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1. No Monitor name When OFF When ON or flashing Remarks Controller motor Controller drive motors and Overheating Overheating causes a overheat indicator pump motor in normal significant output loss When 3 temperature component temperature returns to normal levels output power returns Remaining Normal battery condition Flashing indicates battery charge battery needs to be warning light recharged soon 4 ON indicates battery needs to be recharged and lifting function inoperable 5 Brake fluid level indicator Normal fluid level Low fluid level Parking brake warning Parking brake disengaged Parking brake light disengaged 7 Malfunction lamp Normal Vehicle malfunction Speedometer 8 Error indicator 9 Battery discharge When no bars show vehicle is drivable but lifting Indicates remaining battery indicator function is inoperable power Hour meter 11213 45 10 T Advances every 0 1 hour Number advances every 6 minutes Hour indication 2 2 VEHICLE ELECTRICAL COMPONENTS Selection of or 1 Apply the parking brake 2 Place the direction lever in NEUTRAL 3 Turn the key switch to the ON position Button 1 Button 2 4 Push and hold button 1 for one to two seconds NOTICE Display will show KPH and a 24 hour clock until it is changed When MPH is selected clock will change to a 12 hour clock Setting the2. 211132 1 Key switch 2 Lighting switch 2 5 VEHICLE ELECTRICAL COMPONENTS Disassembly and Reassembly Disassembly 211133 Sequence 1 Console box front panel 2 Central vehicle monitor panel 3 Direction lever 4 Steering tilt lever Disassembly procedure 1 Remove the front panel and monitor panel from the console box 2 Disconnect the harness connectors from the horn and direction lever 3 Remove the screw from the steering tilt lever and remove the lever from the rear panel of the console box 4 Remove the rear panel Reassembly Follow the disassembly procedure in reverse 2 6 Console box rear panel Key switch Light switch Tilt steering lock lever Screw 211134 VEHICLE ELECTRICAL COMPONENTS Direction Lever Structure 3 211135 1 Lever 3 Connector 2 Harness 4 Screw 2 7 VEHICLE ELECTRICAL COMPONENTS Accelerator Control Accelerator pedal Initial position 1 5 to 2 5 Stopper bolt Switching position of idle switch Floor plate 30 to 32 mm 1 18 to 1 26 in Accelerator lever Accelerator Adjusting screw Position meter 211136 Adjustment procedure 1 Disconnect the battery plug 2 Set the stopper bolt to 30 to 32 mm 1 18 to 1 26 in from the floor to the upper face of bolt 3 Adjust the mounting angle
3. CAT Service Manual MC FC Chassis Mast amp Options EP16KT ETB4A 00011 up EP18KT ETB5A 00011 up EP20KT ETB5A 50001 up For use with EP16KT EP20KT Controller Service Manual 99719 66100 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 truck 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 1t was approved for printing Cat lift truck reserves the right to change specifications or design without notice and without incurring obligation Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions Indicates a specific potential hazard that could result in serious bodily injury or death AAWARNING Indicates a specific potential hazard that may result in bodily injury or damage to or destruction of the machine CAUTION NOTE Indicates a condition that can cause damage to or shorten service life o
4. 1765 3891 1975 4354 Tread Front Rear EF ny 635967 85967 366 7 Tires Number Front Rear 2 2 2 2 2 2 Tires Size Front 18 x 7 8 18 x 7 8 200 50 10 Rear 15 x 4 5 8 15 x 4 5 8 15 x 4 5 8 Turning Radius mm in 1517 59 7 1620 63 8 1645 64 8 Travel Speeds Unloaded Loaded km h mph 16 14 9 9 8 7 16 14 9 9 8 7 16 14 9 9 8 7 Gradeability Loaded 19 17 15 Lift Speeds Unloaded Loaded m in sec 0 60 0 40 23 6 15 7 0 60 0 39 23 6 15 4 0 60 0 38 23 6 15 0 Lowering Speed Unloaded Loaded m in sec 0 50 0 52 19 7 20 5 0 50 0 52 19 7 20 5 0 50 0 52 19 7 20 5 Battery Voltage V 48 48 48 Battery Rated Capacity 5 hrs MAX Ah 600 720 720 Battery Compartment Size mm 521x1006x650 624x1006x650 624x 1006 x 650 Length x Width x Height Gn 20 5 x 39 6 x 25 6 24 6 x 39 6 x 25 6 24 6 x 39 6 x 25 6 Tilt Angle forwards backwards 6 7 69 79 62 79 Traction Motor 60 min rating kW 2 4 5 2 4 5 2 4 5 Hydraulic Motor kW 11 5 11 5 11 5 Steering Motor 60 min rating kW 0 54 0 54 0 54 Traction Motor Control Method IGBT CHOPPER IGBT CHOPPER IGBT CHOPPER Hydraulic Motor Control Method IGBT CHOPPER IGBT CHOPPER IGBT CHOPPER VEHICLE ELECTRICAL COMPONENTS Console BOX at node du 2 1 Functions of Central Vehicle Monitor System 2 1 Electrical Components in Console BOX sica dd 2 5 Disassembly and Reassembly une a 2 6 Direction
5. Lever ee ee ee 2 7 Accelerator Control 2 8 Key io 2 9 Lighting SAGE 2 9 FUSES I 2 10 Lamp Specification Chart 2 10 Troubleshooting of Lighting and Horn Systems 2 11 JOVSUGK BOX A A 2 12 Finger tip Control System 2 2 222 2 14 a 2 14 Maintenange Preeaulions curras ta 2 15 Op rating Principles visa ocio 2 16 How to Set Controler aa aan a aa 2 20 Troubles SONT dur nine 2 25 VEHICLE ELECTRICAL COMPONENTS Console Box 1 Central vehicle monitoring system CVMS Mode selector button Steering tilt lever Key switch Lighting switch Mode check button our For setting the clock and selection of KPH 193043 refer to Selection of KPH or MPH and Setting the clock Functions of Central Vehicle Monitor System CVMS Operations 208077 No Monitor name When OFF When ON or flashing Remarks 1 Service indicator Starts flashing 20 hours before set time Remains ON when set time is reached 2 Motor brush wear Drive motor and pump motor Brushes are worn After brushes are replaced indicator brushes in operable condition indicator turns OFF 2 1 VEHICLE ELECTRICAL COMPONENTS
6. with standard nuts and bolts If possible make all repairs with the truck parked on a level hard surface Block truck so it does not roll while working on or under truck Disconnect battery and discharge any capacitors electric trucks before starting to work on truck Hang Do not Operate tag in the Operator s Compartment Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures Determine type of metal being welded and select correct welding procedure and electrodes rods or wire to provide a weld metal strength equivalent at least to that of parent metal Do not damage wiring during removal operations Reinstall the wiring so it 1 not damaged nor will it be damaged in operation by contacting sharp corners or by rubbing against some object or hot surface Do not connect wiring to a line containing fluid Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair If a guard or shield must be removed to perform the repair work use extra caution Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed which requires the mast in the raised position Loose or damaged fuel lubricant and hydraulic lines tubes and hoses can cause fires Do not bend o
7. Fuses blown out Open or short in circuit d Poor grounding e Bulbs burnt out Recharge or replace Check and replace Repair or replace Clean ground spot and re make connection Replace Will light dimly a Dead or weak battery b Burned contact points in switches Loose terminals d Dirty lenses e Waterdrops inside lenses f Bulbs expired service life Check and recharge Repair or replace Retighten Clean Dry and replace packings Replace dE Will not light a Lighting switch defective b Bulbs burnt out Replace Replace Other lamps Working lamp will not light a Working lamp switch defective b Bulbs burnt out Correct if improperly installed replace if internally defective Replace Will not give blast of sound a Fuse blown out b Open or short in circuit c Horn switch defective d Horn defective e Horn button defective Check and replace Repair or replace Replace Replace Repair or replace Will give an offensive blast of of sound a Horn switch defective b Horn defective Replace Replace VEHICLE ELECTRICAL COMPONENTS _ Joystick Box Description This system unlike the conventional mechanical control is electronically actuated to reduce the effort required of the operator in moving the control levers for lift tilt and attachment functions 101466 1 In the duple
8. ION Serial Number Locations Chassis number Nameplate Mast number 211129 1 2 GENERAL INFORMATION Chassis and Mast Model Identification Chassis EP 16 e wheel models Generation designator Maximum capacity 16 1600 kg 3500 Ib 18 1800 kg 4000 Ib 20 2000 kg 4400 Ib Battery type Mast Maximum lifting height 30 stands for 3000 mm 118 in Order of the minor change for the original for the first change for the second change and so on Applicable truck model designation 15 1 ton class 20 2 ton class Kind of mast G simplex mast H duplex mast J triplex mast Major change 17 for the original 2 for the first change and so on up to 9 GENERAL INFORMATION Dimensions 211130 Technical Data GENERAL INFORMATION Truck Models EP16KT EP18KT EP20KT Class 1 6 ton 1 8 ton 2 0 ton Load Capacity Load Center N kgf mm 15690 1600 500 17650 1800 500 19610 2000 500 Ibf in 3500 20 4000 20 4400 20 Truck size Length to Fork Face A 1893 74 5 1996 78 6 2032 80 0 Width B mm in 1070 42 1 1070 42 1 1130 44 5 Gud 204003 2040 80 3 2040 80 3 Wheelbase D in 1307 51 5 1410 55 5 1410 55 5 Service Weight W O Battery kg Ib 1700 3748
9. R TRAIN Procedure and suggestions for removal and installation TRANSFER UNITS Procedures and suggestions for disassembly and reassembly REAR AXLE Rear axle Rear wheels BRAKE SYSTEM Caliper Brake pedal Master cylinder STEERING SYSTEM Steering control valve HYDRAULIC SYSTEM Tank Pump Control valve Lift and tilt cylinders Flow regulator valve Down safety valve MASTS AND FORKS Simplex mast Duplex mast Triplex mast SERVICE DATA Inspection standards Periodic replacement of parts Lubrication standards Main component weight Tightening torque for standard bolts and nuts Special tools OPTIONS Rearview mirror kit Backup buzzer kit Working lamp kit Tire kit GENERAL INFORMATION Vehicle Exterior IM EIE A 1 1 MOE asuste iii 1 1 Serial Number Locations 1 2 Chassis and Mast Model Identification 1 3 DIMENSIONS 1 4 Technical Data GENERAL INFORMATION Vehicle Exterior Joystick box FC models A GA 7 YA Ve Control lever MC models 211267 Models This manual applies to EP16KT 8 and EP20KT 5 UE RU o 215775 2 15 5 5 1717 o AREE 6 6 Aja o E 1 1 GENERAL INFORMAT
10. 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 loose fitting or torn clothing Remove all rings from fingers when working on machinery 3 Do not work on any truck that is supported only by jacks or a hoist Always use blocks or jack stands to support the truck before performing any disassembly S Do not operate this truck unless you have read and understand the instructions in the OPERATION amp MAINTENANCE MANUAL Improper truck operation is dangerous and could result in injury or death Lower the forks or other implements to the ground before performing any work on the truck this cannot be done make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly 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 Alw
11. ays 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 To avoid back injury use a hoist when lifting components which weigh 23 kg 50 lb or more Make sure all chains hooks slings etc are in good condition and are of the correct capacity Be sure hooks are positioned correctly Lifting eyes are not to be side loaded during a lifting operation To avoid burns be alert for hot parts on trucks which have just been stopped and hot fluids in lines tubes and compartments Be careful when removing cover plates Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure before removing the last two bolts or nuts completely Be careful when removing filler caps breathers and plugs on the truck Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure The danger is even greater 1f the truck has just been stopped because fluids can be hot 10 11 12 13 14 15 16 17 18 Always use tools that are in good condition and be sure you understand how to use them before performing any service work Reinstall all fasteners with same part number Do not use a lesser quality fastener if replacements are necessary Do not mix metric fasteners
12. clock 103043 1 Apply the parking brake 2 Place the direction lever in NEUTRAL 3 Turn the key switch to the ON position 4 Push and hold button 1 until the minutes display flashes Release button 1 6 Adjust the minutes with button 2 7 Push button 1 and release when the hours display flashes 8 Adjust the hour with button 2 9 Push button 1 to lock in the time Error code display Indication Condition E When key switch is set to ON with direction lever in or position Turns OFF when the lever is set to Z Right drive motor overheat Z Left drive motor overheat Z Pump motor overheat Z Controller overheat Worn right drive motor brush Z Worn left drive motor brush Z Worn pump motor brush Z Faulty setting of lift lever A 0 S 0 Z Faulty setting of tilt lever 2 3 VEHICLE ELECTRICAL COMPONENTS Error code display Indication Condition ON Faulty setting of attach 1 lever H 4 ON Faulty setting of attach 1 lever Option 2 4 VEHICLE ELECTRICAL COMPONENTS Electrical Components in Console Box Horn cable Monitor cable E 2 Direction lever switch cable
13. f the machine Pub No 99719 66100 HOW TO READ THIS MANUAL Disassembly diagram example 1 Each disassembly diagram is followed by Disassembly sequence and Suggestions for disassembly Disassembly sequence Sequence 1 Cover Bolt Washer part name lt 2 Output shaft name lt Suggestion for disassembly 1 Output shaft removal Unit mm in a 0 020 to 0 105 Re beved 0 00079 to 0 00413 cylinder and piston 0 15 0 0059 A Standard value Repair or service limit WARNING SAFETY gt A WARNING The proper and safe lubrication and maintenance for this lift truck recommended by Cat lift truck are outlined in the OPERATION 8 MAINTENANCE MANUAL for these trucks Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death Read and understand the OPERATION amp MAINTENANCE MANUAL before performing any lubrication or maintenance 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 1s 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
14. of the position meter using the adjusting screw so the switch inside the position meter turns on when the accelerator lever is moved 1 5 to 2 59 from the initial position 206805B Make sure the inside switch turns ON by checking the continuity between the two terminals indicated by arrows using an ohmmeter 2 8 VEHICLE ELECTRICAL COMPONENTS Key Switch Terminal B M Connection Main fuse nec destination Battery O OFF O ON AI 206806 Lighting Switch Terminal 2 5 3 6 Connection Battery Battery Head Working destination lamps lamp OFF OO ON 1 e e ON 2 3 Working Lamp 211137 2 9 VEHICLE ELECTRICAL COMPONENTS Fuses Capacity A Location Main connecting device 500 Main fuse 325 Main controller Pump motor 50 Steering motor 15 Key switch Lighting switch Fuse holder 10 Power relay NOTE Refer to Parts Manual for proper replacement fuses Lamp Specification Chart Item Bulb Quantity Bulb color Remarks Lamp 48 V External diagram Head lamps 2 Clear 45 W CQ Working lamp 1 Clear 45 W C 205833 2 10 Troubleshooting of Lighting and Horn Systems Complaint Possible cause VEHICLE ELECTRICAL COMPONENTS Remedy Lamps general Will not light a Dead or weak battery b
15. r strike high pressure lines or install ones which have been bent or damaged Inspect lines tubes and hoses carefully Do not check for leaks with your hands Pin hole very small leaks can result in a high velocity oil stream that will be invisible close to the hose This oil can penetrate the skin and cause personal injury Use cardboard or paper to locate pin hole leaks 19 20 21 Tighten connections to the correct torque Make sure that all heat shields clamps and guards are installed correctly to avoid excessive heat vibration or rubbing against other parts during operation Shields that protect against oil spray onto hot exhaust components in event of a line tube or seal failure must be installed correctly Relieve all pressure in air oil or water systems before any lines fittings or related items are disconnected or removed Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure Do not operate a truck if any rotating part is damaged or contacts any other part during operation Any high speed rotating component that has been damaged or altered should be checked for balance before reusing GROUP INDEX GROUP INDEX Items GENERAL INFORMATION Serial number locations Dimensions Technical data VEHICLE ELECTRICAL COMPONENTS Console box Key switch Lamp specification chart POWE
16. x and triplex full free masts more oil returns from the 1st lift cylinder than from the 2nd lift cylinders to allow the 1st lift cylinder to retract faster for better maneuverability 2 12 2 This system provides the following safety functions VEHICLE ELECTRICAL COMPONENTS a b c When the pump motor is not running the lift tilt and attachment functions will not work even if the control levers are moved When the emergency switch is in the ON pushed position the lift tilt and attachments functions will not work even if the control levers are moved When the seat switch is not ON the operator is not seated the lift tilt and attachments d functions will not work even if the control levers are moved The fault detection indicator Y in the LED alerts the operator to malfunctions involving the electrical system and also an inoperable status If any problem occurs in the lift system for example the system becomes inoperative
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