Caterpillar EC15K Lift Truck Service Manuals – PDF DOWNLOAD

Description

Caterpillar EC15K Lift Truck Service Manuals – PDF DOWNLOAD

DESCRIPTION:

Caterpillar EC15K Lift Truck Service Manuals – PDF DOWNLOAD

FOREWORD :

This service manual is a guide to servicing of Cat® lift trucks. The instructions are grouped by systems to serve the convenience of your ready reference. Long productive life of your lift trucks depends to a great extent on correct servicing — servicing consistent with what you will learn from this service manual. Read the respective sections of this manual carefully and familiarize yourself with all the components you will work on, before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual are of the trucks with the serial numbers in effect at the time it was approved for printing. Cat lift truck reserves the right to change specifications or design without notice and without incurring obligation.

SAFETY PRECAUTIONS:

The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed.

1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product.
2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loosefitting or torn clothing. Remove all rings from fingers when working on machinery.
3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.
4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

TABLE OF CONTENTS:

Caterpillar EC15K Lift Truck Service Manuals – PDF DOWNLOAD

Caterpillar EC15N Controller Service Manual

CONTROLLER
TROUBLESHOOTING
CIRCUITS

Caterpillar EC15K Chassis & Mast Service Manual

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
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
ii
TABLE OF CONTENTS
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
iii
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
Inspection after Disassembly 6 6
Reassembly 6 7
Suggestions 6 8
Steer Pump
Removal 6 9
Installation 6 10
Disassembly 6 11
Sequence 6 11
Working Rules and Tips 6 12
Suggestions 6 12
Inspection after Disassembly 6 14
Reassembly 6 15
Sequence 6 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
iv
TABLE OF CONTENTS
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
v
TABLE OF CONTENTS
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
vi
TABLE OF CONTENTS
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

Caterpillar GE SX Controls EC15K Service Manual

1 GENERAL INFORMATION & FEATURES
Glossary 1-1
Motor Options 1-5
Nameplate and Serial Number Locations 1-6
Features of the Control System 1-7
Basics of Circuit Operation 1-8
Standard Display 1-17
Premium Display 1-18
Premium Display Set up Modes 1-19
Vehicle Monitoring System 1-20
Traction Control Logic Flow Chart 1-21
General Maintenance Instructions 1-22
General Trouble Shooting Instructions 1-24
2 PROGRAMMING
Handset 2-1
Operation 2-2
GE Sentry Set-up Procedures 2-2
Function Settings 2-4
Controller Setup 2-15
Traction Controller Settings 2-16
Accelerator Setup 2-23
Pump Controller Settings 2-25
Memory Maps 2-30
Speedometer Setup 2-34
3 CHECKS & REPAIRS
General Information 3-1
Fuses 3-2
Exploded View of Contactor 3-3
Contactor Repair 3-4
Truck Management Module 3-5
Thermal Transfer 3-6
Traction Control 3-10
Trouble Shooting Tips (Motors) 3-11
Unsatisfactory Brush Performance 3-12
Commutator Surfaces Conditions 3-18
4 SX CONTROL CONNECTIONS & TROUBLESHOOTING
BY SYMPTOM
SX Control 4-1
Failures that Cause Reduced or No Motor Torque 4-2
Misoperation of Other Features 4-5
TABLE OF CONTENTS
5 WIRING
Traction Bypass with Pump Contactor Schematic 5-1
Pump Contactor Schematic 5-3
Traction Bypass with Pump Contactor Schematic 5-5
Traction Bypass with Pump Control Schematic 5-7
Pump Control Schematic 5-9
Traction Motor Controller with Pump motor Controller and Bypass 5-11
Voltage Checks 5-13
TMM7A (Truck Management Module) 5-16
Pump Driver 5-18
Pump Time Delay 5-19
6 DIAGNOSTIC STATUS CODES
Basic Checks 6-1
Status Codes 6-2

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CATERPILLAR EC15K LIFT TRUCK SERVICE MANUALS – PDF DOWNLOAD:

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