1.
Service Manual
SENB8474-01
Chassis & Mast
EC35N, EC40N, EC45N A2EC4-60200-up
EC55N A2EC5-60200-up
Lift
Trucks
®
For use with GE SX Control Service Manual.

2.
i
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 AND REDUCTION DIFFERENTIAL
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Procedures and Key Points for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Reduction and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Axle Shaft and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
CHAPTER 3: TRANSFER ASSEMBLY
Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

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CHAPTER 4: REAR AXLE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Procedures and Key Points for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Adjustment of Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
CHAPTER 5: BRAKE SYSTEM
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Master Cylinder and Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

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CHAPTER 5: BRAKE SYSTEM (cont.)
Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Adjustment and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Automatic Adjuster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Procedure for Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Brake Fluid Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Inspecting Reservoir Tank Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Procedures for Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
CHAPTER 6: STEERING SYSTEM
Steering System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Oil Flow Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Steering Gear
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Steer Pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

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CHAPTER 7: HYDRAULIC SYSTEM
Hydraulic System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Removal and Installation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Hydraulic Pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Placing Pump Back into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
Control Valve
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
Lift and Tilt Cylinders
Removal
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
Disassembly
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
Inspection and Adjustment
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56

6.
v
TABLE OF CONTENTS
CHAPTER 8: MAST AND FORKS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Dual-stage Full Free Panoramic Mast (Duplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Chain, Chain Wheel Support and Chain Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
Clearance Adjustment on Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
Mast Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
Main Roller Shim Replacement (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34
Mast Strip Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34
Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38
Lift Cylinder Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.41
CHAPTER 9: SERVICE DATA
Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Fine Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Fine Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Course Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Course Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Weight of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Special Tool Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19

7.
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

8.
1.1
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.
Truck Models Covered
This service manual furnishes service and maintenance information for the following trucks.
Truck Model Serial Number
EC35N A2EC4-60200-up
EC40N A2EC4-60200-up
EC45N A2EC4-60200-up
EC55N A2EC5-60200-up

9.
1.2
GENERAL INFORMATION
Nameplate and Serial Number Locations

10.
1.3
GENERAL INFORMATION
Dimensions

11.
1.4
GENERAL INFORMATION
Dimensions Chart
Ref# Truck Model EC35N EC40N EC45N EC55N
A Maximum Lift 4650 (183) 4650 (183) 5055 (199) 5320 (209)
B Free Lift 150 (5.9) 150 (5.9) 160 (6.3) 160 (6.3)
C
Maximum Fork Spacing
1060 (41.5) 1060 (41.5) 1060 (41.5) 1060 (41.5)
(outside to outside)
D Fork Length 1220 (48) 1220 (48) 1220 (48) 1220 (48)
E
Tilt Angle
6° / 8° 6° / 8° 6° / 8° 6° / 8°
(forward/backward)
F Overall Length 3640 (143.3) 3691 (145.3) 3746 (147.5) 3912 (154.0)
G
Overall Width
1270 (50.0) 1270 (50.0) 1315 (52.0) 1420 (55.9)
(outside of tires)
H
Overall Height (to top of
2270 (89.5) 2270 (89.5) 2350 (92.5) 2120 (83.5)
mast, lowered)
I
Overall Height (to top of
2341 (92.2) 2341 (92.2) 2341 (92.2) 2341 (92.2)
overhead guard)
J
Overall Height (to top of
4550 (179.1) 4550 (179.1) 4115 (162.0) 4125 (162.4)
mast, extended)
K Tread (front) 1040 (41.0) 1040 (41.0) 1065 (42.0) 1116 (44.0)
L Tread (rear) 965 (38.0) 965 (38.0) 965 (38.0) 965 (38.0)
M Wheelbase 1575 (62.0) 1575 (62.0) 1575 (62.0) 1720 (67.7)
N Front Overhang 450 (17.7) 450 (17.7) 465 (18.3) 480 (18.9)
O Rear Overhang 395 (16) 446 (18) 486 (19) 492 (19)
P
Underclearance
(at center of wheelbase)
106 (4.2) 106 (4.2) 106 (4.2) 106 (4.2)
Unit: mm (in.)

12.
Standard Controller GE SX Controller
Standard Simplex Mast Size meters 3.3 3.3 3.3 2.9
Without 4581 4833 5677 6448
Service Weight Battery
kg (lb)
(10099) (10656) (12516) (14215)
(standard axle) With Max. 6849 7101 7945 8716
Battery (15099) (15656) (17516) (19215)
Rated Capacity/ kg/mm 3500/500 4000/500 4500/600 5500/600
Load Center (lb/in.) (7000/24) (8000/24) (10,000/24) (12,000/24)
Maximum Fork Height mm (in.) 4650 (183) 4650 (183) 5055 (199) 5320 (209)
Lift Speed 36V m/sec. 0.25 (50) 0.22 (43) 0.20 (39) 0.17 (33)
(Rated Load) 48V (fpm) 0.31 (64) 0.34 (67)) 0.25 (49) 0.21 (41)
Lowering Speed (rated load) 0.54 (106) 0.56 (110)
Tilt Angle (forward/backward) degrees 6° / 8°
Free Lift mm (in.) 150 (5.9) 160 (6.3)
Travel Speed 36V km/h 14.0 (8.7) 13.8 (8.6) 13.7 (8.5) 13.6 (7.3)
(Without Load) 48V (mph) 17.0 (10.6) 16.9 (10.5) 15.8 (10.3) 16.6 (10.3)
Minimum Turning mm 2214 2258 2294 2468
Radius (in.) (87) (89) (90) (97)
Traction Motor 36V 60min. 15.3 (11.4)
Output 48V HP(kW) 20.9 (15.5)
Transfer Type Spur
Gear Ratio 5.131
Reduction Type Spiral Bevel
Gear Ratio 4.571
Axle Housing Banjo
Differential Gear Type/ Gears Straight Bevel/2
Number Pinions Straight Bevel/2
1.5
GENERAL INFORMATION
General Information (Standard Models)
Truck Model
Units EC35N EC40N EC45N EC55N
Work
Performance
Traveling
Performance
PowerTrain

13.
1.6
GENERAL INFORMATION
Type Dynamic Load Sense
Turning Angle
Inside
Degrees
82°
Outside 59°
Steering Wheel Diameter mm (in.) 328 (13)
Cylinder Minimum kgf/cm
2
120 (1706) [11,768]
Test Pressure (psi) [kPa]
Type Self-Adjusting Duo-Servo
Inside Drum
mm (in.) 317.5 (12.50)
Diameter
Service Brake
Lining
mm (in.) 10 (0.39)
Thickness
Master
mm (in.)
Primary 31.75 (1.25)
Cylinder ID Secondary 19.05 (0.75)
Wheel 31.75 (1.250)
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]
Mounting
Front Wheels Fixed Type
Rear Wheels Center Pivot Type
Wheel Oscillation
3°
Alignment Angle
Degrees
Camber 1°
Truck Model
Units EC35N thru EC55N
PowerSteeringSystemBrakeSystemTravelingSystem

14.
1.7
GENERAL INFORMATION
Type Gear
Hydraulic Pump Make Haldex - Barnes
Model W1500
Displacement cc (cu in.) 38 (2.32)
Make Husco International
Control Valve Model 5000CC Sectional Valve
Relief kgf /cm2 Aux 155 (2250) 15513
Pressure (psi) [kPa] Lift Tilt 197 (2850) 19650
Flow Regulator Type Variable
Valve Regulated liter
100 (6100) 115 (7018)
Flow Rate (cu.in.) / min
Lift Cylinders ID 60 (2.36) 70 (2.75)
Stroke 1650 (64.96)
Tilt Cylinders
ID
mm (in.)
100 (3.937)
Stroke 120 (4.724)
Hydraulic Tank Capacity liter Liter
48 (12.7)
(Approx) (US gal.)
Mast Model CJ type
Flange ID X flange
Outer 118x28x24x13 (4.6x1.1x0.9x0.5)
130x30x26x15
back thickness X (5.1x1.2x1.0x0.6)
flange front
thickness X web Inner, Middle 118x24x24x12 (4.6x0.9x0.9x0.47) 130x26x26x13
thickness (5.1x1.0x1.0x0.5)
Main Rollers Bearing Ball Bearing
Diameter x Width, mm (in.) 118x32 (4.65x1.26) 130x34 (5.12x1.34)
Side Rollers Bearing Lubricating type needle roller bearing
Diameter x Width, mm (in.) 52x36 (2.05x1.42)
Lift Chains BL834 BL1034
Forks (length x width x thick), mm (in.) 1220x150x50 (48x6x2)
Fork Spread (outer width), mm (in.) 1060 (41.5)
Voltage 36 / 48
Amp Hours (6 hr. rate) 36V 1760
48V 1540
Compartment
Height 590 (23.22)
Dimensions
mm (in.)
Length 1003 (39.5)
Width 1156 (45.5)
Weight (Min/Max) kg (lb) 1500 / 2268 1650 / 2268 1800 / 2268
(3400 / 5000) (3600 / 5000) (3975 / 5000)
Truck Model
Units EC35N EC40N EC45N EC55N
HydraulicSystemMastandForksBattery

15.
CHAPTER 2: FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications ................................................................................................................................................ 2.1
Structure ................................................................................................................................................... 2.2
Procedures and Key Points for Removal and Installation.............................................................................. 2.3
Front Tire ................................................................................................................................................. 2.3
Front Axle Assembly................................................................................................................................ 2.4
Reduction and Differential ...................................................................................................................... 2.6
Axle Shaft and Hub ....................................................................................................................................... 2.6
Disassembly............................................................................................................................................. 2.7
Inspection and Repair.............................................................................................................................. 2.8
Assembly ................................................................................................................................................. 2.9
Adjustments ............................................................................................................................................ 2.15
Troubleshooting .............................................................................................................................................. 2.18
Service Data .................................................................................................................................................. 2.19
FRONT AXLE AND REDUCTION DIFFERENTIAL

16.
2.1
FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications
Truck Models EC35N thru EC55N
Items
Gear type Spiral bevel gear
Reduction ratio 4.571
Housing type Banjo type
Large Straight bevel gear x 2
Type and number of gears
Small Straight bevel gear x2
Front axle type Full-floating axle tube type
Suspension Front wheel Frame fixing type
RunningDifferentialReduction
Gear

17.
206653
•
•
• •
•
•
•
•
2.2
FRONT AXLE AND REDUCTION DIFFERENTIAL
Sequence
1 Front wheel hub drum
2 Front axle support
3 Axle shaft
4 Axle housing
5 Reduction bevel pinion
6 Reduction bevel gear
7 Differential case
8 Differential carrier
Structure
1 5 6 7 8
432

18.
Installation
Follow the removal sequence in reverse. Be
careful with the following key point.
Tighten wheel nuts evenly to the specified
torque to prevent tire shimmy.
NOTE
Insure wheel nut mounting holes are free of
paint and grease before torquing wheel nuts.
Wheel nut tightening torque 551±55
N·m (kgf·m) [lbf·ft] (56.2 ± 5.6)
[406.5 ± 40.6]
Procedures and Key Points for Removal and Installation
206654
206665
200227
206655
(a) Lifting the vehicle with a crane, attach
a cable to the outer and inner mast
crossmembers, and lift the vehicle.
Use protection cloth for the cable.
Tightening sequence
2
1
1
8
2
34
5
6 7
Front Tire
Removal
1 Wheel nut 2 Front tire
Special tool needed
Wheel socket MCF-1098
Preparation
(1) Pull the hand brake lever, and place wheel
stoppers at the rear tires.
(2) Loosen the wheel nuts about two rotations,
and lift the vehicle with a crane or a hydraulic
unit.
(b) Lifting the vehicle with the mast, tilt
the mast fully backward, place jack
stands which can bear the weight under
the mast, and tilt the mast forward until
the front tires are off the ground.
NOTE
For both methods, place jack stands under
the frame to prevent it from falling.
2.3
FRONT AXLE AND REDUCTION DIFFERENTIAL

19.
Front Axle Assembly
Preparation
(1) Pull the hand brake lever, and place wheel
stoppers at the front and rear tires.
(2) Remove the mast and the lift bracket assem-
bly. (Refer to Mast and Fork section.)
(3) Loosen the front tire nuts about two rotations,
and jack up the vehicle.
(4) Place jack stands under the frame on both
sides at the front so that the vehicle becomes
level.
(5) Remove the front tires. (Refer to Front Tire
Removal procedure.)
(6) Drain differential oil.
NOTE
If replacing the front axle housing, carry out
the above preparation.
Removal
206666
3
2
3
4
1
2.4
FRONT AXLE AND REDUCTION DIFFERENTIAL
Sequence
1 Axle shaft, Bolt, Spring washer
2 Bolt, Spring washer
3 Nuts, Spring washers, Bolts
4 Front axle assembly

20.
(b) Attach a cable with protection cloth to the
mast fitting on the front axle assembly,
and lift the assembly until the cable is
taught. Wind the cable rope twice firmly.
(c) To remove bolts, remove the bolts at the
top on both sides, and insert a guide bar.
Then remove the other bolts.
Installation
Follow the removal sequence in reverse. Be care-
ful with the following key points.
(1) Clean the mounting surface on the differential
carrier completely, and apply liquid gasket
before installation.
(2) Apply liquid gasket to the mounting surface
of the axle shaft, and tighten bolts.
Tightening torque of 128.3 ± 12.8
axle shaft bolts (13.1 ± 1.3)
N·m (kgf·m) [lbf·ft] [94.7 ± 9.4]
(3) Tighten axle support bolts to the specified
torque.
Key points for removal
(1) Removing axle support bolts
(a) Place jack stands under the front of the
transmission to support it.
206667
←←
Reduction and Differential
When replacing the reduction gear, replace the
reduction pinion, too.
Tooth contact of the reduction gear and the
reduction pinion must be adjusted by mating
the transfer assembly on the pinion side and
the differential carrier on the gear side.
Therefore remove the transfer assembly and
the differential carrier from the frame before
adjusting the tooth contact.
Dismount the traction motor before removing
or installing the transfer assembly. (Refer to
Power Line section.)
Place the transfer assembly on a stable work
bench, and remove the differential carrier.
2.5
FRONT AXLE AND REDUCTION DIFFERENTIAL
Tightening EC35N
torque of axle thru
support bolts EC55N
N-m 693.8
(kgf•m) (70.8)
[lbf•ft] [512]

21.
Axle Shaft and Hub
Sequence
1 Front tire
2 Axle shaft, Bolt, Spring washer
3 Bolt, Lock washer, Lock nut
4 Taper roller bearing (inner)
5 Front hub drum assembly
Taper roller bearing (outer), Oil seal,
Taper roller bearing, Spacer and Oil seal
6 Retainer, O-ring
Preparation
(1) Loosen front wheel nuts about two rotations,
and jack up the vehicle.
(2) Place stands or wood blocks under the frame
on both sides at the front so that the vehicle is
at the level position when viewed from the
front.
(3) Remove the front tires.
(4) Drain differential oil.
Disassembly
206656
1
2
3
4
5
6
2.6
FRONT AXLE AND REDUCTION DIFFERENTIAL
NOTE
Normally, disassemble the front axle while the
axle housing is installed to the frame.

22.
Key points for disassembly
(1) Removing lock nut
Use the special tool A to remove the lock nut.
Special tool needed
Socket wrench A MCF-1102
200232
200233
(2) Removing front wheel hub
Use a universal hub puller or a gear puller to
remove the front wheel hub.
If the interfit of the taper roller bearing (inner
race) is tight, the inner oil seal may fall off and
the taper roller bearing may remain in the axle
housing.
In this case, insert a wedge-shape tool
between the taper roller bearing (inner) and
the retainer to take out the taper roller bearing.
A
(3) Using a bearing puller, remove the inner race
of tapered roller bearing left on the axle
housing, along with the seal retainer.
203651
2.7
FRONT AXLE AND REDUCTION DIFFERENTIAL

23.
Inspection and Repair
(1) Axle shaft 2
(a) Insert the differential bevel gear to the
axle shaft, and measure looseness in the
rotating direction with a dial gauge.
A: Standard value B: Repair limit
Service limit
Looseness of the A
0.07 to 0.17
axle shaft spline (0.0028 to 0.0067)
mm (in.) B 0.5 (0.020)
(b) Measuring axle shaft bend
(i) Attach a dial gauge to the center of the
axle shaft, and rotate the axle shaft.
Measure bend of the axle shaft.
A: Standard value B: Repair limit
Service limit
Axle shaft bend A
1.0 or less
(1/2 of gauge reading) (0.039)
mm (in.) B 2.0 (0.079)
(ii) Attach a dial gauge to the edge of the
flange, and rotate the axle shaft.
Measure deflection of the flange.
A: Standard value B: Repair limit
Service limit
Flange deflection A 0.04 (0.0015)
mm (in.) B 0.5 (0.020)
(2) Retainer 6
Check for wear or damage on the retainer cir-
cumference.
(3) Front hub drum 5
If uneven wear or damage is found on the
inner surface of the brake drum, grind and
repair.
A: Standard valueB: Repair limit
Service limit
Inner diameter A 317.5 (12.5 )
of brake drum
mm (in.) B 318.5 (12.539)
200235
200276
+0.2
0
+0.078
0
2.8
FRONT AXLE AND REDUCTION DIFFERENTIAL

24.
Assembly
Sequence
1 Retainer, O-ring
2 Front hub drum assembly
2a Taper roller bearing (outer)
2b Spacer
2c Oil seal
2d Oil seal
3 Taper roller bearing (inner)
4 Lock nut, Lock washer, Bolt
5 Axle shaft, Bolt, Spring washer
6 Front tire, Wheel nut
206657
6
4
5
3
5
2 1
•
•
•
•
•
•
•
•
• •
••
•
•
2.9
FRONT AXLE AND REDUCTION DIFFERENTIAL
2d 2a 2c 2b

25.
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