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Complete workshop & service manual with electrical wiring diagrams for Caterpillar Lift Trucks EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Caterpillar Lift Trucks EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
MANUAL LIST:
99799-80120 – EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL Chassis & Mast Service Manual.pdf
EC15K, EC18K, EC18KL
A3EC1-10200-up
A3EC1-20200-up
A3EC1-30200-up
A3EC2-40200-up
EC20K, EC25K
A3EC2-10200-up
A3EC2-20200-up
A3EC2-30200-up
A3EC2-40200-up
A3EC2-80200-up
EC25KE, EC25KL, EC30K
A3EC3-10200-up
A3EC3-20200-up
A3EC3-30200-up
A3EC3-40200-up
A3EC3-80200-up
EC30KL
A3EC4-40200-up
EXCERPT:
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
Front Wheels .
2.2
Removal
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 .
2.9
Installation and Setting Preload
2.9
Reduction Differential
Description.
2.10
Disassembly
2.11
Inspection after Disassembly
2.12
Reduction Gear .
2.12
Differential
2.12
Reassembly .
2.13
Inspection and Adjustment
2.15
Side Bearing Preload
2.15
Reduction Gear Backlash
2.15
Reduction Gear Face Runout
2.16
Tooth Contact
2.16
Tooth Contact Adjustment .
2.17
Chapter 3: Transfer Assembly
Description. 3.1
Disassembly 3.2
Disassembly Sequence . 3.2
Inspection after Disassembly 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
Inspection and Adjustment
4.17
Minimum Turning Radius Adjustment
4.17
Chapter 5: Brake System
Description.
5.1
Automatic Adjusting Device .
5.1
General Information.
5.1
Master Cylinder
Disassembly 5.2
Inspection after Disassembly 5.3
Reassembly . 5.3
Service Brakes
Disassembly
(EC15K – 18KL)
5.4
(EC20K – 30KL)
5.5
Inspection after Disassembly
5.7
Reassembly
(EC15K – 18KL) 5.8 (EC20K – 30KL) 5.9
Wheel Cylinders
Disassembly 5.12
Inspection after Disassembly 5.13
Reassembly . 5.13
Inspection and Adjustment 5.14
Steering System
Description 6.1
Steering System 6.1
Oil Flow Sequence . 6.1
General Information . 6.1
Steering Gear
Steering Wheel
Removal 6.2
Installation. 6.2
Steering Gear . 6.3
Inspection after Removal 6.4
Disassembly 6.5
Working Rules and Tips 6.6
Suggestions 6.6
Inspection after Disassembly 6.6
Reassembly 6.7
Suggestions . 6.8
Steer Pump
Removal 6.9
Installation.6.10
Disassembly6.11
Sequence6.11
Working Rules and Tips6.12
Suggestions 6.12
Inspection after Disassembly6.14
Reassembly 6.15
Sequence6.15
Suggestions 6.16
Inspection after Reassembly 6.18
Chapter 7: Hydraulic System
Hydraulic System
Description.
7.1
Schematic .
7.1
Hydraulic Tank .
7.2
Hydraulic Pump
7.3
Control Valve .
7.5
Lift and Tilt Cylinders .
7.6
Flow Regulator Valve.
7.7
Down Safety Valve
7.8
Removal and Installation Warning.
7.9
Chapter 7: Hydraulic System, continued
Hydraulic Pump
Removal 7.10
Installation . 7.11
Disassembly 7.12
Working Rules and Tips 7.13
Suggestions . 7.14
Inspection after Disassembly 7.16
Body 7.16
Mounting Flange Face. 7.16
Bushes and Balance Plate 7.16
Gears . 7.16
Reassembly . 7.17
Inspection after Reassembly . 7.22
Control Valve
Removal 7.23
Installation . 7.24
Disassembly 7.25
Suggestions . 7.27
Reassembly . 7.27
Lift and Tilt Cylinders
Removal
Lift Cylinders 7.28
Tilt Cylinders 7.31
Disassembly
Lift Cylinders 7.33
Tilt Cylinders 7.34
Flow Regulator Valve. 7.35
Inspection after Disassembly 7.36
Precautions for Reassembly . 7.36
Inspection and Adjustment
Hydraulic Tank . 7.37
Control Valve . 7.38
Lift and Tilt Cylinders . 7.40
Adjusting Method. 7.41
Testing . 7.42
Chapter 8: Mast and Forks
Description
8.1
Removal and Installation
8.2
Disassembly
8.4
Inspection after Disassembly
8.6
Reassembly
8.7
Inspection and Adjustment .
8.8
Forks .
8.8
Chain Tension Adjustment
8.9
Clearance Adjustment on Lift Bracket
8.10
Mast Clearance Adjustment
8.13
Main Roller Shim Replacement
8.15
Mast Strip Adjustment.
8.15
Tilt Angle Adjustment
8.16
Lift Cylinder Stroke Adjustment
8.17
Bleeding Lift Cylinders
8.17
Service Data .
8.19
Troubleshooting
8.20
Chapter 9: Troubleshooting Section
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
Tightening Torques for Standard Bolts and Nuts
10.18
Fine Thread—With Spring Washer
10.18
Fine Thread—Without Spring Washer.
10.19
Coarse Thread—With Spring Washer .
10.20
Coarse Thread—With Spring Washer .
10.21
Maintenance Chart
10.22
Planned Replacement Parts
10.28
Lubrication Information
10.29
Chart
10.29
Lubricant Specifications.
10.30
Recommended Brands of Lubrications .
10.30
Weight of Major Components (Approximate)
10.31
Special Service Tools
10.32
Special Tool Illustrations
10.33
Inspection Guide
10.36
…