CATERPILLAR CAT EP16NT EP18NT EP20NT FORKLIFT LIFT TRUCKS Service Repair Manual Instant Download

1
Service Manual
MC/FC
Chassis, Mast Options
EP16NT EP18NT EP20NT
ETB11-20011-up ETB13-20011-up ETB13-70001-up
For use with EP16NT-EP20NT Controller Service
Manual.
99759-6B110
2
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 situation
which, if not avoided, could result in death or
serious injury.
! WARNING
Indicates a potentially hazardous situation
which, if not avoided, may result in death or
serious injury or damage to the machine.
!
CAUTION
Indicates a condition that can cause damage to,
or shorten service life of, the machine.
NOTE
Pub. No. 99759-6B110
3
HOW TO READ THIS MANUAL Disassembly diagram
(example)
Each disassembly diagram is followed by
Disassembly sequence and Suggestions for
disassembly. Disassembly sequence

• Sequence
• Cover, Bolt, Washer (part name)
• Output shaft (part name)
• Suggestion for disassembly
• (1) Output shaft removal

Unit mm (in.)
Clearance between cylinder and piston A 0.020 to 0.105 (0.00079 to 0.00413)
Clearance between cylinder and piston B 0.15 (0.0059)
A Standard value
B Repair or service limit
4
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! WARNING
SAFETY
! WARNING
! WARNING
Do not operate these trucks unless you have read
and understand the instructions in the OPERATION
MAINTENANCE MANUAL. Improper truck operation
is dangerous and could result in injury or death.
The proper and safe lubrication and
maintenance for these lift trucks,
recommended by Cat lift truck, are outlined in
the OPERATION MAINTENANCE MANUAL. Improper
performance of lubrication or maintenance
procedures is dangerous and could result in
injury or death. Read and understand the
OPERATION MAINTENANCE MANUAL before performing
any lubrication or maintenance on these trucks.

1. Lower the forks or other implements to the ground
   before performing any work on the truck. If this
   cannot be done, make sure the forks or other
   implements are blocked correctly to prevent them
   from dropping unexpectedly.
2. 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. Always 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.
3. 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.
4. To avoid burns, be alert for hot parts on trucks
   which have just been stopped and hot fluids in
   lines, tubes and compartments.
5. 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.
6. 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 if the truck has just been stopped
   because fluids can be hot.

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
is 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.
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 lift jacks or a hoist. Always use blocks or
   jack stands to support the truck before
   performing any disassembly.

6

1. Always use tools that are in good condition and
   be sure you understand how to use them before
   performing any service work.
2. Reinstall all fasteners with same part number. Do
   not use a lesser quality fastener if
   replacements are necessary. Do not mix metric
   fasteners with standard nuts and bolts.
3. 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.
4. Disconnect battery and discharge any capacitors
   (electric trucks) before starting to work on
   truck. Hang Do not Operate tag in the
   Operators Compartment.
5. 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.
6. 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.
7. 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.
8. 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.
9. 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.

1. 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.
2. 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.
3. 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.

7
GROUP INDEX
GROUP INDEX Items
GENERAL INFORMATION Serial number locations, Dimensions, Technical data
VEHICLE ELECTRICAL COMPONENTS Console box, Key switch, Lamp specification chart
POWER 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
1
2
3
4
5
6
7
8
9
10
11
8
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
9
GENERAL INFORMATION
Vehicle Exterior
Control lever (MC models)
Joystick box (FC models)
211128
Models This manual applies to EP16NT, EP18NT and
EP20NT.
Truck Model Serial Number
EP16NT ETB11-20011-up (48V)
EP18NT ETB13-20011-up (48V)
EP20NT ETB13-70001-up (48V)
1-1
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GENERAL INFORMATION
Serial Number Locations Mast number
Chassis number
Nameplate
211268
1-2
11
GENERAL INFORMATION
Chassis and Mast Model Identification
Chassis EP
16 N T
Three wheel models Generation designator Maximu
m capacity 16 1600 kg (3500 lb) 18 1800 kg
(4000 lb) 20 2000 kg (4400 lb) Battery type
Mast 4
G
15
A
30
Maximum lifting height 30 stands for 3000 mm
(118 in.) Order of the minor change (A for
the original, B for the first change, C 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 (1 for the
original, 2 for the first change, and so on up
to 9)
1-3
12
GENERAL INFORMATION Dimensions
B
E
F
C
D A
211269
1-4
13
GENERAL INFORMATION
Technical Data
Truck Models Truck Models Truck Models Truck Models EP16NT EP18NT EP20NT
Class Class Class Class 1.6 ton 1.8 ton 2.0 ton
Load Capacity/Load Center Load Capacity/Load Center Load Capacity/Load Center N (kgf)/mm lbf/in. 15690 (1600)/500 3500/20 17650 (1800)/500 4000/20 19610 (2000)/500 4400/20
Truck size Length to Fork Face A Length to Fork Face A mm (in.) 1893 (74.5) 1996 (78.6) 2032 (80.0)
Truck size Width B Width B mm (in.) 1070 (42.1) 1070 (42.1) 1130 (44.5)
Truck size Height of Overhead C Guard Height of Overhead C Guard mm (in.) 2048 (80.6) 2048 (80.6) 2048 (80.6)
Wheelbase D Wheelbase D Wheelbase D mm (in.) 1307 (51.5) 1410 (55.5) 1410 (55.5)
Service Weight (including battery) Service Weight (including battery) Service Weight (including battery) kg (lb) 3090 (6812) 3290 (7253) 3520 (7760)
Tread Front/Rear E/F Tread Front/Rear E/F Tread Front/Rear E/F mm (in.) 913/170 (35.9/6.7) 913/170 (35.9/6.7) 935/170 (36.8/6.7)
Tires Number Front/Rear Tires Number Front/Rear Tires Number Front/Rear Tires Number Front/Rear 2/2 2/2 2/2
Tires Size Tires Size Front Front 18 ? 7-8 18 ? 7-8 200/50-10
Tires Size Tires Size Rear Rear 15 ? 4.5-8 15 ? 4.5-8 140/55-9
Turning Radius Turning Radius Turning Radius mm (in.) 1517 (59.7) 1620 (63.8) 1645 (64.8)
Travel Speeds Unloaded/Loaded Travel Speeds Unloaded/Loaded Travel Speeds Unloaded/Loaded km/h (mph) 17/17 (10.6/10.6) 17/17 (10.6/10.6) 17/17 (10.6/10.6)
Gradeability Loaded 5 min., at 1.6 km/h (1.0 mph) Gradeability Loaded 5 min., at 1.6 km/h (1.0 mph) Gradeability Loaded 5 min., at 1.6 km/h (1.0 mph) Gradeability Loaded 5 min., at 1.6 km/h (1.0 mph) 27 25 23
Lift Speeds Unloaded/Loaded Lift Speeds Unloaded/Loaded Lift Speeds Unloaded/Loaded m (in.)/sec 0.60/0.50 (23.6/19.7) 0.60/0.44 (23.6/17.3) 0.60/0.40 (23.6/15.7)
Lowering Speed Unloaded/Loaded Lowering Speed Unloaded/Loaded 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 Battery Voltage Battery Voltage V 48 48 48
Battery Rated Capacity (5 hrs.) MAX Ah Battery Rated Capacity (5 hrs.) MAX Ah Battery Rated Capacity (5 hrs.) MAX Ah Battery Rated Capacity (5 hrs.) MAX Ah 600 720 720
Battery Compartment Length ? Width ? Height Battery Compartment Length ? Width ? Height Battery Compartment Length ? Width ? Height mm (in.) 521 ? 1006 ? 650 (20.5 ? 39.6 ? 25.6) 624 ? 1006 ? 650 (24.6 ? 39.6 ? 25.6) 624 ? 1006 ? 650 (24.6 ? 39.6 ? 25.6)
Tilt Angle (forwards-backwards) Tilt Angle (forwards-backwards) Tilt Angle (forwards-backwards) Tilt Angle (forwards-backwards) 6-7 6-7 6-7
Traction Motor, 60 min short duty Traction Motor, 60 min short duty Traction Motor, 60 min short duty kW 2 ? 6.3 2 ? 6.3 2 ? 6.3
Hydraulic Motor Hydraulic Motor Hydraulic Motor kW 14 14 14
Traction Motor Control Method Traction Motor Control Method Traction Motor Control Method Traction Motor Control Method MOSFET MOSFET MOSFET
Hydraulic Motor Control Method Hydraulic Motor Control Method Hydraulic Motor Control Method Hydraulic Motor Control Method MOSFET MOSFET MOSFET
1-5
14
VEHICLE ELECTRICAL COMPONENTS
Console Box ............................................................................................ 2 1
Functions of Central Vehicle Monitor System ............................................ 2 1
Electrical Components in Console Box ..................................................... 2 5
Disassembly and Reassembly .................................................................. 2 6
Direction Lever ........................................................................................ 2 7
Accelerator Control ............................................................................... 2 8
Key Switch ............................................................................................... 2 9
Lighting Switch ....................................................................................... 2 9
Fuses ......................................................................................................... 2 10
Lamp Specification Chart .................................................................... 2 10
Troubleshooting of Lighting and Horn Systems ............................ 2 11
Joystick Box ............................................................................................ 2 12
2
15
VEHICLE ELECTRICAL COMPONENTS
1 6 2 5 3 4 103043
Console Box

1. Central vehicle monitoring system (CVMS)
2. Mode selector button
3. Steering tilt lever
4. Key switch
5. Lighting switch
6. Mode check button

NOTE
For setting the clock and selection of KPH or
MPH, refer to Selection of KPH or MPH and
Setting the clock.
Functions of Central Vehicle Monitor System (CVMS)
9 9 8
10
1 2 3 4 4 5 6 7
Operations Operations 211131
No. Monitor name Monitor name Monitor name When OFF When OFF When OFF When OFF When OFF When ON or flashing When ON or flashing When ON or flashing When ON or flashing Remarks Remarks
1 Service indicator Service indicator Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached.
Seat belt warning Seat belt warning Seat belt warning Seat belt is fastened. Seat belt is fastened. Seat belt is fastened. Seat belt is fastened. Seat belt is fastened. Seat belt is not Seat belt is not Seat belt is not Seat belt is not
2 light light light fastened when operator sits on seat fastened when operator sits on seat fastened when operator sits on seat fastened when operator sits on seat
(seat switch is turned (seat switch is turned (seat switch is turned (seat switch is turned
on). on). on). on).
2-1
16
VEHICLE ELECTRICAL COMPONENTS
No. Monitor name When OFF When OFF When OFF When OFF When OFF When OFF When ON or flashing Remarks
3 Controller/motor overheat indicator Controller, drive motors and pump motor in normal temperature Controller, drive motors and pump motor in normal temperature Controller, drive motors and pump motor in normal temperature Controller, drive motors and pump motor in normal temperature Controller, drive motors and pump motor in normal temperature Controller, drive motors and pump motor in normal temperature Overheating Overheating causes a significant output loss. When component temperature returns to normal levels, output power returns.
4 Remaining battery charge warning light Normal battery condition Normal battery condition Normal battery condition Normal battery condition Normal battery condition Normal battery condition Flashing indicates battery needs to be recharged soon. ON indicates battery needs to be recharged and lifting function inoperable.
5 Brake fluid level indicator Normal fluid level Normal fluid level Normal fluid level Normal fluid level Normal fluid level Normal fluid level Low fluid level
6 Parking brake warning light Parking brake disengaged Parking brake disengaged Parking brake disengaged Parking brake disengaged Parking brake disengaged Parking brake disengaged Parking brake disengaged
7 Malfunction lamp Normal Normal Normal Normal Normal Normal Vehicle malfunction
8 Speedometer KPH, MPH KPH, MPH KPH, MPH KPH, MPH KPH, MPH KPH, MPH KPH, MPH
8 Error indicator KPH, MPH KPH, MPH KPH, MPH KPH, MPH KPH, MPH KPH, MPH KPH, MPH
9 Battery discharge indicator When no bars show, vehicle is drivable but lifting function is inoperable. When no bars show, vehicle is drivable but lifting function is inoperable. When no bars show, vehicle is drivable but lifting function is inoperable. When no bars show, vehicle is drivable but lifting function is inoperable. When no bars show, vehicle is drivable but lifting function is inoperable. When no bars show, vehicle is drivable but lifting function is inoperable. When no bars show, vehicle is drivable but lifting function is inoperable. Indicates remaining battery power.
10 Hour meter 1 2 3 4 5 Advances every 0.1 hour (Number advances every 6 minutes.) Hour indication Advances every 0.1 hour (Number advances every 6 minutes.) Hour indication Advances every 0.1 hour (Number advances every 6 minutes.) Hour indication
2-2
17
VEHICLE ELECTRICAL COMPONENTS
Selection of KPH or MPH

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 for one to two seconds.

Button 1
Button 2
NOTICE Display will show KPH and a 24-hour clock
until it is changed. When MPH is selected, the
clock will change to a 12-hour clock.
Setting the clock
103043

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 until the minutes display
   flashes.
5. 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.

2-3
18
VEHICLE ELECTRICAL COMPONENTS Error code display
Indication Indication Condition
E E Indicator flashes if seat switch is turned off during driving operation. Then, indicator turns on when seat switch is turned on again. Indicator turns off when direction lever and accelerator pedal are returned.
(E) 0 ON Right traction motor overheated
E 1 ON Left traction motor overheated
E 2 ON Pump motor overheated
E 5 ON Right traction inverter overheated
E 6 ON Left traction inverter overheated
E 7 ON Pump inverter overheated
H 1 ON Faulty setting of lift lever
H 2 ON Faulty setting of tilt lever
H 3 ON Faulty setting of attachment 1 lever
H 4 ON Faulty setting of attachment 2 lever
H 5 ON Faulty setting of attachment 3 lever
(L) (L) Indicator flashes if seat switch is turned off during lifting operation. Then, H1 to H5 turn on when seat switch is turned on again. Indicator turns off when lifting operation is suspended.
2-4
19
VEHICLE ELECTRICAL COMPONENTS
Electrical Components in Console Box
Horn cable
Monitor cable
2
Direction lever switch cable
1
211132

1. Key switch
2. Lighting switch

2-5
20
VEHICLE ELECTRICAL COMPONENTS Disassembly and
Reassembly Disassembly
7 2 6 3 1 5 4 211133
Sequence

1. Console box (rear panel)
2. Key switch
3. Light switch

1. Console box (front panel)
2. Central vehicle monitor panel
3. Direction lever
4. Steering tilt lever

• Disassembly procedure
• Remove the front panel and monitor panel from the
  console box.
• Disconnect the harness connectors from the horn
  and direction lever.
• Remove the screw from the steering tilt lever,
  and remove the lever from the rear panel of the
  console box.
• Remove the rear panel.

T-nut Tilt steering lock lever Screw 211134
Reassembly Follow the disassembly procedure in
reverse.
2-6
21
VEHICLE ELECTRICAL COMPONENTS
Direction Lever Structure
4 4 1 2 3 211135

1. Lever
2. Harness

1. Connector
2. Screw

2-7
22
VEHICLE ELECTRICAL COMPONENTS Accelerator Control
Accelerator pedal
Initial position
Stopper bolt
1.5 to 2.5
Lock nut
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
• Disconnect the battery plug.
• Set the stopper bolt to 30 to 32 mm (1.18 to 1.26
  in.) from the floor to the upper face of bolt.
• Adjust the mounting angle 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 2.5 from the initial
  position.
• Make sure the inside switch turns ON by checking
  the continuity between the two terminals
  (indicated by arrows) by using an ohmmeter.

206805B
2-8
23
VEHICLE ELECTRICAL COMPONENTS
Key Switch
Terminal B M M
Connection destination Main fuse Battery Logic card Logic card
(OFF) ?
I (ON) ? ?
206806
Lighting Switch
Terminal 2 5 3 6
Connection destination Battery Battery Head lamps Working lamp
OFF ? ?
ON (1) ? ? ?
ON (2) ? ? ? ?
2
3
6 3 5 2
5
6
2
Head Lamp Fuse Working Lamp
211137
2-9
24
VEHICLE ELECTRICAL COMPONENTS Fuses
Capacity (A) Location Main connecting device
500 Contactor assembly Traction motor
500 Contactor assembly Pump motor
15 Fuse holder Key switch, Lighting switch
10 Fuse holder Power relay
NOTE Refer to Parts Manual for proper
replacement fuses.
Lamp Specification Chart
Item Lamp Quantity Bulb color Bulb Bulb Remarks
Item Lamp Quantity Bulb color 48 V External diagram Remarks
Head lamps 2 Clear 45 W
Working lamp 1 Clear 45 W
205833
2-10
25
VEHICLE ELECTRICAL COMPONENTS Troubleshooting of
Lighting and Horn Systems
Complaint Complaint Possible cause Remedy
Lamps-general Will not light Dead or weak battery Fuse(s) blown Open or short in circuit Poor grounding Bulbs burnt out Recharge or replace. Check and replace. Repair or replace. Clean ground spot and re-make connection. Replace.
Lamps-general Will light dimly Dead or weak battery Burned contact points in switches Loose terminals Dirty lenses Water drops inside lenses Bulbs expired service life Check and recharge. Repair or replace. Retighten. Clean. Dry and replace packing. Replace.
Head Will not light Lighting switch defective Bulbs burnt out Replace. Replace.
Other lamps Working lamp will not light Lamp switch defective Correct if improperly installed replace if
Other lamps internally defective.
Other lamps b) Bulbs burnt out Replace.
Horn Will not sound a) Fuse blown Check and replace.
Horn b) Open or short in circuit Repair or replace.
Horn c) Horn switch defective Replace.
Horn d) Horn defective Replace.
Horn e) Horn button defective Repair or replace.
Horn Will give an offensive sound Horn switch defective Horn defective Replace. Replace.
lamps
2-11
26
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.
Tilt control lever Lift control lever
Backward Raise Neutral Neutral Forward Lower
211138
(1) In the duplex 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
27
VEHICLE ELECTRICAL COMPONENTS
(2) This system provides the following safety
functions

1. When the pump motor is not running, the lift,
   tilt and attachment functions will not work even
   if the control levers are moved.
2. 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.
3. When the seat switch is not ON (the operator is
   not seated), the lift, tilt and attachments

functions will not work even if the control
levers are moved.
(d) The fault detection indicator 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.)
2-13
28
POWER TRAIN
Procedure and Suggestions for Removal and
Installation ......... 3 1 Removal
..................................................
..................................................
3 1 Installation .............................
..................................................
.................. 3 7 Service Data
..................................................
.......................................... 3 9
3
29

• POWER TRAIN
• Procedures and Suggestions for Removal and
  Installation
• Removal
• Remove the masts.
• (Refer to MASTS AND FORKS section.)
• Removing batteries

1. Disconnect the battery plug.
2. Open the battery cover, and lock it in the open
   position.
3. Remove the side covers (L.H., R.H.) and front
   covers (L.H., R.H.).

213016
(4) Attach suspending ropes or adequate lifting
device to the batteries. Unit kg (lb)
206918
Truck Model Item EP16NT EP18NT, EP20NT
Battery weight 1090 1225
(maximum) (2403) (2700)
(5) Remove the battery retaining plate and pin,
and then remove the batteries.
3-1
30
POWER TRAIN 3. Removing front wheels

• Pull the parking brake lever and block the rear
  wheels.
• Loosen the wheel nuts by two turns. Then, raise
  the front end of the truck using a hoist or the
  hydraulic system.
• Hoisting
• Using a sling and eye-bolts at both ends of the
  cross member at the top of the outer mast, lift
  the front end of the truck with a hoist.
• Using hydraulic system
• Tilt the mast fully backward and place wood
  blocks under the mast. Tilt the mast forward to
  raise the front end.

210757
!
CAUTION
After raising the front end, place jack stands
under the frame to prevent the truck from falling.

1. Remove the wheel nuts.
2. Remove the wheel.

Solid pneumatic tire Solid tire 206920
Truck Model Item 1 ton class 2 ton class
Tire size of front wheels 18 ? 7 - 8 200/50-10

• Removing steps and floor plates
• Steps (L.H., R.H.)
• Step plates (L.H., R.H.)
• Floor plate

(3)
Floor plate B
(1)
(1)
(2)
Remove floor plate B. Disconnect the accelerator
connector mounted on the back side of the floor
plate, then remove floor plate A.
Floor plate A
(2)
211153 3-2
31
POWER TRAIN
5. Removing steering hoses Disconnect the
steering hoses and pipes at the connectors.
206922
6. Removing delivery pipe and drive motor harness
MC models

• Remove the drive motor harness at the connector.
• Disconnect the harnesses of the thermal and speed
  sensors located on the right and left sides.
• The harnesses are secured to the delivery pipe
  with clamps. Loosen the clamps, and remove the
  delivery pipe.

Delivery pipe
211345
3-3
32
POWER TRAIN 7. Removing brake components
(i) (ii) (iii) (v) (iv)
(vi) 206824

• Loosen the parking brake lever, and remove
  parking brake cable assemblies (i) (L.H.) and
  (ii) (R.H.).
• Disconnect the parking brake cables at the
  calipers, and keep the cables together on the
  frame near the center brake.
• Position a drip pan, and disconnect brake fluid
  tube (iii) at the master cylinder.
• Disconnect brake pipes (iv, v) (L.H., R.H.) at
  the master cylinder. Disconnect the branch brake
  hoses (L.H., R.H.) from the brake pipes.
• Remove brake pedal assembly (vi).

3-4
33
POWER TRAIN
8. Removing return hoses Remove return hose (1)
from the control valve, and return hose (2) from
the lift cylinder.
(1) (2) 206925

• Remove drive motors cables (L.H., R.H.).
• Remove the generators (speed sensors) of the
  transfers (L.H., R.H.).
• Removing tension rods and brackets
• Loosen right and left nuts (1) by approximately 6
  mm (0.24 in.).
• Remove bolts (2), and take out bracket (3) and
  tension bolt (4) together from each side of the
  vehicle.

(3)
(3)
Left transfer
Right transfer
(2)
(2)
(4)
(1)
206926
3-5
34
POWER TRAIN 11. Removing transfer assemblies,
drive motors and calipers
Left transfer
Right transfer
(iii)
Gravity center
(ii)
(ii)
(i)
(i)
Frame
Frame
(iv)
Gravity center
(iii)
(iv)
206927
Remove the transfer assemblies with the drive
motors and calipers mounted. First, dismount the
left transfer, lower it, then pull it out from
the front of the vehicle. Then, dismount the
right transfer, lower it, then pull it out from
the front.
Cow hitch 206928

• When suspending the assembly, position the wire
  rope at the gravity center.
• The suspending wire rope must be cow hitched.
• When using a textile sling, make two loops to
  prevent slipping.
• Remove bolt (i) from the lower part of the step
  and remove bolt (ii) from the frame, then remove
  the assembly.
• Remove bolt (iii), and dismount the caliper
  assembly.
• Remove bolt (iv) and dismount the drive motor.
  (See illustration No. 206927.)

Total weight of transfer, drive motor and caliper
115 kg (253.5 lb)
3-6
35
POWER TRAIN
Installation Follow the removal sequence in
reverse. For installation, follow the
instructions below.
!
CAUTION
When mounting the transfer assembly on the frame,
do not insert a finger into the bolt hole to
check hole alignment. 1. Be sure to tighten
bolts to the specified torque.
Front of vehicle
3 4
4 3
5
5
2
2
1
1
206785
A Standard value
Unit Nm (kgfm) lbfft
Tightening torque Drive motor mounting bolt 1 A 108 10 (11 1) 79.56 7.23
Tightening torque Transfer assembly mounting bolt 2 A 508 51 (51.8 5.2) 374.7 37.6
Tightening torque Bracket mounting bolt 3 A 176 18 (17.9 1.8) 129.5 13.0
Tightening torque Bolt nut 4 A 231 24 (23.6 2.4) 170.7 17.4
Tightening torque Hub nut 5 A 157 (16) 115.8
2. Bleed the brake oil line. (Refer to BRAKE
SYSTEM section.)
3-7
36
POWER TRAIN

• After installing the parking brake cable, be sure
  to adjust.
• (Refer to BRAKE SYSTEM section.)
• Pour oil into the transfer cases Remove oil
  level plug (1). Remove oil inlet plug (2).
• Pour appropriate oil in the oil inlet. Make sure
  the oil level reaches the level plug location.
• Unit liter (U.S. gal)

Left transfer (2) (1) Front of
vehicle Right transfer (2) (1) 206786
Left transfer Right transfer
Oil quantity 1.09 (0.29) 1.86 (0.49)

• Bleeding hydraulic oil line and inspecting oil
  level
• Operate the tilt cylinders in the forward and
  backward directions to bleed the tilt cylinders.
  Operate the lift cylinders in the vertical
  directions to fill the cylinders with oil.
• Lower the lift cylinders to the lowest position,
  and check the oil level gauge. If the oil level
  is low, add oil to the specified level.
• Checking steering oil line
• Operate the steering wheel to make sure that it
  operates smoothly.

3-8
37
POWER TRAIN
Service Data
A Standard value
Truck Models Item Truck Models Item Truck Models Item Truck Models Item Truck Models Item Truck Models Item Truck Models Item 1 ton class 1 ton class 1 ton class 2 ton class 2 ton class
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Drive motor mounting bolt 1 Drive motor mounting bolt 1 Drive motor mounting bolt 1 A 108 10 (11 1) 79.56 7.23 108 10 (11 1) 79.56 7.23 108 10 (11 1) 79.56 7.23 108 10 (11 1) 79.56 7.23 108 10 (11 1) 79.56 7.23
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Transfer assembly mounting bolt 2 Transfer assembly mounting bolt 2 Transfer assembly mounting bolt 2 A 508 51 (51.8 5.2) 374.7 37.6 508 51 (51.8 5.2) 374.7 37.6 508 51 (51.8 5.2) 374.7 37.6 508 51 (51.8 5.2) 374.7 37.6 508 51 (51.8 5.2) 374.7 37.6
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Bracket mounting bolt 3 Bracket mounting bolt 3 Bracket mounting bolt 3 A 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Bolt nut 4 Bolt nut 4 Bolt nut 4 A 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Hub nut 5 Hub nut 5 Hub nut 5 A 157 (16) 115.8 157 (16) 115.8 157 (16) 115.8 157 (16) 115.8 157 (16) 115.8
Power Line 5 2 1 3 4 4 3 1 2 5 206785
3-9
38
TRANSFER UNITS
Specifications .......................................................................................... 4 1
Structure and Functions ....................................................................... 4 2
Procedures and Suggestions for Disassembly and
Reassembly ............................................................................................. 4 4
Disassembly ............................................................................................. 4 4
Inspection after Disassembly .................................................................... 4 5
Reassembly .............................................................................................. 4 6
Service Data ............................................................................................ 4 8
4
39
TRANSFER UNITS
Specifications
Truck Model Item Truck Model Item 1 ton class 2 ton class
Transfer Gear type Constant-mesh type, 3 stages (helical gears) Constant-mesh type, 3 stages (helical gears)
Transfer Reducing gear ratio 58 x 83 x 45 20.151 24 16 28 58 x 83 x 45 20.151 24 16 28
4-1
40
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41
TRANSFER UNITS Structure and Functions (Part 1)
Front of vehicle
7
7
A
A
8
8
9
6
6
3
1
5
4
5
2
206785

1. Transfer (left)
2. Traction motor (left)
3. Transfer (right)
4. Traction motor (right)
5. Frame

1. Wheel hub
2. Front tire
3. Bracket
4. Tension rod

Section A Mast support mounting section
Since two traction motors are installed in a
limited space, the traction motors are offset in
position. Tension rod 9 connects brackets 8, and
includes a turnbuckle to serve as a thrust rod
for the left and right transfer units.
Sections A support masts.
4-2
42
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