99759-92100

Service Manual

Options Supplement

EP16KT ETB4A-00011-up (48 V)

EP16KT ETB4B-00011-up (36 V)
EP18KT ETB5A-00011-up (48 V)
EP18KT ETB5B-00011-up (36 V)
EP20KT ETB5A-50001-up (48 V)
EP20KT ETB5B-50001-up (36 V)
 FOREWORD

This service manual is a guide to servicing of the options for Caterpillar® Lift Truck models
EP16KT, EP18KT and EP20KT.

Long productive life of your lift trucks depends to a great extent on correct servicing – the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know 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 were of the trucks of
serial numbers in effect at the time it was approved for printing. Caterpillar 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:

WARNING Indicates a specific potential hazard

resulting in serious bodily injury or
death.

CAUTION Indicates a specific potential hazard

resulting in bodily injury, or damage
to, or destruction of, the machine.

Indicates a condition that can cause

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

Pub. No. 99759-92100

 WARNING

SAFETY

WARNING WARNING
The proper and safe lubrication and Do not operate this truck unless you have
maintenance for this lift truck, recommended read and understand the instructions in the
by Caterpillar, are outlined in the OPERATION & MAINTENANCE MANUAL.
OPERATION & MAINTENANCE MANUAL for Improper truck operation is dangerous and
these trucks. could result in injury or death.
Improper performance of lubrication or
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 & before performing any work on the truck. If this
MAINTENANCE MANUAL before performing cannot be done, make sure the forks or other
any lubrication or 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 work.
or debris from steps, walkways or work platforms
A knowledge of the system and/or components is
before using. Always face truck when using steps,
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 welder’s 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 18. Loose or damaged fuel, lubricant and hydraulic
sure you understand how to use them before lines, tubes and hoses can cause fires. Do not
performing any service work. bend or strike high pressure lines or install ones
11. Reinstall all fasteners with same part number. Do which have been bent or damaged. Inspect lines,
not use a lesser quality fastener if replacements tubes and hoses carefully. Do not check for leaks
are necessary. Do not mix metric fasteners with with your hands. Pin hole (very small) leaks can
standard nuts and bolts. result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
12. If possible, make all repairs with the truck parked
the skin and cause personal injury. Use cardboard
on a level, hard surface. Block truck so it does not
or paper to locate pin hole leaks.
roll while working on or under truck.
19. Tighten connections to the correct torque. Make
13. Disconnect battery and discharge any capacitors
sure that all heat shields, clamps and guards are
(electric trucks) before starting to work on truck.
installed correctly to avoid excessive heat,
Hang “Do not Operate” tag in the Operator’s
vibration or rubbing against other parts during
Compartment.
operation. Shields that protect against oil spray
14. Repairs, which require welding, should be onto hot exhaust components in event of a line,
performed only with the benefit of the appropriate tube or seal failure, must be installed correctly.
reference information and by personnel adequately
20. Relieve all pressure in air, oil or water systems
trained and knowledgeable in welding procedures.
before any lines, fittings or related items are
Determine type of metal being welded and select
disconnected or removed. Always make sure all
correct welding procedure and electrodes, rods or
raised components are blocked correctly and be
wire to provide a weld metal strength equivalent at
alert for possible pressure when disconnecting any
least to that of parent metal.
device from a system that utilizes pressure.
15. Do not damage wiring during removal operations.
21. Do not operate a truck if any rotating part is
Reinstall the wiring so it is not damaged nor will it
damaged or contacts any other part during
be damaged in operation by contacting sharp
operation. Any high speed rotating component
corners, or by rubbing against some object or hot
that has been damaged or altered should be
surface. Do not connect wiring to a line
checked for balance before reusing.
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.
 AMBER STROBE KIT

208640

This kit consists of following parts:

1 Bracket 5 Terminal (male)
2 Bolt 6 Terminal (female)
3 Nut, Spring washer, Washer 7 Machine screw
4 Strobe lamp 8 Nut, Spring washer, Washer

Installation
Start by:
The harness C must have been installed. The harness C is a component of the headlamp kit. If the headlamp kit
has not been installed yet, install it before starting this operation.

1. Attach male terminal 5 and female terminal 6 to the strobe lamp’s red wire and black wire, respectively. (No
detrimental problem will occur even if the terminals are attached to the wires reversely.)
2. Install strobe lamp 4 on bracket 1 using machine screws 7 as well as nut, spring washer, and washers 8. (2
places)
3. Install in position the bracket 1 fitted with the strobe lamp on the head guard (there are holes for this purpose)
using two each of bolts 2, nuts, spring washers and washers 3.
4. Connect the strobe lamp’s terminals (5 and 6) to the harness C’s terminals assigned to the strobe lamp.
5. Insulate the connected terminal pairs from each other by wrapping electrical tape round each terminal pair. If
there is slack in the harness, bundle it neatly with tape or clips.
6. Place the direction lever in the Reverse (R) position to check that the strobe lamp flickers.

–1–
 BACK BUZZER KIT

208641

This kit consists of following parts:

1 Buzzer 4 Clip band
2 Washer 5 Terminal (male)
3 Bolt 6 Terminal (female)

Installation
Start by:
The harness C must have been installed. The harness C is a component of the headlamp kit. If the headlamp kit
has not been installed yet, install it before starting this operation.

1. Attach male terminal 5 and female terminal 6 to the buzzer’s red wire and black wire, respectively.
2. Install in position the buzzer 1 on the leg of the head guard (there are holes for this purpose) using two each of
washers 2 and bolts 3.
3. Route the buzzer wires into the counterweight passing through the gap in it (see drawing). Then connect buzzer
terminals 5 and 6 to the harness C’s terminals assigned to the buzzer.
4. Insulate the connected terminal pairs from each other by wrapping electrical tape round each terminal pair. If
there is slack in the harness, bundle it with tape or clips.
5. Hold the wires on the leg of the head guard with clip band 4. Tuck the excess wires into the counterweight
neatly.
6. Place the direction lever in the Reverse (R) position to make sure that the backup buzzer sounds.

–2–
 HEAD LAMP KIT (48 V and 36 V)
(Not applicable to EU models)

208642

This kit consists of following parts:

1 Head lamp (48 V or 36 V)*… 2 pcs. 6 Harness D … 2 pcs.
2 Rear working lamp (48 V or 36 V)*… 1 pc. 7 Switch assembly … 1 pc.
3 Light bracket … 3 pcs.
4 Bolt washer assembly … 6 pcs. *: Headlamp 1 and rear working lamp 2 are
5 Harness C … 1pc. completely the same except their names.

Installation
1. Install light brackets 3 in position on the head guard (there are holes for this purpose) using bolt and washer
assemblies 4 (use two bolt and washer assemblies for each bracket).
2. Attach the lamps to brackets 3 using the bolts and nuts A supplied with the kit (two lamps at the front; one lamp
at the rear).
3. Pass harness C 5 through the head guard’s rear left pillar with its connector end facing down (see the harness C
drawing on the next page).
4. Pass one harness D 6 through the head guard’s front pillar and the other through the front right pillar, with the
end having black wire fitted with a female terminal of each harness facing down (see the harness D drawing on
the next page).
5. Connect the harness C’s and harness D’s terminals to the corresponding headlamp and rear working lamp
terminals as well as to the harness B’s terminals.
6. Insulate the connected terminal pairs from each other by wrapping electrical tape round each terminal pair. If
there is slack in any harness, tuck excess wires into the corresponding head guard pillar neatly. Bundle harness B
if necessary with tape or clips.

–3–
 208643

7. Check the direction in which the switch assembly 7 (lighting switch) should be installed (see drawing above).
Install the switch assembly in position on the console box.
8. Connect the lighting switch according to the drawing above.

Lighting Switch

208644 103042

9. Perform lamp operation test. Place the switch in the OFF, ON1, and ON2 positions one after another to make
sure that the lamps are in the following conditions.
OFF position: All lamps are OFF.
ON1 position: Only headlamps are ON.
ON2 position: Both headlamps and rear working lamp are ON.
10. Check the light beam angles regarding the following. Adjust them if necessary.
(a) Any lamp beam must not be above the horizontal.
(b) Each lamp beam center must be parallel with straightly forward or backward lines with tolerance of 15°.

–4–
 REARVIEW MIRROR KIT
(Not applicable to EU models)

208645

This kit consists of following parts:

1 Bracket (for rearview mirror) … 2 pcs. 4 Bolt … 2 pcs.
2 Spring washer … 2 pcs. 5 Rearview mirror … 2 pcs.
3 Nut … 2 pcs.

Installation
1. The dimension shown in the drawing is a typical dimension.
2. The rearview mirror is usually mounted on the outer side of a head guard pillar. It also can be mounted on the
inner side of the pillar.

–5–
 ADDITIONAL-ON CONTROL VALVE KIT
(For MC model)
Description
This kit includes all the parts necessary for adding a No. 4 section valve to the standard MC hydraulic control valve.

This kit consists of following

parts:
1 Valve assembly
2 Tie rod
3 Tie rod
4 Rod
5 Pin
6 Snap pin
7 Washer
8 Clevis pin
9 Split pin
10 Washer
11 Bushing
12 Lever
13 Knob
14 Microswitch

208646

Installation
1. Remove the existing tie rod nuts to detach the end cover.
2. Add the No. 4 section valve to the existing control valve sections and secure them together using tie rods 2 and 3,
and the existing tie rod nuts. Tighten the nuts to the torque indicated in the drawing.
3. Install the microswitch 14.
4. Install lever 12 on the shaft.
5. Connect the control valve to the lever.
6. Adjust the microswitch. Follow the instructions in the Service Manual for the method of adjustment.

–6–
 FOOT-OPERATED DIRECTION CONTROL KIT
(Not applicable to US EE model)
Description
This kit is used to convert the hand-operated forward/reverse directional control mechanism into a foot-operated
control (pedal) mechanism which combines also the accelerator control function.

208647

This kit consists of following parts:

1 Pedal assembly
2 Harness (foot direction control)
3 Plug
4 Bolt
5 Clip
6 Bolt (with washer)
7 Floor plate

–7–
Installation
Floor plate related parts
The parts marked * are not reused.
1. Remove the existing floor plate from the truck.
Keep the two bolts as they will be used later.
2. Detach the accelerator assembly, accelerator pedal,
stopper bolt, and all other parts from the floor plate.
Keep all the parts except those marked (*) in the
drawing on the right for reuse in the following
steps.
3. Attach the accelerator assembly removed in step 2
above to floor plate 7 (kit component).
4. To floor plate 7, attach the lock nut (removed from
the floor plate) and stopper bolt 4. Adjust the
height of the stopper bolt to the dimension
indicated in the drawing on the preceding page.
206805B

Forward/reverse lever related parts

5. Detach the F.N.R lever assembly from the steering
column by removing the machine screws.
Disconnect the harness connected to the F.N.R
lever at the CN6 connector by which it is connected
to harness B.
6. Close the F.N.R lever hole with plug 3 (see the
drawing on the preceding page).

206802A

Harness related parts

7. Install pedal assembly 1 on floor plate 7
using the pin and snap ring (removed in step
2 above). Make necessary adjustments
referring to the relevant Service Manual.
8. Retain the harness that is connected to the
foot pedal on the floor plate using clip 5 and
bolt 6.
9. Arrange the harness connected to the foot
pedal as shown in the drawings at the right
and on the next page.
10. Connect one end of harness 2 to the harness
B’s CN6 connector and the other end to the
pedal harness. See the harness connection
drawing on the preceding page.

206848

–8–
11. Retain the foot control related harness
together with harness B using the existing
clamps.
12. Connect the accelerator assembly harness to
harness B. Install the floor plate using two
bolts.
13. Depress the pedal to make sure that its
movement is not restricted by the cable
attached to the pedal. If necessary, perform
adjustments for free movement of the pedal.

208649

14. Set selector switch 5 on the logics card to

ON (from OFF).
15. Perform an operation test to make sure that
everything operates correctly.

(Reference)

208650

208651

–9–
 EE MODEL AND EE UNCOVERED BATTERY MODEL
(US EE MODEL)
Description
The EE model differs from the standard US model in the components shown by solid lines in the drawing below.
The difference between them is essentially the covering h for the electrical components that can become origin of
fire, on the EE model
The EE uncovered battery model is equipped with a side cover and battery insulator to satisfy the EE requirements.

208652

EE model’s components that differ from standard US model’s components are as follows:
1 Controller assembly: enclosed type for 5 Side cover
compliance with the EE requirements. 6 Battery bulkhead
2 Drive motor: enclosed type; the motor itself is 7 Fastener
same as the standard US model’s motor. 8 Battery cable
3 Pump motor: enclosed type. 9 Controller cover
4 Hydraulic pump: differs from the standard US 10 Air louver
model’s pump in the flanged suction and delivery 11 EE label
port design as well as the pump’s construction to 12 UL approved plate
match the enclosed type pump motor. See Page 12
for further details.

– 10 –
 EE uncovered battery model

208563

EE uncovered battery model’s components that differ from EE model’s components are as allows:
1 Side covers (right and left): installed in place of the EE model’s side covers (parts 5 shown on the preceding
page).
2 Battery insulator: attached to the back surface of the battery cover.

– 11 –
Hydraulic Pump
The hydraulic pump for the EE model’s pump is largely different from the standard US model’s pump. The EE
model’s pump has the construction shown below.

208654

1 Cover 8 Center bushing assembly

2 Body 9 Flange
3 Bushing ER assembly 10 Body seal
4 Bushing EL assembly 11 Bushing seal
5 Front drive gear 12 Bolt
6 Rear drive gear 13 Oil seal
7 Driven gear 14 Snap ring

– 12 –