Caterpillar EP30CA1(J) Lift Trucks Service Manuals – PDF DOWNLOAD

Description

Caterpillar EP30CA1(J) Lift Trucks Service Manuals – PDF DOWNLOAD

DESCRIPTION:

Caterpillar EP30CA1(J) Lift Trucks Service Manuals – PDF DOWNLOAD

INTRODUCTION :

Most accidents happen due to the disregard of basic safety rules and precautions. To prevent accidents from happening, the factors that cause them must be avoided beforehand. Before operating this machine, carefully read this manual so that you fully understand the safety precautions and the proper procedures and instructions for inspection and maintenance.

• Performing maintenance and repair without adequate knowledge can cause accidents. A manual cannot cover every possible cause of an accident, so you also need to take precautions for items not mentioned in this Service Manual.
• It is especially important to do repair and maintenance work not covered in this manual under the direction of an instructor experienced at the task being performed.

Using this “Service Manual-Chassis & Mast” :

• This manual has information about the layout and names of main components, explains disassembly, assembly, inspection, adjustment, and maintenance procedures, and contains troubleshooting hints that apply mainly to the model EP-CA1. For EP-CA1J series, refer to EP-CA1 specifications and descriptions if not otherwise specified.
• It is important to note that in order to improve quality, performance, and safety parts used in this forklift truck are subject to change and that some portions of the contents and illustrations in the Workshop Manual at the time of printing may not be identical due to these changes.

TABLE OF CONTENTS:

Caterpillar EP30CA1(J) Lift Trucks Service Manuals – PDF DOWNLOAD

Caterpillar EP30CA1(J) Chassis & Mast Lift Trucks Service Manual

WORKING SAFELY 1
1 Precautions for safe inspection and
maintenance 1
2 Safety labels 5
3 Model name and serial numbers 9
4 Maintenance cautions 11
5 Tightening torque for bolts 14
6 Maintenance tools and inspection devices 15
6-1 Maintenance tools 15
6-2 Inspection devices 19
7 Marks and Symbols 21
1 GENERAL 23
1-1 Appearance 23
1-2 Specifications 24
2 FRONT AXLE (DRIVE) 27
2-1 Location and name of parts 27
2-2 Disassembly and reassembly 29
2-2-1 Front tire – removal and installation 29
2-2-2 Front axle – disassembly and reassembly 35
2-3 Inspection and adjustment 45
2-3-1 Gears – inspection and replacement 45
2-3-2 Wheel hub and Hub bolt – inspection 45
2-4 Troubleshooting 46
2-4-1 Front axle – troubleshooting 46
3 REAR AXLE 47
3-1 Names of parts 47
3-2 Disassembly and reassembly 48
3-2-1 Rear axle- removal and installation 48
3-2-2 Rear axle- disassembly and reassembly 50
3-2-3 Rear axle – Reassembling method and caution 52
3-3 Inspection and adjustment 55
3-3-1 Bushing – inspection 55
3-3-2 Center arm – inspection 55
3-3-3 Tie rod Comp – inspection 55
3-3-4 Knuckle – inspection 55
3-3-5 King pin – inspection 56
3-3-6 Hub and Hub bolt – inspection 56
3-3-7 Rear axle Comp – inspection 56
3-4 Troubleshooting 57
3-4-1 Rear axle- troubleshooting 57
4 TIRE 59
4-1 Location, name and tire size 59
4-1-1 Tire name 59
4-1-2 Tire size 59
4-2 Inspection and adjustment 60
4-2-1 Hub nut – inspection 60
4-2-2 Rim and Rim bolt – inspection 60
4-2-3 Air pressure – inspection 61
4-2-4 Tire – visual inspection and replacement 61
4-3 Troubleshooting 62
4-3-1 Tire – troubleshooting 62
5 STEERING 63
5-1 Location and name of parts 63
5-2 Disassembly and reassembly 64
5-2-1 Steering -removal and installation 64
5-2-2 Steering linkage – disassembly and reassembly 66
5-3 Inspection and adjustment 68
5-3-1 Joint – inspection and replacement 68
5-3-2 Knob – inspection and replacement 68
5-3-3 Steering wheel – inspection and replacement 68
5-3-4 Actuator – inspection and adjustment 69
5-4 Troubleshooting 70
5-4-1 Steering linkage – troubleshooting 70
6 BRAKE 71
6-1 Location and name of parts 71
6-1-1 Foot brake linkage – names of parts 71
6-1-2 Parking brake linkage – names of parts 72
6-2 Disassembly and reassembly 73
6-2-1 Wheel brake – removal and installation 73
6-2-2 Wheel brake – disassembly and reassembly 77
6-3 Inspection and adjustment 78
6-3-1 Wheel brake – inspection and adjustment 78
6-3-2 Shoe and lining – inspection and replacement 78
6-3-3 Adjustor Ass’y – inspection and replacement 79
6-3-4 Wheel cylinder Ass’y
– inspection and replacement 79
6-3-5 Master cylinder A’ssy
– inspection and replacement 80
6-3-6 Brake pedal – inspection 80
6-3-7 Parking brake lever – inspection and adjustment 81
6-3-8 Brake linkage – adjustment 81
6-3-9 Brake circuit – air bleeding 83
6-4 Troubleshooting 85
6-4-1 Brake – troubleshooting 85
7 HYDRAULIC SYSTEM 87
7-1 Hydraulic circuit 87
7a HYDRAULIC PUMP 89
7a-1 Location and name of parts 89
7a-2 Disassembly and reassembly 90
7a-2-1 Hydraulic pump – removal and installation 90
7a-3 Inspection and adjustment 91
7a-3-1 Hydraulic pump – inspection 91
7a-4 Troubleshooting 92
7a-4-1 Hydraulic pump – troubleshooting 92
7b OIL TANK AND OIL PIPNG 93
7b-1 Location and name of parts 93
7b-1-1 Plastic oil tank – main part names 93
7b-1-2 Iron oil tank – main part names 93
7b-2 Disassembly and reassembly 94
7b-2-1 Cautions when
disassembling and reassembling Oil tank 94
7b-2-2 Cautions when replacing the oil piping 94
7b-3 Inspection and adjustment 95
7b-3-1 Oil – inspection 95
7b-3-2 Recommended oil and Oil quantity 95
7b-3-3 Oil tank and Filters – cleaning and check 96
7b-4 Troubleshooting 96
7b-4-1 Oil tank – troubleshooting 96
7c CONTROL VALVE 97
7c-1 Location and name of parts 97
7c-2 Disassembly and reassembly 99
7c-2-1 Control valve – removal and installation 99
7c-3 Inspection and adjustment 102
7c-3-1 Relief pressure – measuring and adjustment 102
7c-3-2 Microswitch – adjustment 103
7c-4 Troubleshooting 104
7c-4-1 Control valve – troubleshooting 104
7d CYLINDER 105
7d-1 Location and name of parts 105
7d-1-1 Lift cylinder – main part names 105
7d-1-2 Tilt cylinder – part names 107
7d-2 Disassembly and reassembly 108
7d-2-1 Lift cylinder (2SP-mast) – removal 108
7d-2-2 Lift cylinder (3FP/2FP-mast) – removal 110
7d-2-3 Tilt cylinder – removal 113
7d-2-4 Lift cylinder – installation and adjustment 114
7d-2-5 Tilt cylinder – installation 114
7d-2-6 Lift cylinder – disassembly and reassembly 115
7d-2-7 Tilt cylinder – disassembly and reassembly 129
7d-3 Inspection and adjustment 130
7d-3-1 Cylinder Comp – inspection 130
7d-3-2 Piston rod – inspection 130
7d-3-3 Vertical and tilt drift – inspection 131
7d-4 Troubleshooting 133
7d-4-1 Cylinder – troubleshooting 133
8 MAST 135
8-1 Location and name of parts 135
8-2 Disassembly and reassembly 137
8-2-1 Lift bracket Ass’y – removal 137
8-2-2 Mast Ass’y – removal 137
8-2-3 Mast – disassembly and reassembly 139
8-3 Inspection and adjustment 142
8-3-1 Mast, Lift bracket and Roller shaft – inspection 142
8-3-2 Back shoe – inspection 143
8-3-3 Lift chain – inspection and replacement 143
8-3-4 Chain bolt – inspection 144
8-3-5 Chain wheel – inspection 144
8-3-6 Hose pulley – inspection 144
8-3-7 Roller – inspection 145
8-3-8 Fork – inspection 145
8-3-9 Lift chain tension – inspection and adjustment 146
8-3-10 Mast leaning – adjustment 147
8-4 Troubleshooting 148
8-4-1 Mast, Lift bracket and Fork – troubleshooting 148
9 MOTOR 149
9-1 Location and name of parts 149
9-1-1 Traction motor – names of parts 149
9-1-2 Hydraulic motor – names of parts 150
9-1-3 EPS motor – names of parts 150
9-1-4 Motors – specifications 151
9-2 Disassembly and reassembly 152
9-2-1 Traction motor – removal and installation 152
9-2-2 Hydraulic motor – removal and installation 153
9-2-3 EPS motor – removal and installation 155
9-2-4 Traction motor – disassembly and reassembly 156
9-2-5 Hydraulic motor – disassembly and reassembly 157
9-2-6 EPS motor – disassembly and reassembly 157
9-3 Inspection and adjustment 158
9-3-1 Rotor Comp (Traction and Hydraulic motor) –
inspection and replacement 158
9-3-2 Armature Comp (EPS motor) – inspection and
replacement 159
9-3-3 Brush, Brush holder and Spring (EPS motor) –
inspection and replacement 159
9-3-4 Oil seal and permanent magnet (EPS motor)
– inspection and replacement 161
9-4 Troubleshooting 161
9-4-1 Motor – troubleshooting 161
10 ELECTRIC PARTS 163
10-1 Location and name of parts 163
10a CONTROL UNIT 165
10a-1 Location and name of parts 165
10a-2 Disassembly and reassembly 166
10a-2-1 Control unit / Capacitor – discharge 166
10a-2-2 Control unit – removal and installation 166
10a-2-3 Control unit – disassembly and reassembly 168
10b MPU BOARD 171
10b-1 Function of each part 171
10b-1-1 MPU board 171
10b-1-2 EPS controller 172
10c DISPLAY PANEL AND DIRECTIONAL SWITCH 173
10c-1 Display panel
– Disassembly and reassembly 173
10c-2 Directional switch
– Disassembly and reassembly 174
10c-2-1 Disassembly and part names 174
10d ACCELERATOR 175
10d-1 Disassembly and reassembly 175
10d-1-1 Accelerator linkage – removal and installation 175
10d-2 Inspection and adjustment 176
10d-2-1 Accelerator linkage – adjustment 176
10e MAIN CONTACTOR AND FUSE 177
10e-1 Disassembly and reassembly 177
10e-1-1 Main contactor and Fuse – removal and
installation 177
10e-2 Inspection and replacement 179
10e-2-1 Main contactor – inspection and replacement 179
10e-2-2 Fuse – replacement 179
10f BATTERY 181
10f-1 Disassembly and assembly 181
10f-1-1 Battery – removal and installation 181
10f-1-2 Battery – replacement 182
10f-2 Inspection and adjustment 183
10f-2-1 Battery – inspection and adjustment 183
10f-2-2 Battery – cleaning 184
10g CHARGER (BUILT – IN) 185
10g-1 Disassembly and reassembly 185
10g-1-1 Charger Ass’y – disassembly and reassembly 185
10g-1-2 Transformer – disassembly and reassembly 186
10g-1-3 Charger – specifications 187
10g-2 Inspection and replacement 188
10g-2-1 Magnetic contactor – inspection 188
10g-2-2 Plug Comp and Receptacle
– inspection and replacement 188
10g-2-3 Link fuse and Fuse stand – inspection 188
10g-3 Voltage tap 189
10g-3-1 Power supply voltage – check 189
10g-3-2 Voltage tap – selection 189
10g-3-3 Voltage tap – change 190
10g-3-4 Link fuse (three-phase voltage) – replacement 190
10g-4 Charging procedure 191
10g-4-1 Normal (Daily charge) 191
10g-4-2 Reserve charge (charging at a pre-set time) 195
10g-4-3 Equalizing charge 204
10g-4-4 Supplementary charging 205
10g-4-5 Charging ahead of long-time storage 205
10g-4-6 Check the specific gravity 205
11 LASER POINTER 207
11-1 Adjustment 207
11-1-1 Fork level – adjustment 207
11-1-2 Laser optical axis – adjustment 207
12 SERVICE DATA 209
12-1 Annual inspection service data 209
12-2 Standard work hours 210

Caterpillar EP30CA1(J) Controller Lift Trucks Service Manual

1 Introduction 1
1-1 EP-CA1 Model Minor change summary 1
2 Basic setting 3
2-1 Indicator panel 3
2-2 Indication of display 4
2-3 Monitor display functions 5
2-4 Mode selection 11
3 Control boards 19
3-1 Basic control board system layout 19
3-2 MPU board 20
3-2-1 MPU board 20
3-2-2 MPU board setting 21
3-3 EPS controller 22
3-3-1 EPS controller 22
3-3-2 EPS controller setting 23
4 Service setting check 25
4-1 Service setting check screen 25
4-2 Adjustment Standards List for EP-CA1 series 27
5 SICOS-AC check and adjustment 29
5-1 Caution while checking and adjustment 29
5-2 How to check and adjust 29
5-2-1 Chassis insulation check 29
5-2-2 Battery voltage calibration 30
5-2-3 Current detector check 31
5-2-4 Model setting 35
5-2-5 Neutral safety check 36
5-2-6 OIS (Operation Interlock System) check 37
5-2-7 Hydraulic speed setting and adjustment 39
5-2-8 Descending regeneration check 42
5-2-9 Switch back (plugging/regenerative) braking
force adjustment 42
5-2-10 Regenerative braking force check and
adjustment 43
5-2-11 Pitching control adjustment 44
5-2-12 Display monitor icon check and setting 45
5-2-13 Display language check and settings 47
5-2-14 Optional function check and settings 48
5-2-15 Load sensor check and calibration 51
5-2-16 Overload check (Option) 53
5-2-17 Display brightness check and adjustment 53
5-2-18 Hour meter check 54
5-2-19 Brake oil level warning check 55
5-2-20 Lift interrupt function check (Option) 56
5-2-21 Turning speed reduction setting and check
(Option) 57
5-2-22 Accelerator potentiometer adjustment 58
5-2-23 Torque sensor adjustment 59
5-2-24 Automatic tilt horizontal stop check (Option) 60
5-3 Control unit 61
5-3-1 Control unit Capacitor – discharge 61
5-3-2 FET module – inspection and replacement 62
5-4 Motor 64
5-4-1 Traction and Hydraulic motor insulationinspection
64
5-4-2 EPS motor – inspection 64
5-5 Other adjustments and checks 65
5-5-1 Transformer – inspection 65
5-5-2 Diode – inspection 65
5-5-3 Auto-power-off function check 66
5-5-4 Battery electrolyte level sensor check (Option) 66
5-5-5 Turn signal lamp check 66
5-5-6 Travel inhibitor check (Option) 67
5-5-7 Cooling fan check 67
5-5-8 Laser pointer check (Option) 67
5-5-9 Built-in charger check 68
5-5-10 Checking charging overheat warning (Option) 69
5-5-11 Ground check 69
5-5-12 Reserve function – inspection 69
6 Troubleshooting 71
6-1 Self diagnosis function 71
6-1-1 Display 71
6-1-2 Error message list 73
6-2 Error history memory 75
6-2-1 Error history memory1 75
6-2-2 Error history memory 2 77
6-2-3 Clearing the error history memory
(memory initialization) 78
6-3 I/O Check 79
6-3-1 I/O Check 79
6-3-2 I/O port table 81
7 Wiring (Diagrams) 87
7-1 Wiring, system 87
7-1-1 EP10CA1-30CA1/EP10HCA1-25HCA1 87
7-2 Wiring, body 88
7-2-1 EP10CA1-30CA1/EP10HCA1-25HCA1 88
7-3 Harness, body 89
7-3-1 EP10CA1-30CA1/EP10HCA1-25HCA1 89
7-3-2 With Parking brake alarm (All models) 90
7-4 Controller wiring 91
7-4-1 EP10CA1-30CA1/EP10HCA1-25HCA1 91
7-5 Controller harness 92
7-5-1 EP10CA1-30CA1/EP10HCA1-25HCA1 92
7-6 Main controller 93
7-6-1 EP10CA1-30CA1/EP10HCA1-25HCA1 93
7-7 BC (200V) 94
7-7-1 Wiring
EP10CA1-30CA1/EP10HCA1-25HCA1 94
7-7-2 Harness
EP10CA1-30CA1/EP10HCA1-25HCA1 95
7-8 BC (400V) 96
7-8-1 Wiring
EP10CA1-30CA1/EP10HCA1-25HCA1 96
7-8-2 Harness
EP10CA1-30CA1/EP10HCA1-25HCA1 97
7-9 Wiring, lamp 98
7-9-1 Revolving lamp linked key SW (All models) 98
7-9-2 Revolving lamp linked Forward & backward
traveling (All models) 99
7-9-3 Revolving lamp linked Backward traveling
(All models) 100
7-9-4 Backup lamp (All models) 101
7-10 Wiring, load sensor 102
7-10-1 Analog Load sensor (All models) 102
7-10-2 Digital Load sensor (All models) 103
7-11 Wiring, warning 104
7-11-1 Charging overheating warning (All models) 104
7-11-2 Parking brake alarm (All models) 105
7-11-3 Harness, accessory,
Parking brake alarm (All models), NFT production 106
7-11-4 Wiring, alarm,
Parking brake alarm (All models), NFT production 107
7-12 Wiring, signal 108
7-12-1 Replenishing signal (All models) 108
7-13 Wiring, wiper 109
7-13-1 Wiper on lower part (All models) 109
7-14 Wiring, rear grip 110
7-14-1 Rear assist grip with horn switch (All models) 110
7-15 Wiring, lift limit 111
7-15-1 Single stage type (All models) 111
7-15-2 2 stage type (All models) 112
7-16 Wiring, lamp (2) 113
7-16-1 Working lamp (All models) 113
7-16-2 Rear lamp (All models) 114
7-17 Wiring, seat heater 115
7-17-1 Seat heater (All models) 115
7-18 Wiring, fork scale 116
7-18-1 Fork scale w/printer, w o/printer (All models) 116
7-19 Wiring, chime/buzzer 117
7-19-1 Chime(buzzer) [forward & backward] (All models) 117
7-19-2 Chime [forward] (All models) 118
7-19-3 Chime [backward] (All models) 119
7-19-4 Chime [forward], ON/OFF switchable (All models) 120
7-19-5 Back buzzer with ON/OFF switch (All models) 121
7-19-6 Buzzer [backward], volume adjustable (All models) 122
7-19-7 Fwd/Bwd buzzer (All models) 123
7-20 Wiring, back lead 124
7-20-1 Back lead (All models) 124
7-21 Wiring, heater 125
7-21-1 Wiring, heater (All models) 125
7-22 Fork horizontal auto stop (All models) 126
7-22-1 Wiring, system (2) 126
7-22-2 Wring, body (2) 127
7-23 Fingertip control (All models) 128
7-23-1 Wiring, system (4) 128
7-23-2 Wiring, body (4) 129
7-24 Wiring, directional switch 130
7-24-1 Right & left lever 130
7-25 Australian Standard compliant (AS) 131
7-26-1 Wiring, system (4) with Fingertip control 131
7-26-2 Wiring, system (5) / AS 132
7-26-3 Wiring, body (5) / AS 133
7-26-4 Harness, AS 134
8 Reference 135
8-1 MPU board connectors 135
8-1-1 Pin arrangement of connector housing 135
8-1-2 Name of parts 135
8-1-3 Installation of terminals into housing 136
8-1-4 How to extract terminals 137
8-1-5 Crimp tools (manufactured by AMP) 138
8-2 Water resistant connector 139
8-2-1 Water resistant connectors 139
8-2-2 Water resistant connectors
(other than those described above) 139

CATERPILLAR EP30CA1(J) LIFT TRUCKS SERVICE MANUALS – PDF DOWNLOAD:

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