Service Manual

MC/FC
Chassis, Mast & Options
EP16NT ETB11-20011-up
EP18NT ETB13-20011-up
EP20NT ETB13-70001-up

For use with EP16NT-EP20NT

Controller Service Manual. 99759-6B110
 FOREWORD

This service manual is a guide for servicing Cat ® lift trucks. For your convenience the
instructions are grouped by systems as a ready reference.

The long productive life of your lift trucks depend on regular and proper servicing. Servicing
consistent with what you will learn by reading this service manual. Read the respective
sections of this manual carefully and familiarize yourself with all of the components before
attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual are for trucks with
serial numbers in effect at the time of printing. Cat lift trucks 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 potentially hazardous

! WARNING situation which, if not avoided, could
result in death or serious injury.

Indicates a potentially hazardous

! CAUTION
situation which, if not avoided, may
result in death or serious injury or
damage to the machine.

Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.

Pub. No. 99759-6B110

 HOW TO READ THIS MANUAL

Disassembly diagram (example)

Each disassembly diagram is followed

by Disassembly sequence and
Suggestions for disassembly.

Disassembly sequence

Sequence
1. Cover, Bolt, Washer (part name)
2. Output shaft (part name)

Suggestion for disassembly

(1) Output shaft removal

Unit: mm (in.)
0.020 to 0.105
A
(0.00079 to 0.00413)
Clearance between
cylinder and piston 0.15
B
(0.0059)
A: Standard value B: Repair or service limit
 ! WARNING

SAFETY

! WARNING ! WARNING
The proper and safe lubrication and Do not operate these trucks unless you have
maintenance for these lift trucks, read and understand the instructions in the
recommended by Cat lift truck, are outlined in OPERATION & MAINTENANCE MANUAL.
the OPERATION & MAINTENANCE MANUAL. 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 on these trucks.
implements are blocked correctly to prevent them
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
The serviceman or mechanic may be unfamiliar with mounting or dismounting a truck. Clean any mud
many of the systems on this truck. This makes it or debris from steps, walkways or work platforms
important to use caution when performing service before using. Always face truck when using
work. A knowledge of the system and/or components steps, ladders and walkways. When it is not
is important before the removal or disassembly of any possible to use the designed access system,
component. provide ladders, scaffolds, or work platforms to
Because of the size of some of the truck components, perform safe repair operations.
the serviceman or mechanic should check the weights 6. To avoid back injury, use a hoist when lifting
noted in this Manual. Use proper lifting procedures components which weigh 23 kg (50 lb.) or more.
when removing any components. Make sure all chains, hooks, slings, etc., are in
Following is a list of basic precautions that should good condition and are of the correct capacity. Be
always be observed. sure hooks are positioned correctly. Lifting eyes
1. Read and understand all warning plates and decals are not to be side loaded during a lifting
on the truck before operating, lubricating or 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 8. Be careful when removing cover plates.
part of the truck or its attachments with a hammer Gradually back off the last two bolts or nuts
or sledge. Use welders gloves, hood/goggles, located at opposite ends of the cover or device and
apron and other protective clothing appropriate to pry cover loose to relieve any spring or other
the welding job being performed. Do not wear pressure, before removing the last two bolts or
loose-fitting or torn clothing. Remove all rings nuts completely.
from fingers when working on machinery. 9. Be careful when removing filler caps, breathers
3. Do not work on any truck that is supported only and plugs on the truck. Hold a rag over the cap or
by lift jacks or a hoist. Always use blocks or jack plug to prevent being sprayed or splashed by
stands to support the truck before performing any liquids under pressure. The danger is even greater
disassembly. if the truck has just been stopped because fluids
can be hot.
10. Always use tools that are in good condition and 19. Tighten connections to the correct torque. Make
be 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,
11. Reinstall all fasteners with same part number. vibration or rubbing against other parts during
Do not use a lesser quality fastener if operation. Shields that protect against oil spray
replacements are necessary. Do not mix metric onto hot exhaust components in event of a line,
fasteners with standard nuts and bolts. tube or seal failure, must be installed correctly.

12. If possible, make all repairs with the truck 20. Relieve all pressure in air, oil or water systems
parked on a level, hard surface. Block truck so it before any lines, fittings or related items are
does not roll while working on or under truck. disconnected or removed. Always make sure all
raised components are blocked correctly and be
13. Disconnect battery and discharge any capacitors
alert for possible pressure when disconnecting
(electric trucks) before starting to work on truck.
any device from a system that utilizes pressure.
Hang “Do not Operate” tag in the Operator’s
Compartment. 21. Do not operate a truck if any rotating part is
damaged or contacts any other part during
14. Repairs, which require welding, should be
operation. Any high speed rotating component
performed only with the benefit of the
that has been damaged or altered should be
appropriate reference information and by
checked for balance before reusing.
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.
15. Do not damage wiring during removal
operations. Reinstall the wiring so it is 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.
16. 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.
17. 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.
18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or 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.
 GROUP INDEX

GROUP INDEX Items

GENERAL INFORMATION Serial number locations, Dimensions, Technical data 1

VEHICLE ELECTRICAL
COMPONENTS
Console box, Key switch, Lamp specification chart 2

POWER TRAIN Procedure and suggestions for removal and installation 3

TRANSFER UNITS Procedures and suggestions for disassembly and reassembly 4

REAR AXLE Rear axle, Rear wheels 5

BRAKE SYSTEM Caliper, Brake pedal, Master cylinder 6

STEERING SYSTEM Steering control valve 7

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
HYDRAULIC SYSTEM Down safety valve 8

MASTS AND FORKS Simplex mast, Duplex mast, Triplex mast 9

Inspection standards, Periodic replacement of parts, Lubrication
SERVICE DATA standards, Main component weight, Tightening torque for standard bolts 10
and nuts, Special tools

OPTIONS Rearview mirror kit, Backup buzzer kit, Working lamp kit, Tire kit 11