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DescriptionCAT Forklift EP20ANT Service, Operation & Maintenance ManualSize:
157 MBFormat: PDFLanguage: English, French, PortugueseBrand: CAT
CaterpillarType of Machine: ForkliftType of Manual: Service Manual, Operation &
Maintenance ManualModel: CAT EP20ANT ForkliftDate: 2021Content:655383_00
Chassis and Mast: Foreward655383_01 Chassis and Mast: Safety
Instructions655383_02 Chassis and Mast: General Information655383_03a
Chassis and Mast: Mechanical Maintenance655383_03b Chassis and Mast:
Mechanical Maintenance655383_03c Chassis and Mast: Mechanical
Maintenance655383_04 Chassis and Mast: Electrical Operation655383_05
Chassis and Mast: Battery Maintenance655383_06 Chassis and Mast: Electric
System Maintenance655383_07 Chassis and Mast: Electric System Adjustments
and Measurements655383_08 Chassis and Mast: Hydraulic Operation655383_09
Chassis and Mast: TruckTool Diagnostics655383_10 Chassis and Mast: Service
Data655383_11 Chassis and Mast: Options655383_12 Chassis and Mast:
Technical Specifications654391-IN Operation & Maintenance Manual654391-UK
Operation and maintenance manual654391-FR User and maintenance
manual654391-PT Operation and maintenance manual655383_06 Chassis and
Mast: Electric System MaintenanceThis part manual inlcude all spare parts number
you need inside this model, for you easier in fixing your forklift replace new spare
part hight performance.This service manual is a guide for servicing Cat Lift Trucks.
For your convenience the instructions are grouped by systems as an easy
reference.This Original Instructions (Operator’s) Manual describes operating
procedures, daily checks and simple maintenance for safe usage of your Cat lift
truck.SERVICE MANUALCHAPTER 1 GENERAL INFORMATION1.1 Model
View1.2 Models Covered1.2.1 Lift Truck Nomenclatures and Definitions1.3 Serial
Number Locations1.4 Dimensions1.5 Technical Data1.6 PerformanceCHAPTER 2
COOLING SYSTEM2.1 Specifications2.2 Structure2.3 Removal and
Installation2.3.1 Fan Belt Removal2.3.2 Suggestions for Removal2.3.3
Installation2.4 Inspection and Adjustment2.4.1 Fan Belt Inspection2.4.2 Fan Belt
Tension2.4.3 Connecting Hoses2.4.4 Coolant2.4.5 Radiator CapCHAPTER 3
ELECTRIC SYSTEM3.1 Chassis Electrical Devices Wiring Outline3.1.1 Harnesses
Layout3.1.2 Components Layout3.2 Structure3.2.1 Console Box3.2.2 Major
Electrical Components3.2.3 Table of Lamps3.3 Console Box3.3.1 Disassembly3.4
Battery Maintenance3.4.1 State of Charge and Electrolyte Specific Gravity (S.G.)
Adjustment3.4.2 Specific Gravity Reading and State of Charge3.4.3 Charging
Precautions3.5 Instrument Panel3.5.1 Instrument Panel Screen Element3.5.2
Basic Screen Display3.5.3 Basic Operation3.5.4 When An Error Occurs3.5.5
Warning Lamps3.5.6 Optional Functions3.5.7 Hour Meters3.5.8
Troubleshooting3.6 Wire Color3.6.2 List of Wire Colors3.7 Troubleshooting3.7.1
Starter System3.7.2 Gauges3.7.3 Lighting System3.8 Electrical
SchematicCHAPTER 4 CONTROLLERS4.1 Outline4.2 Main Functions4.2.2
Instrument Panel4.2.3 VCM (Vehicle Control Module)1-M4.2.4 ECM (Gasoline
Engine Control Module)4.2.5 Remote Input/Output Units4.2.6 GSE Connector4.3
Service Tool Functions4.3.1 Service Tool Menus4.3.2 Service Tool Box4.4 Mast
Interlock System4.4.1 Function4.4.2 VCM1-M Controller, Mast Interlock System
Checking Procedure4.4.3 Active Test Inspection Procedure4.5 Driving Interlock
System4.5.1 Function4.5.2 Driving Interlock System Checking Procedure for
Powershift T/M Lift Trucks4.5.3 Active Test Inspection Procedure4.6 Seat Belt
Warning Lamp4.6.1 Function4.6.2 Seat Belt Warning Lamp Checking
Procedure4.7 Parking Brake Warning Buzzer and Lamp4.7.1 Function4.7.2
Parking Brake Warning Buzzer/Lamp Checking Procedure4.7.3 Parking Brake
Warning Buzzer/Lamp Checking Procedure with Key in OFF Position4.8 Harness
Codes4.9 Controller Details4.9.1 VCM1-M Controller4.9.2 Seat Switch/Seat Belt
Switch4.9.3 Parking Brake Switch4.9.4 Direction Lever4.9.5 Speed Sensor4.9.6
T/M Solenoid4.9.7 Unload Solenoid4.9.8 Lift Lock Solenoid4.9.9 Warning
Buzzer4.9.10 Warning Buzzer Relay4.9.11 Warning Buzzer Circuit4.9.12
Instrument Panel4.10 Error Codes and Troubleshootings4.10.1 Error Code
Display4.10.2 Diagnosis Table (F Code)4.10.3 Error Codes and
Troubleshooting4.11 Locations of Sensors and SwitchesCHAPTER 5 POWER
TRAIN5.1 Removal and Installation (MC Models)5.1.1 Removal of Engine and
Transmission Assembly5.1.2 Removal of Engine and Transmission Assembly (for
Gasoline-Engine Lift Trucks)5.2 Removal and Installation (FC Models)5.2.1
Removal of Engine and Transmission AssemblyCHAPTER 6 POWERSHIFT
TRANSMISSION6.1 Structure and Functions6.1.1 Transmission6.1.2 Torque
Converter6.1.3 Control Valve6.1.4 Hydraulic System Schematic of Powershift
Transmission6.2 Removal and Installation6.2.1 Removal6.2.2 Installation6.3
Control Valve6.3.1 Disassembly6.3.2 Reassembly6.4 Input Shaft Assembly6.4.1
Disassembly6.5 Oil Pump Assembly6.5.1 Disassembly6.5.2 Reassembly6.6
Inspection and Adjustment6.6.1 Oil Pressure Measurement6.6.2 Clutch (Inching)
Pedal Adjustment6.6.3 Inching Cable, Adjustment6.7 Troubleshooting6.8
Tightening Torque6.9 Service DataCHAPTER 7 FRONT AXLE AND REDUCTION
DIFFERENTIAL7.1 Structure7.1.1 Front Axle7.1.2 Reduction Differential7.2
Removal and Installation7.2.1 Front Wheels7.3 Front Axle7.3.2 Reduction
Differential7.4 Disassembly and Reassembly7.4.1 Front Axle7.4.2 Reduction
Differential7.5 Troubleshooting7.6 Service DataCHAPTER 8 REAR AXLE8.1
Structure and Functions8.1.1 Rear Axle in General8.1.2 Structure of Each
Component8.1.3 Steering Cylinder8.2 Removal and Installation8.2.1 Rear Wheel
and Rear Axle Assembly8.3 Disassembly and Reassembly8.3.1 Wheel Hub,
Disassembly and Reassembly8.3.2 Knuckle (King Pin), Disassembly and
Reassembly8.3.3 Steering Cylinder, Disassembly and Reassembly8.3.4 Tie Rod,
Disassembly and ReassemblyCHAPTER 9 BRAKE SYSTEM9.1 Structure9.1.1
Brake System9.2 Disassembly and Reassembly9.2.1 Master Cylinder9.2.2 Wheel
Brakes9.2.3 Wheel Cylinder9.3 Inspection and Adjustment9.3.1 Automatic
Adjuster Test9.3.2 Manual Adjustment9.3.3 Parking Brake Cable Adjustment9.3.4
Brake Pedal Adjustment9.3.5 Brake Lines Bleeding9.3.6 Braking Performance
Test9.3.7 Parking Brake Lever9.4 Troubleshooting9.5 Service DataCHAPTER 10
STEERING SYSTEM10.1 Structure and Functions10.1.1 Steering System10.1.2
Steering Valve10.1.3 Steering Column10.2 Disassembly and Reassembly10.2.2
Steering Wheel and Steering Valve, Removal and Installation10.2.3 Steering
Wheel10.2.4 Steering Valve10.2.5 Tilt Lock Lever10.3 Steering Valve10.3.1
Disassembly10.3.2 Reassembly10.4 Troubleshooting10.5 Service DataCHAPTER
11 HYDRAULIC SYSTEM11.1 Structure and Functions11.1.1 Outline11.2
Hydraulic Circuit Diagram (For Models With MC Control Valve)11.3 Hydraulic
Circuit Diagram (For Models With FC Control Valve)11.4 Hydraulic Tank11.5
Hydraulic Pump (Gear Pump)11.6 Control Valve11.7 Flow Regulator Valve (for
Models with FC Control Valve Only)11.8 Down Safety Valve11.9 Lift Cylinder11.10
Tilt Cylinder11.11 Disassembly and Reassembly11.11.1 Hydraulic Pump11.11.2
Lift Cylinder11.11.3 Tilt Cylinder11.11.4 Flow Regulator Valve11.11.5
Piping11.11.6 Suction Strainer and Return Filter11.12 Inspection and
Adjustment11.12.1 Hydraulic Tank11.12.2 Control Valve11.12.3 Descent
Test11.12.4 Forward Tilt Test11.13 Troubleshooting11.13.2 Hydraulic System
Cleaning After a Component Failure11.14 Service Data11.15 MC Control
Valve11.15.1 Structure and Operation11.15.2 Control Valve, Removal and
Installation11.15.3 Disassembly and Assembly11.16 FC Control Valve11.16.1
Structure and Operation11.16.2 Disassembly and AssemblyCHAPTER 12 MAST
AND FORKS12.1 Simplex Mast12.1.1 Mast System12.2 Structure and
Functions12.2.1 Simplex Mast (5A15C to 5A33C)12.2.2 Mast Operation12.3
Removal and Installation12.3.1 Mast and Lift Bracket Assembly12.4 Disassembly
and Reassembly12.4.1 Simplex Mast Disassembly12.4.2 Simplex Mast
Reassembly12.5 Removal and Installation of Mast Rollers and Strips without
Removing12.5.1 Simplex Mast12.6 Inspection and Adjustment (Simplex
Mast)12.6.2 Forks12.6.3 Chain Tension Inspection and Adjustment12.6.4
Checking Chain Elongation12.6.5 Adjusting Clearance Between Lift Bracket Roller
and Inner Mast12.6.6 Mast Roller Clearance Adjustment12.6.7 Mast Strip
Clearance Inspection and Adjustment12.6.8 Tilt Angle Adjustment12.6.9 Right and
Left Lift Cylinder Stroke Inspection and Adjustment12.7 Troubleshooting (Simplex
Mast)12.8 Service Data (Simplex Mast)12.9 Duplex Mast12.9.1 Mast System12.10
Structure and Functions12.10.1 Duplex (Dual Full-Free Panoramic) Mast (5B15C
to 5B33C)12.10.2 Mast Operation12.11 Removal and Installation12.11.1 Mast and
Lift Bracket Assembly12.12 Disassembly and Reassembly12.12.1 Duplex Mast
Disassembly12.12.2 Duplex Mast Reassembly12.13 Removal and Installation of
Mast Rollers and Strips without Removing12.13.1 Duplex Mast12.14 Inspection
and Adjustment (Duplex Mast)12.14.1 Inspection and Adjustment (Duplex
Mast)12.14.2 Forks12.14.3 Chain Tension Inspection and Adjustment12.14.4
Checking Chain Elongation12.14.5 Adjusting Clearance Between Lift Bracket
Roller and Inner Mast12.14.6 Mast Roller Clearance Adjustment12.14.7 Mast Strip
Clearance Inspection and Adjustment12.14.8 Tilt Angle Adjustment12.14.9 Right
and Left Lift Cylinder Stroke Inspection and Adjustment12.15 Troubleshooting
(Duplex Mast)12.16 Service Data (Duplex Mast)12.17 Triplex Mast12.17.1 Mast
System12.18 Structure and Functions12.18.1 Triplex (Triple Full-Free Panoramic)
Mast (5C15C to 5C33C)12.18.2 Mast Operation12.19 Removal and
Installation12.19.1 Mast and Lift Bracket Assembly12.20 Disassembly and
Reassembly12.20.1 Triplex Mast Disassembly12.20.2 Triplex Mast
Reassembly12.21 Removal and Installation of Mast Rollers and Strips without
Removing12.21.1 Triplex Mast12.22 Inspection and Adjustment (Triplex
Mast)12.22.2 Forks12.22.3 Chain Tension Inspection and Adjustment12.22.4
Checking Chain Elongation12.22.5 Adjusting Clearance between Lift Bracket
Roller and Inner Mast12.22.6 Mast Roller Clearance Adjustment12.22.7 Mast Strip
Clearance Inspection and Adjustment12.22.8 Tilt Angle Adjustment12.22.9 Right
and Left Lift Cylinder Stroke Inspection and Adjustment12.23 Troubleshooting
(Triplex Mast)12.23.1 Troubleshooting (Triplex Mast)12.24 Service Data (Triplex
Mast)12.24.1 Triplex MastCHAPTER 13 SERVICE DATA13.1 Maintenance
Schedule13.2 Maintenance Note13.2.1 Brake System13.2.2 Cooling System13.2.3
Electric System13.2.4 Engine System13.2.5 Frame and Chassis13.2.6 Fuel
System13.2.7 Hydraulic System13.2.8 Ignition System13.2.9 Intake
System13.2.10 Front End Section13.2.11 Steering and Axle System13.2.12 T/M
and Drive System13.2.13 Wheels and Tires13.2.14 General13.3 Tightening
Torque for Standard Bolts and Nuts13.4 Periodic Replacement Parts13.4.2
Location of Periodic Replacement Parts13.5 Lubrication Instructions13.5.1
Lubrication Chart13.5.2 Fuel and Lubricant Specifications13.5.3 Adjustment Value
and Oil Quantities13.6 Special Service Tools13.6.1 Special Service Tools
(Standard Tools for Both MC and FC LiftTrucks)13.6.2 Special Service Tools (for
FC Lift Truck Only)13.6.3 Special Service Tools (for Powershift
Transmission)OPERRATION MANUALCHAPTER 1 SAFETY RULES AND
PRACTICES1.1 SAFETY SIGNS AND SAFETY MESSAGES1.2 WARNING
SYMBOLS AND LEVELS1.3 OPERATOR QUALIFICATIONS1.4 SAFETY
GUARDS1.5 PERSONAL PROTECTIVE EQUIPMENT FOR OPERATING LIFT
TRUCK1.6 DAILY INSPECTION1.7 OPERATOR RESPONSIBILITY1.8
GENERAL1.9 NO RIDERS1.10 TRAVELING1.11 LOADING1.12 DOCKBOARDS
(BRIDGE PLATES), TRUCKS AND RAILROAD CARS1.13 SURFACE AND
CAPACITY1.14 FUEL HANDLING1.15 INSTALLATION OF ATTACHMENTS1.16
IN CASE OF TIP-OVER1.17 TRANSPORTING LIFT TRUCK1.17.2 APPROACH
ANGLE, DEPARTURE ANGLE AND GANGWAY1.17.3 HOISTING (LIFTING) UP
THE TRUCK1.18 FUNCTION TESTS1.19 TRACTION BAR1.20 POSITION OF
DATA AND CAPACITY PLATES AND DECALS1.21 DATA AND CAPACITY
PLATES AND DECALS1.21.2 DATA PLATE1.21.3 IDENTIFICATION
NUMBERS1.21.4 CAUTION DRIVE DECAL (IN CASE OF TIP-OVER
DECAL)1.21.5 WARNING DRIVE DECAL (TRAINED AND AUTHORIZED)1.21.6
PINCH POINT DECAL1.21.7 CAUTION FORK DECAL1.21.8 MAST WARNING
DECAL1.21.9 CAUTION DRIVE DECAL (OPERATION)1.21.10 RADIATOR
WARNING DECAL1.21.11 COOLING FAN WARNING DECAL1.21.12 ADJ LPG
WARNING DECAL1.21.13 LPG LATCH WARNING DECAL1.21.14 LPG FUEL
WARNING DECALCHAPTER 2 OPERATING CONTROLS AND FUNCTIONS2.1
APPLICATIONS2.2 APPLICATION FOR CAT LIFT TRUCKS2.3 PROHIBITED
APPLICATIONS FOR CAT LIFT TRUCKS2.4 MAIN COMPONENTS2.5 METERS,
INDICATORS AND WARNING LIGHTS2.5.2 LCD2.5.3 OPERATION
BUTTONS2.5.4 ! MULTIPURPOSE WARNING LIGHT2.5.5 MALFUNCTION
INDICATOR LIGHT-ENGINE CHECK WARNING2.5.6 OIL PRESSURE
WARNING LIGHT2.5.7 CHARGE WARNING LIGHT2.5.8 PARKING BRAKE
WARNING LIGHT2.5.9 SEAT BELT WARNING LIGHT2.5.10 METER
DISPLAY2.5.11 WATER TEMPERATURE GAUGE2.5.12 FUEL GAUGE2.5.13
TRANSMISSION POSITION2.6 MALFUNCTION AND WARNING
INDICATIONS2.6.2 MAST INTERLOCK WARNING2.6.3 LPG LEVEL
WARNING/LPG RACK LOCK WARNING2.6.4 TORQUE CONVERTER FLUID
TEMP WARNING2.6.5 RADIATOR LEVEL WARNING2.6.6 AIR CLEANER
WARNING2.6.7 SERVICE REMINDER DISPLAY2.6.8 DISPLAYS WHEN
MALFUNCTION OCCURS2.7 DRIVER RECOGNITION MODE2.8 LPG
REMAINING TIME MANAGEMENT2.9 SWITCHES2.9.2 HORN BUTTON2.9.3
REAR RIGHT GRIP WITH HORN BUTTON2.9.4 IGNITION SWITCH2.9.5
LIGHTING AND TURN SIGNAL SWITCHES2.9.6 MAXIMUM SPEED CHANGE
SWITCH (OPTION)2.9.7 THROTTLE SENSITIVITY ADJUST SWITCH
(OPTION)2.9.8 BACK-UP OPERATION LIGHT SWITCH (OPTION)2.10
OPERATING CONTROLS2.10.2 SELECTOR LEVER2.10.3 PARKING BRAKE
LEVER2.10.4 INCHING BRAKE PEDAL2.10.5 BRAKE PEDAL2.10.6
ACCELERATOR PEDAL2.10.7 CARGO-HANDLING CONTROL LEVERS2.10.8
ANSI/ITSDF STANDARDS FOR LIFT TRUCK CLAMP ATTACHMENTS2.10.9
STEERING CHARACTERISTICSCHAPTER 3 OPERATING THE LIFT TRUCK3.1
OPERATION3.2 INSPECTION BEFORE OPERATING3.3 LIFT TRUCK
OPERATING PRECAUTIONS3.4 PRECAUTIONS FOR COLD AND HOT
WEATHER3.5 OPERATIONAL PROCEDURES3.6 LPG LIFT TRUCK
STARTING3.7 PROCEDURE FOR JUMP STARTING EFI ENGINES3.8
AUTOMATIC TRANSMISSION3.9 LOADING3.10 TRANSPORTING LOADS3.11
UNLOADING3.12 CLIMBING3.13 STOPPING AND PARKING THE LIFT
TRUCK3.14 FORKS3.15 SEAT ADJUSTMENT3.15.1 SUSPENSION SEAT
OPERATOR’S WEIGHT ADJUSTMENT3.15.2 FORWARD AND BACKWARD
CONTROL LEVER3.15.3 BACKREST INCLINATION ADJUSTMENT3.15.4
LUMBAR ADJUSTMENT3.15.5 SWIVEL SEAT3.16 SEAT BELT3.17 TOP
PANEL3.18 TILT STEERING WHEEL3.19 SERVICE RELEASE LATCH3.20
RADIATOR COVER3.21 REARVIEW MIRROR (OPTION)3.22 LPG CYLINDER
(TANK) HOLDERCHAPTER 4 GENERAL CARE AND MAINTENANCE4.1 WET
CELL BATTERY CARE AND MAINTENANCE4.2 BATTERY SPECIFIC
GRAVITY4.3 DAILY INSPECTION4.4 OPERATOR’S DAILY CHECKLIST
(SAMPLE)4.5 MAINTENANCE AND INSPECTION4.5.1 ENGINE OIL LEVEL4.5.2
REFILLING ENGINE OIL4.5.3 ENGINE COOLANT LEVEL4.5.4 REFILLING
ENGINE COOLANT4.5.5 COOLING SYSTEM BLEEDING INSTRUCTIONS4.5.6
BRAKE FLUID LEVEL4.5.7 REFILLING BRAKE FLUID4.5.8 AUTOMATIC
TRANSMISSION FLUID LEVEL4.5.9 REFILLING AUTOMATIC TRANSMISSION
FLUID4.5.10 HYDRAULIC OIL LEVEL4.5.11 REFILLING HYDRAULIC OIL4.5.12
STEERING WHEEL PLAY4.5.13 WHEEL AND TIRE4.5.14 TIRE
REPLACEMENT4.5.15 CHECKING MAST4.5.16 CHECKING LIFT CHAIN4.5.17
FORK INSPECTION4.5.18 FORK REPAIR4.5.19 CHECKING HORN4.5.20
CHECKING LIGHTS4.5.21 CHECKING CARGO-HANDLING CONTROL
LEVER(S)4.5.22 CHECKING BRAKE PEDAL4.5.23 PEDAL FREE PLAY4.5.24
CHECKING PARKING BRAKE LEVER4.5.25 CHECKING TOP PANEL
LOCK4.5.26 FUSES4.5.27 CHECKING AIR CLEANER4.5.28 CHECKING FAN
BELT4.5.29 DRAINING OF TAR FROM THE VAPORIZER4.5.30 PRECAUTIONS
FOR USING LPG4.5.31 RECOMMENDED LPG FUEL TYPE4.5.32 CYLINDER
(TANK) SIZE4.5.33 LPG CYLINDER (TANK) REPLACEMENT4.5.34 REFILLING
LPG CYLINDERS (TANKS)4.5.35 PERIODIC MAINTENANCE AND
LUBRICATION SCHEDULE4.5.36 PERIODIC MAINTENANCE AND
LUBRICATION SCHEDULE FOR EMISSION CONTROL SYSTEM4.5.37
LUBRICATION CHART4.5.38 RECOMMENDED LUBRICANTS4.5.39
RECOMMENDED SAE VISCOSITY CHART4.5.40 PUTTING LIFT TRUCK IN
STORAGE4.6 SIDE SHIFT4.6.1 OVERVIEW OF SIDE SHIFT4.6.2 MAIN TERMS
USED IN THIS SECTION4.6.3 SAFETY RULES AND PRACTICES4.6.4 SIDE
SHIFT CONTROL LEVER OPERATION4.6.5 SIDE SHIFT OPERATION4.6.6
DAILY CHECKS AND SIMPLE MAINTENANCECHAPTER 5
SPECIFICATIONS5.1 MODEL IDENTIFICATION5.1.1 MODEL VARIATION
(LONG MODEL CODE) BREAKDOWN5.2 MAIN TRUCK5.2.1 MAIN TRUCK –
2C7000 AND 2C8000/2C8000-SWB5.3 MAST5.3.1 2C7000 AND
2C8000/2C8000-SWB5.4 FUEL AND OIL CAPACITY5.5 ENGINE5.6 ENGINE OIL
CAPACITY5.7 NOISE LEVELCAT FULL PROGRAM: ” CLICK HERE “CAT PDF
FULL COLLECTION: ” CLICK HERE “
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Luther Martin.
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Note.
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views, than with the arguments advanced in the letter. Of the author,
Randolph himself gives us a clue in his letter to Madison, of February
29, 1788, where he writes:
A writer calling himself Plain Dealer, who is bitter in principle vs. the
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