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Caterpillar EP16CPN to EP20PN Chassis and Mast Service Manual 99759-6M120
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Caterpillar EP16CPN to EP20PN Chassis and Mast Service Manual 99759-6M120

$50.00

  • Type Of Manual: Service Manual
  • Manual ID: 99759-6M120
  • Number of Pages: 346
  • Size: 29.1MB
  • Format: PDF
Category:
  • Model List:

    • EP16CPN, EP18CPN, EP16PN, EP18PN, EP20PN
  • 1. _FOREWORD
  • 2.
  • 3. _GENERAL_INFORMATION
  • 4. _ELECTRICAL_COMPONENTS
  • 5. _POWER_TRAIN
  • 6. _TRANSFER_UNITS
  • 7. _REAR_AXLE
  • 8. _BRAKE_SYSTEM
  • 9. _STEERING_SYSTEM
  • 10. _HYDRAULIC_SYSTEM
  • 11. _MAST_AND_FORKS
  • 12. _SERVICE_DATA
  • 13. _PANEL_CABIN
  • 13.1. FOREWORD
  • 13.1.1. Safety
  • 13.1.2. LOCKOUT/TAGOUT
  • 13.1.3. How to Use This Manual
  • 13.1.3.1. Forklift Model
  • 13.1.4. Symbols and Abbreviations
  • 13.1.5. Units
  • 13.2. Chapter 1 GENERAL INFORMATION
  • 13.2.1. Model View
  • 13.2.2. Lift Truck Models Covered
  • 13.2.3. Serial Number Locations
  • 13.2.4. Specifications
  • 13.3. Chapter 2 ELECTRICAL COMPONENTS
  • 13.3.1. Console
  • 13.3.1.1. MC Model
  • 13.3.1.2. FC Model
  • 13.3.2. Disassembling Console
  • 13.3.2.1. Disassembling Sequence
  • 13.3.2.2. Suggestions for Disassembly
  • 13.3.3. Assembling Console
  • 13.3.4. Meter panel
  • 13.3.4.1. Functions of Meter panel
  • 13.3.4.2. Adjusting and Setting of Meter panel
  • 13.3.4.3. Diagnostic Code List
  • 13.3.5. Key Switch
  • 13.3.6. Lighting Switch (Rear Working Light)
  • 13.3.6.1. Lights
  • 13.3.6.2. Specification Chart
  • 13.3.7. Horn Switch and Battery Disconnect Switch
  • 13.3.7.1. MC Model
  • 13.3.7.2. FC Model
  • 13.3.8. Troubleshooting of Lighting and Horn Systems
  • 13.3.9. Parking Brake Switch
  • 13.3.10. Combination Switch
  • 13.3.10.1. Direction lever
  • 13.3.10.2. Light Switch, Turn Signal Switch (option)
  • 13.3.11. Disassembling Accelerator Control
  • 13.3.11.1. Disassembling Sequence
  • 13.3.11.2. Adjusting
  • 13.3.12. FC Armrest
  • 13.3.12.1. Lift Switch
  • 13.3.12.2. Tilt Switch
  • 13.3.12.3. Armrest FNR Switch (FC Model Option)
  • 13.3.12.4. Forward and Backward Adjustment
  • 13.3.12.5. Up and Down Adjustment
  • 13.3.13. Foot Direction Control (Option)
  • 13.3.14. Dual Pedal (Option)
  • 13.3.15. Fuses
  • 13.4. Chapter 3 POWER TRAIN
  • 13.4.1. Removing Battery
  • 13.4.2. Removing Front Wheels
  • 13.4.3. Removing Transfer Assemblies, Traction Motors
  • 13.4.4. Installing Transfer Assemblies, Traction Motors and Calipers
  • 13.4.5. Service Data
  • 13.5. Chapter 4 TRANSFER UNITS
  • 13.5.1. Specifications
  • 13.5.2. Structure
  • 13.5.2.1. External View
  • 13.5.2.2. Structure
  • 13.5.3. Disassembling Transfer Units
  • 13.5.3.1. Preparation
  • 13.5.3.2. Disassembly Sequence
  • 13.5.4. Inspecting Transfer Units
  • 13.5.5. Assembling Transfer Units
  • 13.5.5.1. Assembly Sequence
  • 13.5.6. Service Data
  • 13.6. Chapter 5 REAR AXLE
  • 13.6.1. Structure
  • 13.6.1.1. Rear Axle
  • 13.6.1.2. Steering Cylinder
  • 13.6.2. Removing Rear Wheels
  • 13.6.2.1. Earth wire
  • 13.6.2.2. Preparation
  • 13.6.2.3. Removing Wheels
  • 13.6.3. Installing Rear Wheel
  • 13.6.4. Removing Rear Axle Assembly
  • 13.6.4.1. Preparation
  • 13.6.4.2. Removal Sequence
  • 13.6.4.3. Suggestions for Removal
  • 13.6.5. Installing Rear Axle Assembly
  • 13.6.6. Disassembling Rear Axle Assembly
  • 13.6.6.1. Disassembly Sequence
  • 13.6.6.2. Suggestions for Disassembly
  • 13.6.7. Inspection Rear Axle Assembly
  • 13.6.8. Installing Steering Cylinder and Hydraulic Pipe
  • 13.6.8.1. Installation Sequence
  • 13.6.9. Assembling Knuckle and Kingpin
  • 13.6.9.1. Assembly Sequence
  • 13.6.9.2. Suggestions for Assembly
  • 13.6.10. Assembling Rear Axle Hub
  • 13.6.10.1. Assembly Sequence
  • 13.6.10.2. Suggestions for Assembly
  • 13.6.11. Removing Steering Sensor
  • 13.6.12. Installing Steering Sensor Assembly
  • 13.6.13. Disassembling Steering Cylinder
  • 13.6.13.1. Disassembly Sequence
  • 13.6.13.2. Suggestions for Disassembly
  • 13.6.14. Inspecting Steering Cylinder
  • 13.6.15. Assembling Steering Cylinder
  • 13.6.15.1. Assembly Sequence
  • 13.6.15.2. Suggestions for Assembly
  • 13.6.16. Adjustment
  • 13.6.16.1. Adjusting of Steering Sensor
  • 13.6.16.2. Adjusting of Minimum Turning Radius
  • 13.6.17. Troubleshooting
  • 13.6.18. Service Data
  • 13.6.18.1. Rear axle
  • 13.6.18.2. Steering cylinder
  • 13.7. Chapter 6 BRAKE SYSTEM
  • 13.7.1. Specifications
  • 13.7.2. Structure
  • 13.7.2.1. Outline of Brake System
  • 13.7.2.2. Brake Pedal Assembly
  • 13.7.2.3. Electro-magnetic Brake Assembly
  • 13.7.3. Removing Master Cylinder
  • 13.7.3.1. Removal Sequence
  • 13.7.4. Disassembling Master Cylinder
  • 13.7.4.1. Disassembly Sequence
  • 13.7.5. Inspecting and Adjusting Master Cylinder
  • 13.7.6. Assembling Master Cylinder
  • 13.7.7. Inspecting and Adjusting Brake Pedal Assembly
  • 13.7.8. Adjusting and Manual Release of Electro-Magnetic Brake
  • 13.7.9. Troubleshooting
  • 13.7.9.1. Brake Pedal Assembly
  • 13.7.9.2. Parking Brake
  • 13.7.10. Service Data
  • 13.7.10.1. Brake Pedal
  • 13.7.10.2. Master Cylinder
  • 13.8. Chapter 7 STEERING SYSTEM
  • 13.8.1. Specifications
  • 13.8.2. Structure
  • 13.8.2.1. Outline of Steering System
  • 13.8.3. Removing Steering Linkage Assembly
  • 13.8.3.1. Removal Sequence
  • 13.8.3.2. Suggestions for Removal
  • 13.8.4. Inspecting Steering Linkage Assembly
  • 13.8.5. Installing Steering Linkage Assembly
  • 13.8.6. Removing PS Pump Assembly
  • 13.8.6.1. Removal Sequence
  • 13.8.6.2. Suggestions for Removal
  • 13.8.7. Installing PS Pump Assembly
  • 13.8.8. Disassembling PS Pump Assembly
  • 13.8.8.1. Hydraulic Oil Drain Procedure
  • 13.8.8.2. Disassembly Sequence
  • 13.8.9. Assembling PS Pump Assembly
  • 13.8.10. Inspecting PS Pump Assembly
  • 13.8.11. Troubleshooting
  • 13.8.12. Service Data
  • 13.8.12.1. PS Pump Assembly
  • 13.8.12.2. Reserve Tank
  • 13.9. Chapter 8 HYDRAULIC SYSTEM
  • 13.9.1. Specifications
  • 13.9.1.1. MC model
  • 13.9.1.2. FC model
  • 13.9.2. Structure
  • 13.9.2.1. Hydraulic Line (MC Model)
  • 13.9.2.2. Hydraulic Line (FC Model)
  • 13.9.2.3. Lift and Tilt Cylinders
  • 13.9.2.4. Down Safety Valve
  • 13.9.3. Removing Control Valve (MC Model)
  • 13.9.3.1. Preparation
  • 13.9.3.2. Suggestions for Removal
  • 13.9.4. Installing Control Valve
  • 13.9.5. Removing Gear Pump
  • 13.9.5.1. Preparation
  • 13.9.5.2. Suggestions for Removal
  • 13.9.6. Installing Gear Pump
  • 13.9.7. Removing Suction Filter and Return Filter
  • 13.9.7.1. Preparation
  • 13.9.7.2. Suggestions for Removal
  • 13.9.8. Installing Suction Filter and Return Filter
  • 13.9.8.1. Suggestions for Installation
  • 13.9.9. Removing Lift Cylinders (Simplex Mast)
  • 13.9.9.1. Removal Sequence
  • 13.9.9.2. Suggestions for Removal
  • 13.9.10. Removing Lift Cylinders (Triplex Mast and Duplex Mast)
  • 13.9.10.1. Removal Sequence
  • 13.9.10.2. Suggestions for Removal
  • 13.9.11. Installing Lift Cylinder
  • 13.9.11.1. Suggestions for Installation
  • 13.9.12. Removing Tilt Cylinders
  • 13.9.12.1. Preparation
  • 13.9.12.2. Suggestions for Removal
  • 13.9.13. Disassembling Lift cylinder
  • 13.9.13.1. Disassembly Sequence
  • 13.9.14. Assembling Lift Cylinder
  • 13.9.14.1. Assembly Sequence
  • 13.9.14.2. Suggestions for Assembly
  • 13.9.15. Disassembling Tilt Cylinder
  • 13.9.15.1. Disassembly Sequence
  • 13.9.16. Assembling Tilt Cylinder
  • 13.9.16.1. Assembly Sequence
  • 13.9.17. Inspecting and Adjusting Hydraulic System
  • 13.9.17.1. Hydraulic Oil
  • 13.9.17.2. Control Valve
  • 13.9.17.3. Adjusting Main Relief Valve (MC model)
  • 13.9.17.4. Adjusting Microswitch
  • 13.9.17.5. Adjusting Tilt Cylinder
  • 13.9.17.6. Adjusting Lift Cylinder Stroke
  • 13.9.17.7. Inspecting Piping
  • 13.9.18. Tests
  • 13.9.18.1. Vertical Drift Test
  • 13.9.18.2. Tilt Drift Test
  • 13.9.19. Troubleshooting
  • 13.9.20. Service Data
  • 13.9.20.1. Gear Pump
  • 13.9.20.2. Control Valve (MC)
  • 13.9.20.3. Lift Cylinder
  • 13.9.20.4. Tilt Cylinder
  • 13.9.21. MC Control Valve
  • 13.9.21.1. General Description
  • 13.9.21.2. Hydraulic Circuit Diagram
  • 13.9.21.3. Hydraulic Circuit
  • 13.9.21.4. Structure – Inlet Cover Section
  • 13.9.21.5. Structure – Lift Valve
  • 13.9.21.6. Structure – Tilt Valve
  • 13.9.22. Construction and Function of FC Control Valve
  • 13.9.22.1. Outline
  • 13.9.22.2. FC Hydraulic System Circuit
  • 13.9.22.3. Bleed-off valve
  • 13.9.22.4. Lift Valve
  • 13.9.22.5. Tilt Valve
  • 13.9.22.6. Attachment Valve
  • 13.9.23. Removing FC Control Valve
  • 13.9.23.1. Preparation
  • 13.9.23.2. Removal Sequence
  • 13.9.23.3. Suggestions for Removal
  • 13.9.24. Installing FC Control Valve
  • 13.9.25. Disassembly of FC Control Valve
  • 13.9.25.1. Disassembly Sequence
  • 13.9.25.2. Suggestions for Disassembly
  • 13.9.26. Assembly of FC Control Valve
  • 13.9.27. Valves Included in the Inlet Section
  • 13.9.28. Disassembling Inlet Section
  • 13.9.28.1. Disassembly Sequence (Part 1)
  • 13.9.28.2. Disassembly Sequence (Part 2)
  • 13.9.28.3. Disassembly Sequence (Part 3)
  • 13.9.28.4. Disassembly Sequence (Part 4)
  • 13.9.28.5. Suggestions for Disassembly
  • 13.9.29. Valves Included in Tilt Section
  • 13.9.30. Disassembling Tilt Section
  • 13.9.30.1. Disassembly Sequence (Part 1)
  • 13.9.30.2. Disassembly Sequence (Part 2)
  • 13.9.30.3. Suggestions for Disassembly
  • 13.9.31. Valves Incorporated in Attachment Section
  • 13.9.32. Disassembling Attachment Section
  • 13.9.32.1. Disassembly Sequence (Part 1)
  • 13.9.32.2. Disassembly Sequence (Part 2)
  • 13.9.32.3. Suggestions for Disassembly
  • 13.9.33. Disassembling End Cover Plate
  • 13.9.34. Cleaning
  • 13.9.35. Inspecting
  • 13.9.36. Precautions for Assembly
  • 13.9.37. Assembling Inlet Section
  • 13.9.37.1. Suggestions for Assembly
  • 13.9.37.2. Disassembly Sequence
  • 13.9.37.3. Suggestions for Assembly
  • 13.9.38. Assembling Tilt Section
  • 13.9.38.1. Suggestions for Assembly
  • 13.9.39. Assembling Attachment Section
  • 13.9.39.1. Suggestions for Assembly
  • 13.9.40. Solenoid Control Valve
  • 13.9.41. Service Data
  • 13.10. Chapter 9 MAST AND FORKS
  • 13.10.1. Mast System
  • 13.10.1.1. Mast Model Code Stamping Position
  • 13.10.1.2. Explanation of Mast Model Code
  • 13.10.1.3. Mast Code and Type
  • 13.10.2. Description
  • 13.10.2.1. Simplex Mast (Dual-Stage Panoramic Mast)
  • 13.10.2.2. Duplex Mast (Dual-Stage Full Free Panoramic Mast)
  • 13.10.2.3. Triplex Mast (Triple-Stage Full Free Panoramic Mast)
  • 13.10.2.4. Operation of Duplex Mast
  • 13.10.2.5. Operation of Triplex Mast
  • 13.10.3. Removing Simplex Mast
  • 13.10.3.1. Removal Sequence
  • 13.10.3.2. Suggestions for Removal
  • 13.10.4. Installing Simplex Mast
  • 13.10.5. Removing Triplex Mast, Duplex Mast
  • 13.10.5.1. Removal Sequence
  • 13.10.5.2. Suggestions for Removal
  • 13.10.6. Installing Triplex Mast, Duplex Mast
  • 13.10.7. Disassembling Simplex Mast
  • 13.10.7.1. Disassembly Sequence
  • 13.10.7.2. Suggestions for Disassembly
  • 13.10.7.3. Inspecting Simplex Mast
  • 13.10.7.4. Assembling Simplex Mast
  • 13.10.8. Disassembling Duplex Mast
  • 13.10.8.1. Disassembly Sequence
  • 13.10.8.2. Suggestions for Disassembly
  • 13.10.8.3. Inspecting Duplex Mast
  • 13.10.8.4. Assembling Duplex Mast
  • 13.10.9. Disassembling Triplex Mast
  • 13.10.9.1. Disassembly Sequence
  • 13.10.9.2. Suggestions for Disassembly
  • 13.10.10. Inspecting Triplex Mast
  • 13.10.11. Assembling Triplex Mast
  • 13.10.12. Mast Height Sensor (Option)
  • 13.10.12.1. Installing Mast Height Sensor
  • 13.10.13. Inspecting and Adjusting Mast and Forks
  • 13.10.13.1. Forks (All Mast Models)
  • 13.10.13.2. Chain Tension Adjustment – Simplex Mast
  • 13.10.13.3. Chain Tension Adjustment – Duplex Mast
  • 13.10.13.4. Chain Tension Adjustment – Triplex Mast
  • 13.10.13.5. Clearance Adjustment for Lift Bracket
  • 13.10.13.6. Mast Clearance Adjustment
  • 13.10.13.7. Main Roller Shim Replacement – Simplex Mast
  • 13.10.13.8. Main Roller Shim Replacement – Duplex Mast
  • 13.10.13.9. Main Roller Shim Replacement – Triplex Mast
  • 13.10.13.10. Mast Strip Adjustment
  • 13.10.13.11. Tilt Angle Adjustment
  • 13.10.13.12. Lift Cylinder Stroke Adjustment
  • 13.10.14. Troubleshooting
  • 13.10.15. Service Data
  • 13.10.15.1. Simplex Mast, Duplex Mast, Triplex Mast
  • 13.11. Chapter 10 Service Data
  • 13.11.1. Inspection Standards
  • 13.11.2. Periodic Replacement of Parts
  • 13.11.2.1. Critical Safety Parts
  • 13.11.3. Tightening Torques for Standard Bolts and Nuts
  • 13.11.3.1. Metric Fine Thread
  • 13.11.3.2. Metric Coarse Thread
  • 13.11.4. Lubrication Instructions
  • 13.11.4.1. Lubrication Chart
  • 13.11.4.2. Recommended Oils and Greases
  • 13.11.4.3. Capacity
  • 13.11.5. Weight of Major Devices
  • 13.11.6. Special tools
  • 13.12. Chapter 11 Panel Cabin
  • 13.12.1. Battery Exchange or Battery Charging
  • 13.12.2. Cleaning Top Roof
  • 13.12.3. Replacing Top Roof
  • 13.12.4. Maintenance
  • 13.13. BACK COVER
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