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This service manual is a guide for servicing Cat® lift trucks of 2.0 ton, 2.5 ton, 3.0 ton
and 3.5 ton models. The instructions are grouped by systems to conveniently provide a
ready reference.
A 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
! WARNING ! WARNING
The proper and safe lubrication and Do not operate this truck unless you have read
maintenance for this lift truck, recommended and understand the instructions in the
by Cat lift truck, are outlined in the OPERATION OPERATION & MAINTENANCE MANUAL.
& MAINTENANCE MANUAL for these trucks. Improper truck operation is dangerous and
Improper performance of lubrication or could result in injury or death.
maintenance procedures is dangerous and
could result in injury or death. Read and 4. Lower the forks or other implements to the ground
understand the OPERATION & MAINTENANCE before performing any work on the truck. If this
MANUAL before performing any lubrication or cannot be done, make sure the forks or other
maintenance. implements are blocked correctly to prevent them
from dropping unexpectedly.
The serviceman or mechanic may be unfamiliar with 5. Use steps and grab handles (if applicable) when
many of the systems on this truck. This makes it mounting or dismounting a truck. Clean any mud
important to use caution when performing service or debris from steps, walkways or work platforms
work. A knowledge of the system and/or components before using. Always face truck when using steps,
is important before the removal or disassembly of any ladders and walkways. When it is not possible to
component. use the designed access system, provide ladders,
Because of the size of some of the truck components, scaffolds, or work platforms to perform safe repair
the serviceman or mechanic should check the weights operations.
noted in this Manual. Use proper lifting procedures 6. To avoid back injury, use a hoist when lifting
when removing any components. components which weigh 23 kg (50 lb.) or more.
Following is a list of basic precautions that should Make sure all chains, hooks, slings, etc., are in
always be observed. good condition and are of the correct capacity. Be
1. Read and understand all warning plates and decals sure hooks are positioned correctly. Lifting eyes
on the truck before operating, lubricating or are not to be side loaded during a lifting operation.
repairing the product. 7. To avoid burns, be alert for hot parts on trucks
2. Always wear protective glasses and protective which have just been stopped and hot fluids in
shoes when working around trucks. In particular, lines, tubes and compartments.
wear protective glasses when pounding on any part 8. Be careful when removing cover plates. Gradually
of the truck or its attachments with a hammer or back off the last two bolts or nuts located at
sledge. Use welders gloves, hood/goggles, apron opposite ends of the cover or device and pry cover
and other protective clothing appropriate to the loose to relieve any spring or other pressure, before
welding job being performed. Do not wear loose- removing the last two bolts or nuts completely.
fitting or torn clothing. Remove all rings from 9. Be careful when removing filler caps, breathers and
fingers when working on machinery. plugs on the truck. Hold a rag over the cap or plug
3. Do not work on any truck that is supported only by to prevent being sprayed or splashed by liquids
lift jacks or a hoist. Always use blocks or jack under pressure. The danger is even greater if the
stands to support the truck before performing any truck has just been stopped because fluids can be
disassembly. hot.
10. Always use tools that are in good condition and be 19. Tighten connections to the correct torque. Make
sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat, vibration
11. Reinstall all fasteners with same part number. Do or rubbing against other parts during operation.
not use a lesser quality fastener if replacements are Shields that protect against oil spray onto hot
necessary. exhaust components in event of a line, tube or seal
failure, must be installed correctly.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not 20. Relieve all pressure in air, oil or water systems
roll while working on or under truck. before any lines, fittings or related items are
disconnected or removed. Always make sure all
13. Disconnect battery and discharge any capacitors
raised components are blocked correctly and be
(electric trucks) before starting to work on truck.
alert for possible pressure when disconnecting any
Hang “Do not Operate” tag in the Operator’s
device from a system that utilizes pressure.
Compartment.
21. Do not operate a truck if any rotating part is
14. Repairs, which require welding, should be
damaged or contacts any other part during
performed only with the benefit of the appropriate
operation. Any high speed rotating component that
reference information and by personnel adequately
has been damaged or altered should be checked for
trained and knowledgeable in welding procedures.
balance before reusing.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or 22. When handling the parts containing asbestos, be
wire to provide a weld metal strength equivalent at careful not to inhale the asbestos. Doing so is
least to that of parent metal. hazardous to your health.
15. Do not damage wiring during removal operations. If the shop dust may contain asbestos, follow the
Reinstall the wiring so it is not damaged nor will it precautions described below.
be damaged in operation by contacting sharp a. Do not use compressed air for cleaning.
corners, or by rubbing against some object or hot b. Do not brush or apply grinder on asbestos
surface. Place wiring away from oil pipe. containing materials.
16. Be sure all protective devices including guards and c. To clean asbestos containing materials, wipe
shields are properly installed and functioning with moistened cloth or use a vacuum cleaner
correctly before starting a repair. If a guard or with particle filter.
shield must be removed to perform the repair work,
d. If you have to handle the parts containing
use extra caution.
asbestos for a long time, be sure to do it in a
17. Always support the mast and carriage to keep well-ventilated area.
carriage or attachments raised when maintenance
e. If the asbestos in the air cannot be removed,
or repair work is performed, which requires the
wear a mask.
mast in the raised position.
f. Be sure to observe the working rules and
18. Loose or damaged fuel, lubricant and hydraulic
regulations.
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which g. When disposing of materials with asbestos, be
have been bent or damaged. Inspect lines, tubes sure to observe the environmental protection
and hoses carefully. Do not check for leaks with regulations of your area.
your hands. Pin hole (very small) leaks can result h. Avoid working in the atmosphere where
in a high velocity oil stream that will be invisible asbestos particles may be suspended.
close to the hose. This oil can penetrate the skin
and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
HOW TO USE THIS MANUAL
(Removal, Installation, Assembly and Disassembly)
209603
Sequence
1 Cover, Bolt, Washer (part name)
2 Snap ring ................ (part name)
209604
Service Data
0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.
TRANSFER AND Structure and Functions, Procedures and Suggestions for Disassembly and
DIFFERENTIAL Reassembly, Service Data 4
Rear Axle, Rear Wheels, Removal and Installation, Disassembly and Reassembly,
REAR AXLE
Adjustment, Troubleshooting, Service Data 6
Specifications, Structure and Functions, Procedures and Suggestions for
BRAKE SYSTEM Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, 7
Service Data
Specifications, Structure and Functions, Procedures and Suggestions for Removal
STEERING SYSTEM and Installation, Steering Gear, Hydraulic Circuit, Troubleshooting, 8
Service Data
Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve,
HYDRAULIC SYSTEM
Down Safety Valve 9
Rearview Mirror Kit, Backup Buzzer Kit, Working Lamp Kit, Tire Kit,
OPTIONS
Foot Direction Control Kit 12
GENERAL INFORMATION
1
Vehicle Exterior ....................................................................................... 1–1
Models ....................................................................................................... 1–1
Serial Number Locations ...................................................................... 1–2
Chassis and Mast Model Identification ............................................ 1–3
Dimensions .............................................................................................. 1–4
Technical Data ......................................................................................... 1–5
GENERAL INFORMATION
Vehicle Exterior
Joystick box
(FC models)
Control lever
(MC models)
103142
Models
This manual applies to EP20K PAC, EP25K PAC, EP30K PAC and EP35K PAC.
1-1
GENERAL INFORMATION
208204
1-2
GENERAL INFORMATION
[Chassis]
EP 20 K PAC
AC motor
Generation designator
Maximum capacity
20: 2000 kg (4400 lb)
25: 2500 kg (5500 lb)
30: 3000 kg (6600 lb)
35: 3500 kg (7700 lb)
Battery type
[Mast]
4 R 35 C 30
Kind of mast
R: simplex mast
S: duplex mast
Y: triplex mast
Major change
(“2” for the original, “3” for the first change, and so
on up to “9”)
1-3
GENERAL INFORMATION
Dimensions
B E F
211638
1-4
GENERAL INFORMATION
Technical Data
Truck size Length to fork face A mm (in.) 2249 (88.5) 2274 (89.5)
Rear 18 × 7 − 8 18 × 7 − 8
Battery voltage V 80 80
Steering pump motor output (60 min. short duty) kW 1.2 1.2
1-5
GENERAL INFORMATION
Truck size Length to fork face A mm (in.) 2522 (99.3) 2577 (101.5)
Rear 18 × 7 − 8 18 × 7 − 8
Battery voltage V 80 80
Steering pump motor output (60 min. short duty) kW 1.2 1.2
1-6
VEHICLE ELECTRICAL COMPONENTS
6
Detail "A"
7
1
A
2
3
4
8 Detail "B"
13
B 12
10
11
211648
2-1
VEHICLE ELECTRICAL COMPONENTS
14
15
211649
2-2
VEHICLE ELECTRICAL COMPONENTS
16
19
18
17
211650
2-3
VEHICLE ELECTRICAL COMPONENTS
24
Detail "C"
Detail "D" 22 21
C
23
20
211651
2-4
VEHICLE ELECTRICAL COMPONENTS
Console Box 1 6
3 7
NOTE 206900
209510
Operations
1 Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached.
4 Brake fluid level indicator Normal fluid level Low fluid level
2-5
VEHICLE ELECTRICAL COMPONENTS
Vehicle speed and Displays the vehicle speed during normal operation The vehicle speed display can
error code display and displays an error code in the event of a be switched between KPH and
7 malfunction. MPH. Follow the steps in
“Selection of KPH or MPH”
below.
Battery discharge The battery charge status is indicated by the ten element indicator. When fully
indicator (BDI) charged, all elements are lit through to the right side. As the battery discharges, the
indicator elements decrease toward the left side. When only one element is on, the
8 remaining battery charge warning indicator 3 in the LED section will flash. When
the indicator completely goes off, the remaining battery charge indicator 3 will be
continuously lit and the vehicle enters power reduction mode.
2-6
VEHICLE ELECTRICAL COMPONENTS
Indication Condition
E If the key switch is turned I (ON) while the direction lever is either in the forward
or reverse position and/or if the accelerator pedal is depressed.
2-7
VEHICLE ELECTRICAL COMPONENTS
Monitor harness
Direction lever
harness
2
3
211652
2-8
VEHICLE ELECTRICAL COMPONENTS
1
5
211653
Sequence
1 Console box (front panel) 4 Steering tilt lock lever
2 Central vehicle monitor panel 5 Console box (rear panel)
3 Direction 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 lock lever, and
remove the lever from the rear panel of the console
box.
(4) Remove the rear panel.
Steering tilt
lock lever
211645
Reassembly
Follow the disassembly procedure in reverse.
2-9
VEHICLE ELECTRICAL COMPONENTS
Direction Lever
Structure
211646
1 Lever 3 Connector
2 Harness 4 Screw, Spring washer
2-10
VEHICLE ELECTRICAL COMPONENTS
Accelerator Control
Accelerator pedal
IDL
Adjusting screw
Position meter
209531
Adjustment Procedures
1. Disconnect the battery plug.
2. Install the position meter by loosely mounting the
adjusting screws.
3. Connect the accelerator pedal rod to the lever.
4. Check that there is no continuity between the E2 and
IDL terminals.
5. Move the lever 1.5 to 2.5° from the initial position.
6. Check that there is continuity between the E2 and IDL
terminals (the idle switch in the position meter is ON),
then finally tighten the adjusting screws of the position
meter.
7. Make sure the stopper bolt height H is approximately
38 to 40 mm (1.50 to 1.57 in.). Depress the accelerator
pedal until it comes in contact with the stopper bolt.
Adjust the height H of the stopper bolt until letter “15”
flashes on the I/O diagnosis display.
2-11
VEHICLE ELECTRICAL COMPONENTS
Key Switch
Terminal B M1, M2
(OFF)
I (ON)
206806A
Lighting Switch
Terminal 2, 5 3 6
2nd position
(Circuit 1 & 2) 209515
2-12
VEHICLE ELECTRICAL COMPONENTS
Fuses
NOTE
Item Bulb
Quantity Bulb color Remarks
Lamp 80 V External diagram
205833
2-13
VEHICLE ELECTRICAL COMPONENTS
Auto-light System
System Operation
With the auto-light switch turned on, the contactor automatically closes the head lamp and working lamp circuits
when the darkness sensed by the auto-light sensor is enough to illuminate the lights.
A Auto-light
sensor assembly
Head lamp
Detail "A"
Auto-light sensor
assembly harness
Harness D
Lighting switch Red
Yellow Yellow
White
Blue
Blue
Auto-light switch White
2-14
VEHICLE ELECTRICAL COMPONENTS
Other Backup lamps will 1. Backup lamp switch defective Correct if improperly installed:
lamps not light replace if internally defective.
2. Bulbs burnt out Replace.
2-15
VEHICLE ELECTRICAL COMPONENTS
Nomenclature
103542A
2-16
VEHICLE ELECTRICAL COMPONENTS
NOTE
Improper setting of the system will result in the
inability to lower the forks in an incremental manner.
Description
The FC 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.
101466A
• This system provides the following safety functions:
(a) The lift, tilt and attachment functions are not (c) The system indicator light in the LED
performed even if the control levers are moved section alerts the operator to problems
when the emergency switch is in ON (pushed) occurring in the electrical system and, at the
position. same time, stops function. (If any problem
(b) The lift, tilt and attachment functions are not occurs in the lift system, for example, the
performed even if the control levers are moved system becomes inoperative.)
when the seat switch is not ON (the operator is
not seated).
2-17
VEHICLE ELECTRICAL COMPONENTS
Operating Principles
(1) The system is activated by turning OFF (pulled, not
pushed) the emergency switch when the key switch and
the seat switch are ON (when the operator is seated).
(2) As the control levers (joysticks) are moved to operate
the equipment (mast and forks), the amount of lever
movement will be translated into an electrical signal;
this signal goes into the controller, where it is
converted to an output signal. At this point the
controller issues an ON signal to increase the pump
motor speed, thereby hydraulic pressure will be
introduced into the control valve. The system is now
ready to actuate the equipment. The output signal is
applied to the proportioning solenoid, selected by the
direction of the joystick movement. Inside the control
valve of the solenoid, the spool is forced to slide,
altering the internal oil passage that directs the oil to
the corresponding cylinders. The spool keeps on
sliding until it comes to the position where the pressure
of its pilot chamber becomes equal to the force of its
centering spring. In the meantime, the cylinder extends
or retracts against its load. As the joystick is moved
back to its neutral position, the signal to the
proportioning solenoid decreases in order to lower the
pilot chamber pressure and allow the centering spring
to push the spool to its neutral position, whereby the
line to the cylinder shuts off. The pressure in the line is
now trapped, holding the cylinder in place. At the
same time, the motor speeds lowers and the part of the
system actuating the equipment goes into a no-load
state.
(3) Supply power to the controller is initiated from the
Power Relay through a 10-Amp fuse. Pressing the
emergency switch shuts down the output to solenoids.
2-18
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