth contact. To check,
face runout at the maximum radius position in apply a thin coat of bluing to several gear teeth on
back of the gear. If the runout exceeds the limit, both drive and coast sides. Press forward on the
check the reduction gear bolts for tightness; reduction pinion and rotate the reduction gear
retighten if necessary. Check the tapered roller back and forth until a contact pattern is noted on
bearings for condition. Readjust or replace them if both concave and convex faces of the gear teeth.
necessary. To adjust the tooth contact, refer to the chart.
Face runout of A 0.05 (0.0020) maximum

reduction gear B 0.05 (0.0020) maximum
Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit
200250
200249
2.17
Tooth Contact Adjustment (EC15N–EC18N)
Tooth Contact Adjustment

Extends from toe Correct tooth contact
to middle portion,
covering not less
1
than 50% of tooth
length.
203669-1
Short contact at 1. Move gear away from pinion.

toe of tooth. 2. Move pinion toward gear by increasing shim thick-
2 ness to secure correct backlash.
203669-2 203669-2A
Short contact at 1. Move gear toward pinion.

heel of tooth. 2. Move pinion away from gear by decreasing shim
3 thickness to secure correct backlash.
203669-3 203669-3A
Heavy contact on 1. Move pinion toward gear by increasing shim thick-

face or upper ness.
4 portion of tooth. 2. Move gear away from pinion to secure correct
backlash.
203669-4 203670-4A
Heavy contact on 1. Move pinion away from gear by decreasing shim

flank or lower thickness.
portion of tooth. 2. Move gear toward pinion to secure correct back-
5
lash.
203669-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
2.18
Tooth Contact Adjustment (EC20N–EC30N)
Tooth Contact Adjustment

Extends from toe Correct tooth contact
to middle portion,
covering not less
1
than 50% of tooth
length.
203670-1
Short contact at 1. Move pinion toward gear by increasing shim

toe of tooth. thickness.
2 2. Move gear away from pinion to secure correct
backlash.
203670-2 203670-2A
Short contact at 1. Move pinion away from gear by decreasing shim

heel of tooth. thickness.
3 2. Move gear toward pinion to secure correct
backlash.
203670-3 203670-3A
Heavy contact on 1. Move pinion toward gear by increasing shim

face or upper thickness.
portion of tooth. 2. Move gear away from pinion to secure correct
4
backlash.
203670-4 203670-4A
Heavy contact on 1. Move pinion away from gear by decreasing shim

flank or lower thickness.
5 portion of tooth. 2. Move gear toward pinion to secure correct
backlash.
203670-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
2.19
TABLE OF CONTENTS
Chapter 3: Transfer Assembly

Description ................................................................................................................................... 3.1
Disassembly ................................................................................................................................. 3.2
Disassembly Sequence................................................................................................................ 3.2
Reassembly.................................................................................................................................. 3.5
TRANSFER ASSEMBLY
Description
Front axle center

1 8 2
6 Traction motor
5 9 4 6 209002
Main component
1 Transfer case 6 Taper roller bearing
2 Transfer cover 7 Lock nut
3 Input gear (13T) 8 Ball bearing
4 Output gear (48T) 9 Plug (standard) or pulse generator (option)
5 Bevel gear set
The transfer assemblies of all the 1 ton, 2 ton,

and 3 ton class trucks share completely identi-
cal components except the different bevel gear
sets as shown below.
No. of teeth on No. of teeth on

bevel pinion bevel gear
1 ton class trucks 7 32
2 and 3 ton class
7 35
trucks
3.1
TRANSFER ASSEMBLY
Disassembly
Start by:
(1) Remove the drain plug on the front axle hous- (3) Remove the traction motor, reduction and dif-
ing to let the oil drain out. ferential assembly and transfer assembly as
(2) Disconnect the connectors of the traction one unit, from the front axle housing.
motor harnesses and pulse generator har- (4) Separate the three assemblies removed in
ness. step (3) from each other.
3 15 Liquid gasket
2
18 1
14
17
Plug (standard)
or 16
Pluse generator (option)
Staked
7
4
6
8 9
13 11 10 12
209002A
Disassembly sequence
1 Bolt 10 Output gear
2 Transfer cover 11 Spacer
3 Side cover with pulse generator, or plug 12 Bearing cup
4 Nut 13 Bearing cup
5 Shim 14 Snap ring
Remove parts 6 and 8 as a unit. Remove parts 15 to 17 as a unit.
6 Bevel pinion shaft 15 Input gear
7 Shim 16 Ball bearing
8 Bearing cone 17 Ball bearing
9 Bearing cone 18 Transfer case
3.2
Thank you very much
for your reading.
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Service Manual

Chassis & Mast

EC25EN, EC25LN, EC30N

Chapter 1: General Information

Chapter 2: Front Axle & Reduction Differential

Chapter 3: Transfer Assembly

Chapter 4: Rear Axle

Chapter 5: Brake System

Chapter 6: Steering System

Chapter 7: Hydraulic System

Chapter 8: Mast and Forks

Disassembly ................................................................................................................................ 8.4

Chapter 10: Maintenance Service Data

Tightening Torques for Taperlock Studs ....................................................................................... 10.19

Chapter 1: General Information

Truck Models Covered

Truck Model Serial Number

Nameplate and Serial Number Locations

Maximum Fork Spacing

Overall Height (to top of

Overall Height (to top of

Overall Height (to top of

General Information (Standard Models)

Units EC15N EC18N EC20N EC25N EC25EN EC25LN EC30N

Standard Controller MHI SX Controller

Lift Speed m/sec.

Lowering Speed (rated load) .50 (98)

Tilt Angle (forward/backward) degrees 5° / 6°

Free Lift mm (in.) 115 (4.5) 130 (5.1) 135 (5.3)

(Without Load) 48V (mph) 18.2 (11.3)

Minimum Turning mm 1790 1840 1990 2045

Transfer Type Spur

Gear Ratio 3.538 3.067

Reduction Type Bevel

Axle Housing Banjo

Differential Gear Type/ Gears Straight Bevel/2

Number Pinions Straight Bevel/2

Units EC15N EC18N EC20N EC25N EC25EN EC25LN EC30N

Type Dynamic Load Sense

Inside 83° 83°

Steering Wheel Diameter mm (in.) 328 (13)

Cylinder Minimum kgf/cm2

Type Self-Adjusting Duo-Servo

Inside Drum +0 0.13(10.00 +0 0.0051)

Type Mechanical, Mounted on Front Wheels

Park Brake Lever kgf 25 to 30

Front Wheels Fixed Type

Displacement cc (cu in.) 25 (1.526) 29 (1.77)

Relief kgf /cm2 AUX 158 (2250) [15513]

Interval Pressure (psi) [kPa] Lift Tilt 185 (2630) [18133}

Hydraulic Tank Capacity liter 1 8 (4.8) 24 (6.3) 30 (7.9)

Main Rollers Type #6308 Ball Bearing #6309 Ball Bearing

Dimensions Height-Edges 589 (23.2)

Chapter 2: Front Axle & Reduction Differential

1. Front wheel hub 5. Reduction pinion

5. Raise the front end of the truck. Use one of

To prevent possible injury, do not replace

Dismount the truck before raising the front

To prevent possible personal injury, raise

Do not put any portion of your body under

Jack Capacities 6. Remove the wheel nuts (loosened in Step 4.)

EC15N–EC18N 3000 kgf (6700 lbf)

It is not necessary to remove the axle