Service Manual

Chassis & Mast

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

99759-83110

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

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
A3EC3-10200-up
A3EC3-20200-up
A3EC3-30200-up
A3EC3-40200-up
A3EC3-80200-up
A3EC4-40200-up

EC25KE, EC25KL, EC30K

EC30KL

1.1

GENERAL INFORMATION

Nameplate and Serial Number Locations

Mast
serial number

Power steering
motor serial number

Chassis
serial number

Traction motor
serial number
Hydraulic motor
serial number

Nameplate
8609141

1.2

GENERAL INFORMATION

Dimensions

8609142

8609143

1.3

GENERAL INFORMATION

Dimensions Chart
Ref#

Truck Model

EC15K, EC18K

EC18KL

EC20K, EC25K

EC25KE

EC25KL

EC30K

EC30KL

3320 (130)

3320 (130)

3340 (131)

3340 (131)

3340 (131)

3310 (130)

3215 (126)

Maximum Lift

Free Lift

115 (4.5)

115 (4.5)

130 (5.1)

130 (5.1)

130 (5.1)

135 (5.3)

135 (5.3)

Maximum Fork Spacing

(outside to outside)1070

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

Fork Length

1070 (42)

1070 (42)

1070 (42)

1070 (42)

1070 (42)

1070 (42)

1070 (42)

Tilt Angle
(forward/backward)

5/6

5/6

5/6

5/6

5/6

5/6

5/6

Overall Length

3050 (120)

3123 (122.8)

3152 (124)

3252 (127.9)

3252 (127.9)

3325 (130.8)

3325 (130.8)

Overall Width
(outside of tires)

945 (37.2)

970 (38.2)

1054 (41.5)

1054 (41.5)

1103 (43.4)

1103 (43.4)

1103 (43.4)

Overall Height (to top of

mast, lowered)

2105 (83)

2105 (83)

2110 (83.5)

2110 (83.5)

2110 (83.5)

2110 (83.5)

2110 (83.5)

Overall Height (to top of

overhead guard)

2180 (85.8)

2180 (85.8)

2207 (86.9)

2207 (86.9)

2207 (86.9)

2207 (86.9)

2207 (86.9)

Overall Height (to top of

mast, extended)

4560 (180)

4560 (180)

4570 (180)

4570 (180)

4570 (180)

4540 (179)

4540 (179)

Tread (front)

793 (31.2)

818 (32.2)

875 (34.4)

875 (34.4)

900 (35.4)

900 (35.4)

900 (35.4)

Tread (rear)

826 (32.5)

826 (32.5)

897 (35.3)

897 (35.3)

897 (35.3)

897 (35.3)

897 (35.3)

Wheelbase

1170 (46.1)

1170 (46.1)

1280 (50.4)

1380 (54.3)

1380 (54.3)

1380 (54.3)

1380 (54.3)

Front Overhang

376 (14.8)

376 (14.8)

394 (15.5)

394 (15.5)

394 (15.5)

406 (15.9)

406 (15.9)

Rear Overhang

434 (17)

507 (19)

408 (16)

408 (16)

408 (16)

469 (18.4)

469 (18.4)

Underclearance
(at center of wheelbase)

118 (4.6)

118 (4.6)

124 (4.9)

124 (4.9)

124 (4.9)

124 (4.9)

124 (4.9)

Unit: mm (in.)

1.4

GENERAL INFORMATION

General Information (Standard Models)

Truck Model
Units

EC15K

EC18K

EC18KL

meters

3.3

3.3

3.3

3.3

3.3

3.3

3.3

3.3

3.3

2095

2335

2595

2685

2870

2695

2865

3335

3502

(4620)

(5140)

(5720)

(5920)

(6330)

(5940)

(6320)

(7353)

(7721)

3298

3534

3797

4296

4482

4509

4681

5150

5317

(7270)

(7790)

(8370)

(9470)

(9880)

(9940)

(10320)

(11353)

(11722)

Standard Controller
Standard Simplex Mast Size
Battery

(standard axle)

With Max.

kg (lb)

Battery

Work
Performance
Traveling
Performance

EC25KE

EC25KL

EC30K

EC30KL

Rated Capacity/

kg/mm

1500/500 1800/500

Load Center

(lb/in.)

(3000/24) (3500/24) (4000/24) (4000/24) (5000/24) (5000/24) (5000/24) (6000/24) (6500/29)

Maximum Fork Height

mm (in.)

1800/500 2000/500

2500/500 2500/500 2500/600

3320 (130)

3340 (131)

3000/500 3500/500

3310 (130) 3215 (126)

Lift Speed

36V

m/sec.

.24 (48)

.23 (45)

.34 (67)

.31 (61)

.28 (56)

.26 (51)

.23 (45)

(Rated Load)

48V

(fph)

.34 (67)

.32 (64)

.47 (93)

.40 (78)

.38 (74)

.36 (70)

.31 (62)

Lowering Speed (rated load)

Tilt Angle (forward/backward)
Free Lift

.50 (99)

.50 (98)

degrees

5 / 6

mm (in.)

Travel Speed

36V

km/h

(Without Load)

48V

(mph)

115 (4.5)

130 (5.1)

12.9 (8.0) 14.3 (8.9)

DNA

17.9 (11.1)

11.6 (7.2)
14.8 (9.2)

135 (5.3)
11.1 (6.9) 10.8 (6.7) 13.2 (8.2)
14.5 (9.0) 14.2 (8.8) 16.4 (10.2)

Minimum Turning

mm

1790

1840

1890

1990

2045

Radius

(in.)

(70.5)

(72.5)

(74.5)

(78.5)

(80.5)

36V

60min.

8.2 (6.1)

9.6 (7.1)

8.3 (6.1)

Output

48V

HP(kW)

DNA

13.4 (10.0)

11.7 (8.7)

Transfer

Type

Gear

Ratio

Reduction

Type

Gear

Ratio

Traction Motor

Power Train

EC25K

GE SX Controller

Without
Service Weight

EC20K

Spur
3.538

4.571

Axle Housing
Differential

3.067
Bevel
5.0
Banjo

Gear Type/

Gears

Straight Bevel/2

Number

Pinions

Straight Bevel/2

1.5

GENERAL INFORMATION
Truck Model

Power Steering System

Units

EC15K

EC18K

EC18KL

Type

EC20K

EC25K

EC25KE

EC25KL

Dynamic Load Sense

Inside

83

83

54

56

Degrees

Turning Angle
Outside
Steering Wheel Diameter

mm (in.)

328 (13)

Cylinder Minimum
Test Pressure

kgf/cm
(psi) [kPa]

107 (1522) [10,500]

Type

163 (2320) [16,000]

Self-Adjusting Duo-Servo

Inside Drum
mm (in.)
Diameter

254

+0 0.13(10.00 +0 0.0051)

Service Brake
Lining
Thickness

mm (in.)

4.87 (0.19)

Master
mm (in.)
Cylinder ID

Traveling System

Brake System

Wheel
Cylinder ID

1.6

22.22 (0.8748)

22.22 (0.8748)

Type
Park Brake

6 (0.24)

28.58 (1.1252)

Mechanical, Mounted on Front Wheels

Lever
Operating
Effort

kgf
(lbf)
[N]

25 to 30
(55 to 66)
[245 to 294]

Front Wheels

Fixed Type

Rear Wheels

Center Pivot Type

Mounting

Wheel
Alignment

Oscillation
Angle
Camber

3
Degrees
1

EC30K

EC30KL

GENERAL INFORMATION
Truck Model
Units

Hydraulic Pump

EC15K

EC18K

EC18KL

Make

Parker Hydraulics, Inc.

1PX230

1SX250

25.(1.526)

29(1.77)

25(1.526)

Hydraulic System

5000CC Sectional Valve

Relief
Pressure

(psi) [kPa]

263 (3750) [25855]

Type

Variable

Regulated
liter
Flow Rate (cu.in.) / min
ID
Stroke

48(2929)

Stroke

79 (3.11)
1
(US gal.)

50 (1.97)

81 (3.19)

8 (4.8)

24 (6.3)

100 x 15 x 12
(3.94 x 0.59 x 0.47)

Outer

Mast and Forks

30 (7.9)

115 x 20 x 13
4.53 x 0.79 x 0.51)

115 x 21 x 13
(4.53 x 0.83 x 0.51)

mm (in.)
100 x 17 x 12
(3.94 x 0.67 x 0.47)

Inner
Type

Side Rollers

100 x 30 (3.94 x 1.18)

Type
Diameter x
Width

115 x 20 x 13
(4.53 x 0.83 x 0.51)

#6308 Ball Bearing

#6309 Ball Bearing

115 x 35 (4.53 x 1.58)

100 x 30 (3.94 x 1.18)

Lubricating type needle roller bearing

mm (in.)

Lift Chains

42 x 36 (1.65 x 1.42)
BL534

Forks (Lgth x Wdth x Thk)

mm (in.)

1070x100x35
(36x4x1.3)

BL634

BL834

1070 x100 x40

(42 x 3.9 x 1.6)

1070 x 125 x 45
(42 x 5 x 1.8)

240 / 818 (9.4/32)

284 / 958 (11.2/37.7)

min/max

Voltage

36/48

Amp Hours (6 hr. rate)

Battery

80 (3.15)

Roller type CL

Diameter x Width

Compartment

Height-Center

Dimensions

Height-Edges

Weight (Min/Max)

1600 (62.99)
70 (2.75)

Mast

Fork Spacing
(out to out)

55 (2.17)

1650 (64.96)

mm (in.)

63 (2.48)

Hydraulic Tank Capacity liter

(Approx)

71(4332)

59 (3600)

45 (1.77)

ID

Tilt Cylinders

EC30KL

Husco International
kgf /cm2

Lift Cylinders

EC30K

1PX290

Model

Flow Regulator

EC25KL

1SX250

Make

Mast
Dimensions
(Flange Inside
Width x THK x
WEB THK)
Main Rollers

EC25KE

Gear

Displacement cc (cu in.) 23.0 (1.403)/rev.

Valve

EC25K

Type

Model

Control Valve

EC20K

36/48

36/48

36/48

36/48

36/48

36V

900

1300

1300

48V

700

800

1000

598 (23.6)
592 (23.3)

mm (in.)

Length

708 (27.9)

Width

906 (35.6)
kg (lb)

750/1200
(1650/2650)

775 (30.5)

875 (34.4)

1003 (39.5
1000/1600 1315/1600
(2200/3550) (2900/3550)

1400/1800
(3100/4000)

1.7

FRONT AXLE: DESCRIPTION

Front Axle
Description

5
7

3
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

FRONT AXLE: REMOVAL & INSTALLATION

Removal
Front Wheels

Suggestions
1. Park the truck on level floor with the parking
brake applied, the direction lever in neutral,
the forks lowered, and the key switch off.

WARNING

Be sure to use the same size and brand 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
100902B

205952

1. Wheel Nuts
2. Front Wheel

NOTE
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

FRONT AXLE: REMOVAL & INSTALLATION

Method 1

Method 3

Position the jack under the frame and raise the

truck until the tire clears the floor.

Fasten a hoist to the mast and lift the front end of

the truck as shown.

100828

Jack Capacities

202778A

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

EC15K - 18KL

3000 kgf (6700 lbf)

EC20K - 30KL

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 it

by blocks.

NOTE
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.

200227

25.4 mm
(1 inch)

100880

2.3

FRONT AXLE: REMOVAL & INSTALLATION

Installation
To install, reverse the removal sequence and do
the following steps.

CAUTION

2. Lower the truck until the tire touches the

floor. Then tighten the wheel nuts in numbered
sequence shown below, in two or three steps,
to the specified torque.
1

Use the same size and brand of tire.

6

Make sure the clamping surfaces of the wheel

nuts and counterbores in the rim are free of dirt.

1. Install the tire and tighten the wheel nuts.

Tighten each nut until its tapered portion is
in full-face contact with the counterbore in
the rim.

4
5
2
205953

Tightening Torque For Wheel Nuts

Wheel Nut
Counterbore

100835A

2.4

EC15K - 18KL

EC20K - 30KL

16 kgfm

38.5 kgfm

(116 lbfft)

(278 lbfft)

[157 Nm]

[378 Nm]

FRONT AXLE: DISASSEMBLY

Disassembly
6

205954

Sequence
1. Axle shaft
2. Lock nut, lock washer, oil seal, and tapered
roller bearing (inner bearing)
3. Hub & drum assembly [Front wheel hub,
brake drum, wheel bolts, drum nuts, and
tapered roller bearing (outer bearing)]

4. Tapered roller bearing (outer bearing), oil

seal, and oil deflector
5. Tapered roller bearing (inner bearing), and
seal retainer
6. Brake assembly
7. Frame support and axle housing

Start By:
1. Remove the mast. (For replacement of the
front axle housing and disassembly of the differential, refer to section, MAST AND FORKS.)

3. Support the front end of the truck at both sides

with blocks or stands to keep the truck in a
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

FRONT AXLE: DISASSEMBLY

Suggestions
Removing the Lock Nut

Removing Bearings

Use a lock nut wrench (Special Tool).

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.

Tool
Lock Nut Wrench

EC15K - 18KL
91268-00800

EC20K - 30KL
03703-59001

Special Tool

203651

200232

Removing Front Wheel Hub

Use a wheel hub puller (Special Tool).
Tool

EC15K - 18KL

Wheel Hub Puller 64309-40100

(Puller seat)
(64309-10601)

EC20K - 30KL
MH061017

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

200233

2.6

FRONT AXLE: DISASSEMBLY

Inspection after Disassembly

Axle Shafts
Looseness of Mating Splines

Runout

Mount the differential bevel gear on the splined

end of the shaft and set a dial indicator as shown
below. Turn the bevel gear and read the indicator.

Set a dial indicator at the middle part of the axle

shaft. Turn the shaft and read the indicator to find
runout.

Runout of shaft

200235

Free movement
(looseness of
splines)

0.07 to 0.17
(0.0028 to 0.0067)

0.5 (0.020)

Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit

Axle Housing
1. Check the surfaces of axle housing in contact
with the mast bearing for damage.
2. Check the entire axle housing for distortion,
dents, and other defects, paying particular
attention to the welds to see if any weld is
cracked.

Oil Seals and Retainers

1. Check the outer surface of the oil seal retainer
for wear or damage.

Face runout of flange

Runout of axle
shaft (1/2 of dial
indicator reading

200236

EC15K -18KL

EC20K 30KL

0.5 (0.020)
maximum

1.0 (0.039)
maximum

1.0 (0.039)

2.0 (0.079)

Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit

Set a dial indicator against the flange of the axle

shaft as shown. Turn the shaft and read the indicator to find face runout.
Face runout of axle
shaft flange

0.05 (0.0020)

0.5 (0.020)

Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit

2. Check the outer and inner oil seals for wear

and damage.

2.7

FRONT AXLE: REASSEMBLY

Reassembly
To reassemble, reverse the steps of the disassembly sequence and do the following steps.

2. Install the inner race and oil seal retainer of

the wheel hub bearing with an installer
(Special Tool).

Axle Housing
1. Install the O-ring in the outer groove (of the
two grooves in the bore of each frame support).
Special tool

2. Apply grease to the surfaces A of the support

and axle housing.
O-ring

Frame support
A

203569

Tool
Installer

EC15K - 18KL
64309-12300

EC20K30KL
91468-00300

200237

3. Apply retaining compound to the flange surfaces of the axle shafts.

Front Wheel Hub

1. Fill the front wheel hub, especially the roller
holder and oil seal lip groove, with grease.

NOTE
Be careful not to apply grease to the brake
drum.

200238

2.8

FRONT AXLE: REASSEMBLY

Hub Bearing Preload

Installation and Setting Preload

Tighten the inner nut to produce the required preload. Tighten the outer nut to the specified torque
and check the preload. Be sure that the preload
noted after tightening the outer nut meets the
specification. This step is for new bearings. Where
the bearings removed in disassembly are reused,
try to produce the preload at the lower side of the
range.

1. Fill the hub with the recommended grease as

listed in the service manual.

Preload for hub bearing

5 to 50 kgfcm
(0.4 to 3.6 lbfft)
[0.5 to 4.9 Nm]

Tightening torque
for
lock nuts

20 kgfm
(145 lbfft)
[196 Nm]

2. Pack the inner and outer bearing with the

recommended grease.
3. Install the inner bearing to the back side of
the hub.
4. Install the inner seal.
5. Clean the lining surface of the drum.
6. Install the hub onto the axle.
7. Install the outer bearing, grease seal and preload nut.
8. If the bearings are being reused, try to produce the lower side of the applied force in
tangential direction.
9. For new bearings, tighten the preload nut to
14 kgfm (101 lbfft) [137 Nm]. Slowly rotate
the hub slightly more than 3 turns, back the
nut off 80, and set the applied force in tangential direction.

Inner nut

Outer nut 200468

10. For models with an outer lock nut, torque the

nut to 20 kgfcm (145 lbfft) [196 Nm]. After
torquing the lock nut, check the force applied
in tangential direction again to insure the preload did not change.

Bar

Spring
balancer

101653

2.9

REDUCTION DIFFERENTIAL: DESCRIPTION

Reduction Differential
Description
3

5 2

1
200240

Sequence
1. Lock plates
2. Side bearing nuts
3. Differential carrier assembly (lock washers,
side bearing caps, and differential carrier)

Start By:
Remove the differential carrier from the transmission case.

2.10

4. Reduction gear and differential gear assembly

(spring pins, pinion shafts, differential pinions,
differential bevel gear, washers, and differential case)
5. Tapered roller bearings

REDUCTION DIFFERENTIAL: DISASSEMBLY

Disassembly
Suggestions

Removing Bearing Inner Races

1. Before removing the differential carrier from

the transmission case, measure the gear
backlash to aid in obtaining correct backlash
at the time of reassembly.

Use a bearing puller to remove the inner races

from the differential case.

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

2.11

BUYNOW

REDUCTION DIFFERENTIAL: DISASSEMBLY

Inspection after Disassembly

Reduction Gear

Differential

Check the teeth for wear, pitting, flaking, or chipping. Minor flaws on the tooth surface can be
repaired by grinding with an oil stone or a hand
grinder. Check the teeth for contact. If the gear is
badly damaged and requires replacement,
replace the pinion too. Reduction gear and pinion
are a matched set and must be changed at the
same time.

1. Check the differential cases for damage.

Check in particular the seat formed of each
case for carrying the side bearing inner race
to see whether the seat surface is galled or
not.
2. Check the sliding surfaces of the thrust washers and gears for wear or damage.
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.
Fit of differential
pinions on spider

0.02 to 0.07
(0.0008 to 0.0028)

0.35 (0.0138)

Unit: mm (in.)
A = Assembly Standard B = Repair or service limit

2.12

REDUCTION DIFFERENTIAL: REASSEMBLY

Reassembly
4

200243

Sequence
1. Tapered roller bearings

3. Spring pin

2. Differential gear assembly [differential case,

thrust washers, bevel gears, pinions, and pinion shaft]

4. Reduction gear
5. Differential carrier assembly [carrier, side
bearing caps, side bearing nuts, and lock
washers]

2.13

REDUCTION DIFFERENTIAL: REASSEMBLY

Suggestions
Reassembling Differential Pinions

Reassembling Differential Case

The thrust washers of the differential gears are to

be used for adjusting the backlash between the
differential gears and pinions. Measure the backlash and, if it exceeds the limit, replace the thrust
washers.

After putting the case assembly in place on the

carrier, install the bearing caps tentatively by
making the cap bolts snug tight. The caps are to
be secured tight after the bearing preload has
been adjusted.

Backlash between
differential gears
and pinions

0.18 to 0.23
(0.0071 to 0.0091)

0.5 (0.020)

Unit: mm (in.)
A = Assembly Standard B = Repair or service limit

Installing Bearing Caps

Be sure to know which are the left and right caps
and to put each cap in place correctly.
Tightening torque for
bearing cap bolts

12.8 kgfm
(93 lbfft)
[126 Nm]

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.
Tightening torque for
reduction gear bolts

2.14

12.0 kgfm
(87 lbfft)
[118 Nm]

REDUCTION DIFFERENTIAL: REASSEMBLY

Inspection and Adjustment

Side Bearing Preload

Reduction Gear Backlash

Tie a wire on the reduction gear tooth and hook a

spring scale to the wire. Tighten the side bearing
nuts while reading the spring scale until the specified preload is obtained.

Adjust the backlash between the reduction gear

and pinion after installing the differential carrier
assembly to the transmission case. To measure
the backlash, set a dial indicator with its spindle
pointing squarely to the tooth face of the reduction gear. With the pinion held, move the gear
back and forth to read the indicator. Adjust the
backlash using the left and right side bearing
nuts and pinion shims.

NOTE
Before measuring the preload, tap the back
of the reduction gear with a copper hammer
while rotating the gear to center between
bearing.

0.15 to 0.25
(0.0059 to
0.0098)

Backlash between
reduction gear and pinion

Unit: mm (in.)

Preload for differential

case side bearings

Min.

15 to 30 kgf
(1.1 to 2.2 lbf)
[1.5 to 2.9 N]

Max.

1.32 to 2.5 kgfcm

(2.9 to 5.5 lbfft)
[13 to 25 Nm]

As force applied to
reduction gear in
tangential direction.

200247

Backlash
Increase
Decrease
Decrease
Increase
200246

Increase
Backlash

Decrease
200248

2.15

REDUCTION DIFFERENTIAL: INSPECTION

Reduction Gear Face Runout

Tooth Contact

Using a dial indicator, check the reduction gear

for face runout at the maximum radius position in
back of the gear. If the runout exceeds the limit,
check the reduction gear bolts for tightness;
retighten if necessary. Check the tapered roller
bearings for condition. Readjust or replace them
if necessary.

Check the gear reduction tooth contact. To check,

apply a thin coat of bluing to several gear teeth
on both drive and coast sides. Press forward on
the reduction pinion and rotate the reduction gear
back and forth until a contact pattern is noted on
both concave and convex faces of the gear teeth.
To adjust the tooth contact, refer to the chart.

Face runout of
reduction gear

0.05 (0.0020) maximum

0.05 (0.0020) maximum

Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit

200250

200249

2.16

REDUCTION DIFFERENTIAL: INSPECTION

Tooth Contact Adjustment (EC15K - 18KL)
Tooth Contact

Adjustment

Extends from toe

to middle portion,
covering not less
than 50% of tooth
length.

Correct tooth contact

203669-1

1. Move gear away from pinion.

Short contact at
toe of tooth.

2. Move pinion toward gear by increasing shim thickness to secure correct backlash.

2
203669-2A

203669-2

1. Move gear toward pinion.

Short contact at
heel of tooth.

2. Move pinion away from gear by decreasing shim

thickness to secure correct backlash.

3
203669-3A

203669-3

1. Move pinion toward gear by increasing shim thickness.

Heavy contact
on face or upper
portion of tooth.

2. Move gear away from pinion to secure correct

backlash.
203670-4A

203669-4

1. Move pinion away from gear by decreasing shim

thickness.

Heavy contact on
flank or lower
portion of tooth.

5
203669-5

2. Move gear toward pinion to secure correct

backlash.
203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

2.17

REDUCTION DIFFERENTIAL: INSPECTION

Tooth Contact Adjustment (EC20K - 30KL)
Tooth Contact

Adjustment

Extends from toe

to middle portion,
covering not less
than 50% of tooth
length.

Correct tooth contact

203670-1

1. Move pinion toward gear by increasing shim thickness.

Short contact at
toe of tooth.

2. Move gear away from pinion to secure correct

backlash.

2
203670-2A

203670-2

1. Move pinion away from gear by decreasing shim

thickness.

Short contact at
heel of tooth.

2. Move gear toward pinion to secure correct

backlash.

3
203670-3A

203670-3

1. Move pinion toward gear by increasing shim

thickness.

Heavy contact on
face or upper
portion of tooth.

2. Move gear away from pinion to secure correct

backlash.
203670-4A

203670-4

1. Move pinion away from gear by decreasing shim

thickness.

Heavy contact
on flank or lower
portion of tooth.

5
203670-5

2. Move gear toward pinion to secure correct

backlash.
203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

2.18

TRANSFER ASSEMBLY

Front axle center

Description
1

Traction motor

7
5

209002

Main component
1
2
3
4
5

Transfer case
Transfer cover
Input gear (13T)
Output gear (48T)
Bevel gear set

6
7
8
9

Taper roller bearing

Lock nut
Ball bearing
Plug (standard) or pulse generator (option)

The transfer assemblies of all the 1 ton, 2 ton, and 3

ton class trucks share completely identical components
except the different bevel gear sets as shown below.
No. of teeth on
bevel pinion

No. of teeth on
bevel gear

1 ton class trucks

32

2 and 3 ton class

trucks

35

3.1

TRANSFER ASSEMBLY
Disassembly
Start by:

(3) Remove the traction motor, reduction and differential assembly and transfer assembly as
one unit, from the front axle housing.

(1) Remove the drain plug on the front axle housing to let the oil drain out.
(2) Disconnect the connectors of the traction motor
harnesses and pulse generator harness.

(4) Separate the three assemblies removed in step

(3) from each other.

Liquid gasket

15

18

14
17
Plug (standard)
or
Pluse generator (option)

16

Staked
7

4
6

9
13

11

10

12
209002A

Disassembly sequence
1 Bolt
2 Transfer cover
3 Side cover with pulse generator, or plug
4 Nut
5 Shim
Remove parts 6 and 8 as a unit.
6 Bevel pinion shaft
7 Shim
8 Bearing cone
9 Bearing cone

3.2

10 Output gear
11 Spacer
12 Bearing cup
13 Bearing cup
14 Snap ring
Remove parts 15 to 17 as a unit.
15 Input gear
16 Ball bearing
17 Ball bearing
18 Transfer case

TRANSFER ASSEMBLY
Suggestions for Disassembly
1. Remove the bevel pinion shaft 6 as follows:

(1) Using a chisel, cut the staked portion of the nut

4, taking care not to damage the bevel pinion
shaft.
(2) Hold the input gear 15 with the special tool to
prevent the bevel pinion 6 from rotating, then
remove the nut 4 and shims 5.

Shaft locking
bar fixing bolt

15

Shaft locking
bar
Special
tool

18

Special tool needed

Staked

Transfer bearing tool

97E67 - 00100

(3) Using the bevel pinion puller (special tool), pull

the bevel pinion 6 out of the bearing cone 9
(See the drawing on the right).
Special tool needed
Bevel pinion puller

4
5
9
8

13

10

12
209003

91268 - 00300

(4) If the bearing cone 8 needs to be removed, use

a bearing puller and a press to pull it from the
bevel pinion 6.
(5) If the bearing cups 12 and 13 need to be
removed, use a bearing cup puller to pull them
out of the transfer case 18.

NOTE
(1) The taper roller bearing cup and cone are an
exclusive pair. If either the cup or cone of a
pair is faulty, replace them as a set.

205829

(2) The removed shims should be kept together

until they are reinstalled. (This only applies
when the bevel pinion and/or taper roller bearing are/is reused.)
(3) The bevel pinion and bevel gear are an exclusive pair. If either of them is defective, replace
them as a set.
205830

3.3

TRANSFER ASSEMBLY
2. Remove the input gear as follows:

(1) Remove the snap ring 14.

(2) Using a sliding hammer, pull the input gear 15,
complete with the ball bearings out of the case
18.
(3) If the ball bearings 16 and 17 need to be
removed, use a puller to pull them out. Do not
attempt to tap them out.

17

M14 1.5
18
Thread

14
15
Rod of sliding
hammer

16
209004

Inspection after disassembly

(1) Check the output gear 10 and the input gear 15 for
damaged/worn teeth and worn splines.
(2) Check the bearings for wear or damage. Make
sure that they rotate freely without making noise.
(3) Check the transfer case for cracks or other damage.
(4) Check the bevel pinion and the bevel gear for
incorrect tooth contact, damage and wear.

3.4