Caterpillar EC15K - EC30KL Forklift Full Complete Workshop Repair Service Manual Pdf

Caterpillar EC15K - EC30KL Forklift Full Complete Workshop Repair Service Manual Pdf

Caterpillar EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL Forklift Service Manual PDF

This service manual contains all necessary service and repair information for Cat EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL electric forklift models. In this service manual you will find detailed specifications, procedures, illustrations and diagrams to service the forklift and electrical system to the manufacturer’s standards. This 2 volume set covers both the forklift chassis and SX Control System. View the Caterpillar EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL Forklift Service Manual on your computer or print off pages as needed.

Covers: Caterpillar EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL Forklift

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

Topics in the Caterpillar EC15K, EC18K, EC18KL, EC20K, EC25K, EC25KE, EC25KL, EC30K, EC30KL Forklift Service Manual:

Chapter 1: General Information
Scope
Truck Models Covered
Nameplate and Serial Number Locations
Dimensions
Dimensions Chart
General Information (Standard Models)

Chapter 2: Front Axle & Reduction Differential
Front Axle
Description
General Information
Front Wheels
Removal
Method 1
Method 2
Method 3
Installation
Disassembly
Removing Front Wheel Hub
Inspection after Disassembly
Reassembly
Axle Housing
Front Wheel Hub
Hub Bearing Preload
Installation and Setting Preload
Reduction Differential
Description
Disassembly
Inspection after Disassembly
Reduction Gear
Differential
Reassembly
Inspection and Adjustment
Side Bearing Preload
Reduction Gear Backlash
Reduction Gear Face Runout
Tooth Contact
Tooth Contact Adjustment

Chapter 3: Transfer Assembly
Description
Disassembly
Disassembly Sequence
Inspection after Disassembly
Reassembly

Chapter 4: Rear Axle
Description
Rear Wheels
Removal
Installation
Rear Axle
Removal
Installation
Disassembly
Inspection after Disassembly
Reassembly
Inspection and Adjustment
Minimum Turning Radius Adjustment
Chapter 5: Brake System
Description
Automatic Adjusting Device
General Information
Master Cylinder
Disassembly
Inspection after Disassembly
Reassembly
Service Brakes
Disassembly
(EC15K – 18KL)
(EC20K – 30KL)
Inspection after Disassembly
Reassembly
(EC15K – 18KL)
(EC20K – 30KL)
Wheel Cylinders
Disassembly
Inspection after Disassembly
Reassembly
Inspection and Adjustment

Chapter 6: Steering System
Steering System
Description
Steering System
Oil Flow Sequence
General Information
Steering Gear
Steering Wheel
Removal
Installation
Steering Gear
Inspection after Removal
Disassembly
Working Rules and Tips
Suggestions
Inspection after Disassembly
Reassembly
Suggestions
Steer Pump
Removal
Installation
Disassembly
Sequence
Working Rules and Tips
Suggestions
Inspection after Disassembly
Reassembly
Sequence
Suggestions
Inspection after Reassembly

Chapter 7: Hydraulic System
Hydraulic System
Description
Schematic
Hydraulic Tank
Hydraulic Pump
Control Valve
Lift and Tilt Cylinders
Flow Regulator Valve
Down Safety Valve
Removal and Installation Warning
Hydraulic Pump
Removal
Installation
Disassembly
Working Rules and Tips
Suggestions
Inspection after Disassembly
Body
Mounting Flange Face
Bushes and Balance Plate
Gears
Reassembly
Inspection after Reassembly
Control Valve
Removal
Installation
Disassembly
Suggestions
Reassembly
Lift and Tilt Cylinders
Removal
Lift Cylinders
Tilt Cylinders
Disassembly
Lift Cylinders
Tilt Cylinders
Flow Regulator Valve
Inspection after Disassembly
Precautions for Reassembly
Inspection and Adjustment
Hydraulic Tank
Control Valve
Lift and Tilt Cylinders
Adjusting Method
Testing

Chapter 8: Mast and Forks
Description
Removal and Installation
Disassembly
Inspection after Disassembly
Reassembly
Inspection and Adjustment
Forks
Chain Tension Adjustment
Clearance Adjustment on Lift Bracket
Mast Clearance Adjustment
Main Roller Shim Replacement
Mast Strip Adjustment
Tilt Angle Adjustment
Lift Cylinder Stroke Adjustment
Bleeding Lift Cylinders
Service Data
Troubleshooting

Chapter 9: Troubleshooting
Front Axle and Reduction Differential
Brake System
Steering System
Hydraulic System
Rear Axle
Mast and Forks

Chapter 10: Maintenance Service Data
Maintenance Service Data
Front Axle and Reduction Differential
Transfer Case
Rear Axle
Brake System
Steering System,
Hydraulic System
Mast and Forks (Simplex Mast)
Tightening Torques for Standard Bolts and Nuts
Fine Thread—With Spring Washer
Fine Thread—Without Spring Washer
Coarse Thread—With Spring Washer
Coarse Thread—With Spring Washer
Maintenance Chart
Planned Replacement Parts
Lubrication Information
Chart
Lubricant Specifications
Recommended Brands of Lubrications
Weight of Major Components (Approximate)
Special Service Tools
Special Tool Illustrations
Inspection Guide=

GENERAL INFORMATION & FEATURES
Glossary
Motor Options
Nameplate and Serial Number Locations
Features of the Control System
Basics of Circuit Operation
Standard Display
Premium Display
Premium Display Set up Modes
Vehicle Monitoring System
Traction Control Logic Flow Chart
General Maintenance Instructions
General Trouble Shooting Instructions

PROGRAMMING
Handset
Operation
GE Sentry Set-up Procedures
Function Settings
Controller Setup
Traction Controller Settings
Accelerator Setup
Pump Controller Settings
Memory Maps
Speedometer Setup

CHECKS & REPAIRS
General Information
Fuses
Exploded View of Contactor
Contactor Repair
Truck Management Module
Thermal Transfer
Traction Control
Trouble Shooting Tips (Motors)
Unsatisfactory Brush Performance
Commutator Surfaces Conditions

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM
SX Control
Failures that Cause Reduced or No Motor Torque
Misoperation of Other Features

5 WIRING
Traction Bypass with Pump Contactor Schematic
Pump Contactor Schematic
Traction Bypass with Pump Contactor Schematic
Traction Bypass with Pump Control Schematic
Pump Control Schematic
Traction Motor Controller with Pump motor Controller and Bypass
Voltage Checks
TMM7A (Truck Management Module)
Pump Driver
Pump Time Delay

6 DIAGNOSTIC STATUS CODES
Basic Checks
Status Codes

Pages: 390
Format: PDF file
Compatibility: Windows/Mac/Tablet
File size: 5mb
Note: Please contact us with your serial number before purchasing. Instant digital download only – no printed copy or CD-ROM media.
Powered by