Cat EP16KT EP18KT EP20KT Lift Truck Service Manual – Chassis, Mast and Options 99719-66100

Description

Cat EP16KT, EP18KT and EP20KT Lift Truck Service Manual – Chassis, Mast and Options

This service manual is the complete chassis, mast and options guide for the Cat EP16KT, EP18KT and EP20KT electric lift trucks, published under document number 99719-66100. Covering 48-volt three-wheel models in the 1.6, 1.8 and 2.0 ton classes, it walks a technician through the systems that keep these trucks productive: electrical and vehicle monitoring, power train, transfer, rear and steering axles, brakes, steering, hydraulics, mast and forks, and the optional equipment bolted onto them. Both Mechanical Control (MC) and Finger-tip Control (FC) variants are documented, so the same book serves either control layout in the fleet.

File Details

• Manual type: Service Manual
• Brand / manufacturer: Cat lift trucks (Mitsubishi Caterpillar Forklift Europe B.V.)
• Document number: 99719-66100
• Publication year shown: 2005
• Language: English
• File format: PDF
• Page count: 311 pages
• Models covered: EP16KT, EP18KT, EP20KT (48V)

Chapters Covered

• Vehicle Exterior – models, serial number locations, chassis and mast model identification, dimensions, technical data
• Electrical System – central vehicle monitor system (CVMS) functions, console box components, direction lever, accelerator control, key and lighting switches, fuses, lamp chart, lighting and horn troubleshooting, joystick box, finger-tip control system, controller setting, error codes
• Power Train – mast removal, battery removal, front wheels, steps and floor plates, steering hoses, delivery pipe and drive motor harness, brake components, return hoses, tension rods, transfer assemblies, drive motors, calipers
• Transfer – gear type, constant-mesh 3-stage helical gear construction, drive force path, transfer ratio 17.478
• Rear Axle and Steering Axle – rear wheels, rear axle, steering axle, rear axle assembly, minimum turning radius
• Brake System – caliper assembly, brake pedal assembly, master cylinder, parking brake lever, pad clearance adjustment, brake switch, fluid line bleeding, parking brake adjustment
• Steering System – open-centre hydraulic steering, steering control valve (Ognibene), steering wheel, steering column, disassembly and reassembly of valve sections
• Hydraulic System – gear pump, control valve (MC and FC), lift and tilt cylinders, flow regulator valve, down safety valve, main relief valve, microswitch adjustment, hydraulic circuit diagrams
• Mast and Forks – dual-stage panoramic (Simplex), dual-stage full free (Duplex), triple-stage full free (Triplex) masts, chain tension, roller clearance, mast strip adjustment, fork inspection
• Service Data – inspection standards, periodic replacement of parts, critical safety parts, lubricating standards, lubricant quantities, main component weights, tightening torques for standard bolts and nuts, special tool table
• Options – rearview mirror kit, backup buzzer kit, working lamp kit, solid tire kit

What makes this document genuinely useful on the shop floor is the way it is organised around systems rather than part numbers. Every major assembly – lift cylinders, tilt cylinders, transfer units, the Ognibene steering control valve, the caliper and master cylinder, the control valve spool sections – has a dismantling sequence, exploded view and a service data table so a technician can measure wear, set preload, shim a roller or torque a bolt to the value the manufacturer expected. Hydraulic circuit diagrams are included in both MC and FC layouts, along with the electrical schematics and controller setting charts that tie the fingertip control system together. The inspection standards chapter alone turns routine maintenance into a checklist with real numbers attached.

Mechanical Control and Finger-tip Control Variants

The manual splits the hydraulic chapter deliberately: a Mechanical Control (MC) portion that covers the KVS control valve with microswitch-triggered lift and tilt signals, and a Finger-tip Control (FC) portion that documents the electronically actuated joystick system, its proportional solenoid valves, inlet section, lift section, tilt section, attachment section and relief valve. Buying the manual once gives you both sides of the fleet, plus the electrical and controller logic that sits behind the FC version.

What You Can Do With This Manual

Owners, fleet mechanics and independent workshops can use this manual to:

• Remove and refit the complete mast and lift bracket assembly on Simplex, Duplex and Triplex masts
• Disassemble, inspect and rebuild the transfer units, traction motors and calipers
• Overhaul the brake master cylinder, caliper, pedal assembly and parking brake lever, then bleed and adjust the system correctly
• Service the Ognibene steering control valve and rear axle assembly
• Reach the lift and tilt cylinders, replace seal kits and set stroke shims to balance cylinder travel
• Diagnose CVMS error codes, check controller setting switches, and troubleshoot the finger-tip control system with the case-by-case flowcharts
• Adjust microswitch ON timing, relief valve pressure, pad clearance, chain tension, mast roller clearance and mast strip clearance
• Look up standard bolt torques, component weights, oil capacities and inspection intervals from one source

Get Your Copy Instantly

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This Cat EP16KT EP18KT EP20KT service manual arrives as an instant PDF download – no shipping, no waiting for a courier, no need to chase a paper binder around the workshop. Open it on a laptop, tablet or phone, print the pages you need for the job in front of you, and keep the rest tucked away for the next one. With the correct dismantling sequences, inspection values and torque figures to hand, you spend less time guessing and more time fixing the truck right the first time.