PDF Service & OMM Manual Caterpillar EP14-20A(C)NT EP16-20A(C)N - 11 MB
This is a complete package for the Caterpillar EP14-20A(C)NT and EP16-20A(C)N series electric forklifts.
It includes both the Operation & Maintenance Manual for daily use and the full Service Manual for in-depth repairs.
This comprehensive set provides all the information an operator or technician needs to run and maintain these machines safely and effectively.
Having both documents ensures you are prepared for any situation.
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OPERATION AND
MAINTENANCE MANUAL
EP14-20A(C)NT
EP16-20A(C)N
English 639370-EN A
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Operation and Maintenance Manual
Corrosive hazard
Electrical hazard
Prohibited action symbols
These symbols are used in warnings and notifications to indicate an action that
should not be taken. The prohibited action symbols are shown below.
No smoking
Limited or restricted access
General symbol for prohibited action
Do not touch
Mandatory action symbols
These symbols are used in warnings and notifications to indicate an action that
must be taken. The mandatory action symbols are shown below.
Wear eye protection
General symbol for mandatory action
Read the manual or instructions
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Operation and Maintenance Manual
5 General information
5.1 Intended use
This truck is a 3-wheel or a 4-wheel sit-on operated electric counterbalanced lift
truck, with sophisticated controls for truck operation, steering and load handling.
It is designed to transport and stack pallets indoors and outdoors. The maximum
capacity with load centre distance is indicated on the truck's capacity plate.
5.2 Prohibited use
Do not use the truck
• To transport or lift people
• To transport or lift unstable loads
• To transport or lift damaged loads
• To transport or lift freely suspended or swinging loads
• To transport or lift broken pallets
• To tow another truck or trailers
• To push, drag or sideshift loads that are on the ground
• At premises with insufficient floor load capacity
• At premises with a risk of fire or explosion (ATEX premises)
• At premises with explosive substances
• As a snowplow or a bulldozer for clearing the ground
• As an adjustable work platform
• As a climbing frame or a ladder
• If the maintenance of the truck is neglected
• If the truck is damaged
• If you are under the influence of intoxicating substances
• With the covers open or removed
5.3 Identification plates of the truck
CAUTION
Make sure that all the plates and stickers on the truck are legible and securely
attached!
Figure 1: Plates and stickers of the truck overview and Figure 2: Emergency exit
sticker (cabin truck) show the plates and stickers of the truck and their locations.
For more details on the plates and stickers of the truck, see APPENDIX A:
Stickers.
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Operation and Maintenance Manual
Control Functionality description
Clamp lever (option) Use the lever with your right hand. Pull the lever backwards to
close the clamp. Push the clamp release button, and then
push the lever forward to release the clamp (the clamp lever
must be in neutral position when the button is pushed). The
lever returns automatically to the central position, when you
release it.
Clamp release button Use the button to enable the release of the clamp. Push the
(option) clamp release button, then push the lever forward to release
the clamp (clamp lever must be in neutral position when the
button is pushed).
5.4.8 Side control panel
7 side control switches can be installed on the side control panel. The switch for
manual working lights is standard equipment and the other switches are
optional.
1
2
3
4
5
6
7
8
Figure 10: Side control panel overview
1. Manual working lights 4. Windshield wiper and washer
(option) (option)
2. Automatic working 5. Rear window wiper (option)
lights (option) 6. Rear window heater (option)
3. Emergency flash 7. Reading light switch (option)
indication (option)
8. Empty
Table 3: Control functionalities
Control Functionality description
Manual working lights Use the manual working lights switch to control the working
(option) lights. The switch has 3 positions:
• OFF
• Forward lights are on and backward lights turn on
automatically when reversing
• Forward and backward lights are on
Automatic working lights When you set the working lights on automatic mode, the lights
(option) turn ON automatically, when the lighting of the working
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Operation and Maintenance Manual
5.4.11.9 Traction and hydraulic interlocking icons
The truck is equipped with an interlocking function that disables the traction and
hydraulics of the truck, in case the seat switch is not activated but the truck
moves.
When the interlocking function activates, the traction interlocking icon N is
shown on the center information area.
13:00
Figure 23: Main view with the traction and hydraulic interlocking icons
To return the traction functions to use:
1. Activate the seat switch,
2. Return the accelerator pedal to the neutral position.
If the seat switch is not activated and an arm rest lever/manual lever is active,
the hydraulic interlocking icon is shown on the truck display.
To return the hydraulic functions to use:
1. Activate the seat switch,
2. Return all hydraulic levers to the neutral position.
5.4.11.10 Message area
In case of informational, warning or error messages, the main view of the truck
display changes to highlight the important information.
Informational message
An informational message gives instructions to the truck operator in cases in
which the truck does not work in the expected way. In case of an informational
message, the color of the stripes in the main view changes to blue and an
information icon with blue background is shown in the bottom left-hand corner of
the truck display. Date and time are replaced with the appropriate informational
message. See Figure 24: Main view with an informational message.
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Operation and Maintenance Manual
5.4.12.3 Dual pedal and brake pedal
1
2
3
Figure 40: Dual pedal and brake pedal overview
1. Accelerator pedal 3. Accelerator pedal backward
forward
2. Brake pedal
5.4.12.4 Pedal functionalities
Table 6: Pedal functionalities
Control Functionality description
Accelerator pedal Use the accelerator pedal with your right foot.
The more you push the accelerator pedal, the
higher the operating speed.
NOTE: Handle the accelerator pedal gently.
Brake pedal The truck has an electric service brake for
reducing the operating speed. Push the brake
pedal gently to slow the speed.
The service brake decelerates the truck and
charges the battery in the following cases:
• When the brake pedal is pushed.
• When the operating direction changes.
• When the accelerator pedal is released.
If the brake pedal is pressed all the way
down, a panic braking function is activated
which stops the truck using a combination of
electric service brake and mechanical
magnetic brake.
NOTE: Practice braking with and without a
load.
Operator presence pedal To drive the truck, push the operator
presence pedal down to the operating
position.
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Operation and Maintenance Manual
1. Turn the weight adjustment handle out.
2. Move the weight adjustment handle up or down.
3. Move the weight adjustment handle back to the center position between the
adjustment stages.
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Operation and Maintenance Manual
WARNING
Lower your body carefully when you enter or exit the operator’s compartment
so that you do not hit yourself to the overhead guard!
CAUTION
Always be careful with your footing when entering and exiting the operator’s
compartment.
Wear appropriate footwear to prevent slide.
Make sure that you do not have grease on your shoes before you enter the
operator’s compartment.
Make sure that your hands are clean and dry to prevent slipping when you hold
the handhold.
7.1.2 Emergency exits (cabin truck)
In an emergency, leave the truck through the operator door. If you cannot use
the operator door leave the truck through the rear window or the side door. See
the emergency exits in Figure 57: Emergency exits.
For instructions on how to open the rear window, see Section 6.2.7 Open the
rear window (cabin truck).
The rear window is marked with an Emergency exit sign, see
Figure 2: Emergency exit sticker (cabin truck) and APPENDIX A: Stickers.
Figure 57: Emergency exits
7.1.3 Operating position
To operate the truck:
• Sit in the operator’s seat.
• Fasten the seat belt, see Section 6.2.5.1 Fasten the seat belt.
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Operation and Maintenance Manual
WARNING IMPROPER OPERATION OR MAINTENANCE COULD RESULT IN
INJURY OR DEATH
MODEL SERIAL NUMBER
MAST: ATTACHMENT:
MODEL MANUFACTURER
BACK TILT DEG. TYPE
MACHINE WEIGHT W/O REMOVABLE ATTACHMENTS
W/O BATTERY FOR BATTERY POWERED TRUCKS. kg
ACTUAL CAPACITY MAST: VERTICAL
MAX FORK HEIGHT H LOAD CENTRE ALLOWABLE WORKING CAPACITY
Q
(mm) D(mm) ON FORKS Q (kg) W/ATTACHMENT Q
(kg)
90582-05100
D
H
Figure 62: Capacity plate
NOTE: The capacity plate can include more actual capacities at other lifting
heights and load centre distances, if applicable.
WARNING
Do not exceed the maximum loading capacity of the truck under any
circumstances. Risk of overturning!
7.6.2 How to stack
To stack:
1. Drive towards the shelf or stacking level with the load lowered and the forks
tilted upwards.
2. Straighten the forks to a level position with tilt function.
3. Lift the load so that is clearly above the stacking height or the shelf level.
Note the height of the upper horizontal beam of the shelf.
4. Drive forward until the forks and load are on top of the shelf.
5. Lower the forks so that they disengage. Make sure that the forks are clear of
both the stacking level and the pallet.
NOTE: Heavy loads can cause forks to bend. If heavy pallet is level during lifting,
forks are not level after load is disengaged.
6. Reverse from the stacking location.
7. Tilt the forks upwards and lower them to the operating height.
7.6.3 How to unstack
To unstack:
1. Drive towards the shelf or stacking level with the forks lowered and tilted
upwards.
2. Straighten the forks to a level position with tilt function.
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Operation and Maintenance Manual
8.5.1 When the battery is charged
1. Set the charger to OFF.
I
O
2. Disconnect the battery connector from the charger connector. Hold the
connectors; do not pull the cables.
3. Examine the battery according to the battery maintenance instructions of the
manufacturer.
4. Connect the battery connector to the truck connector. Make sure that the
battery cables remain completely safe within the frame of the truck.
5. Close the battery cover and the door.
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Operation and Maintenance Manual
2. Lift the battery cover up.
3. Remove the locking pin from the holder.
4. Lock the battery cover on the upright position with the locking pin.
WARNING
When you close the battery cover, do not hold the battery cover from the edges
or do not leave your hand between the cover and the truck frame. Risk of
crushing! Risk of trapping!
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Operation and Maintenance Manual
• Examine the welds of outer masts and cylinder support for cracking.
• Examine the lifting carriage welds for cracking.
• Examine the rollers, roller pins and welds for cracking and damage.
• Examine the overhead guard for deformation, cracking and damage.
Change the following once a year or 1000 operational hours, which comes first:
• Hydraulic oil
• Transmission oil
For recommended lubricants, see Section 9.10 Oils and lubricants.
9.10 Oils and lubricants
NOTE: Make sure that you do not mix different lubricants. It is possible that
different brands of lubricants are not compatible with each other.
Table 15: Oils and lubricants
Hydraulic oil
Ambient temperatures -40...+0°C ISO VG 15
Ambient temperatures -10...+30°C ISO VG 32
Ambient temperatures +10...+50°C ISO VG 46
Transmission oil
In accordance with SAE 80W-90; API GL-5
Lubrication points
Grease NLGI. No. 1 or 2 grade multipurpose type
(lithium base)
Rear axle
Grease In accordance with Heliolene Grease GRA 2
Black
9.10.1 Mast chains
For the best chain life, use graphite or molybdenum type lubricants (for
example, sprays), which evaporate and leave the graphite or molybdenum on
the chain.
CAUTION
If you use oil or grease to lubricate the chains in dusty or sandy operating
conditions, dirt particles can stick to the chains and cause rapid wear from
abrasion.
9.10.2 Mast channels
For the lubrication of the mast channels, use lubrication grease NLGI No. 2 that
contains molybdenum disulphide.
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Operation and Maintenance Manual
11.2 Tilt angle sensor / display status indication
with FC
Figure 77: Tilt angle sensor overview
The tilt display informs the truck operator of the tilt angle through the truck
display. The tilt angle is measured via an analogue angle sensor.
The tilt angle minimum, maximum and centre positions must all have individual
values. The values are set though the TruckTool software. The tilt angle is
shown to the truck operator through the truck display with 3 symbols, see
Table 16: Tilt angle symbols.
Table 16: Tilt angle symbols
Symbol Description
Tilt centered icon
Tilt below center position icon
Tilt above center position icon
The tilt angle symbols are shown on the top right corner of the truck display.
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Operation and Maintenance Manual
11.6.1 Replace the air filters of the heater
To replace the air filters of the heater:
1. Remove the filters from the rack on the side of the heater.
2. Put new filters to the rack.
11.7 Windshield washer (cabin truck)
The front and rear windows of the cabin truck have windshield wipers.
2
1 1
2 3
Figure 85: Windshield washer
1. Windshield wipers 3. Windshield washer tank and
2. Windshield wiper pumps
motors
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Operation and Maintenance Manual
Truck type 16ACN 18ACN 16AN 18AN 20AN
Noise level, value at dB(A) 65 65 65 65 65
8.4
operator’s ear (EN 12053)
Towing coupling design / DIN15170- DIN15170- DIN15170- DIN15170- DIN15170-H
8.5
DIN type, ref. H H H H
12.3 Mast availability charts
● Available option
o Standard equipment
E Available, option may extend lead time
— Not available
CSM Contact CSM department
Mast type M-Code Availability Height [mm]
Simplex CSM 2000
CSM 2600
CSM 2800
2FP300 ● 3000
2FP330 ● 3290
CSM 3500
2SP370 ● 3720
2SP410 ● 4090
2SP450 ● 4480
2SP500 ● 5000
2SP550 ● 5500
2SP600 ● 6000
Duplex CSM 2800
2FP300 ● 3000
2FP330 ● 3290
CSM 3500
2FP370 ● 3700
2FP400 ● 4030
Triplex 3FP370 ● 3700
3FP400 ● 4000
3FP430 ● 4310
3FP480 ● 4750
3FP510 ● 5090
3FP550 ● 5490
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Operation and Maintenance Manual
Before daily 1,000 h or
use Monthly every year
(Operator) (Owner) (Service)
Hoses and cylinders C
Lubricate the pump axle splines Every 2 years
Mast
Mounting of the mast C
Visual inspection of the wear level of the C
mast rollers and contact surface
Chain setting, adjustment if necessary C C C
Chain lubrication (clean and lubricate), G
see Section 9.10.1 Mast chains.
Chain wear measurement and C
replacement if over the 2% limit
Chain anchors and locking pins check C
Tightness of the hydraulic connections, C C
hoses and pipes, possible leaks and
damages
Tightness of the cylinders and piston C
rods, possible leaks and damages
Lifting and lowering speed C