Caterpillar EP35N Lift Truck Operation & Maintenance Manual – PDF DOWNLOAD

Description

Caterpillar EP35N Lift Truck Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Caterpillar EP35N Lift Truck Operation & Maintenance Manual – PDF DOWNLOAD

• Only adequately trained service persons are allowed to carry out service operations. The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones. It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts.
• Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your truck dealer for qualified, authorized and efficient maintenance service.

Foreword:

• This manual is a guide for operating and maintaining lift trucks. Before you start to test, operate or repair a lift truck, read this manual carefully and familiarize yourself with all of the instructions. The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing.
• The manufacturer reserves the right to change specifications or designs without notice and without incurring obligations. Unauthorized copying and lending of this material is strictly prohibited.

TABLE OF CONTENTS:

Caterpillar EP35N Lift Truck Operation & Maintenance Manual – PDF DOWNLOAD

Contents 3
1 Foreword 8
2 How to read this manual 9
2 1 Safety-related signs 9
2 2 Symbols and abbreviations 9
2 2 1 Safety symbols 9
3 Safety instructions 11
3 1 Safety requirements for industrial trucks 11
3 2 Electromagnetic compatibility 11
3 3 Non-ionizing radiation 11
3 4 Noise 12
3 5 Vibration 12
3 6 Instructions for site supervision 12
3 7 Occupational safety 13
3 8 Requirements for the truck operator 13
3 9 Emergency procedures 13
3 10 Stability 14
3 10 1 Center of gravity 14
3 10 2 Capacity of the lift truck 15
3 11 Work at dangerous premises 15
3 12 Repairs and structural modifications 16
3 13 Overhead guard and load support 16
4 Operating environment 17
4 1 Prohibited usage 17
4 2 Free space 18
4 3 Lighting 18
4 4 Bearing capacity of the floor 18
4 5 Use of elevators 18
4 6 Driveways 18
4 7 How to operate the truck on ramps 19
4 8 How to operate the truck on loading bridges 19
4 9 Wind forces 19
5 General information 20
5 1 Truck 20
5 1 1 Intended use 20
5 1 2 Delivery 20
5 2 Identification plates on the truck 20
5 3 Overview of the truck 22
5 3 1 Operating devices 22
Copyright© 2014 by MCFE All rights reserved Revision: A Document ID: 623322 4 (172)
EP25-35(C)N Operation and Maintenance Manual
5 3 2 Control panel 23
5 3 3 Steering wheel 24
5 3 4 Arm rest 25
5 3 5 Manual levers 27
5 3 6 Side control panel 29
5 3 7 Display panel 30
5 3 8 Truck operation modes 32
5 3 9 Truck display 33
5 3 9 1 Display control buttons 33
5 3 9 2 Main view of the truck display 34
5 3 9 3 Hierarchy of the truck display menus 45
5 3 10 Pedals 49
5 3 10 1 Acceleration pedal and brake pedal 50
5 3 10 2 Acceleration pedal, operator presence pedal and brake pedal 50
5 3 10 3 Dual pedal and brake pedal 51
5 3 10 4 Pedal functionalities 51
5 3 11 Operator’s seat 53
5 3 12 Motor, hydraulic system and electrical system 54
5 3 12 1 Electric panel 55
5 3 12 2 Hydraulic system 56
5 3 12 3 Drive axle 57
5 3 13 Lifting carriage 57
5 3 13 1 Integrated sideshift carriage 58
5 3 13 2 Integrated fork positioner with sideshift 58
5 3 14 Mast 59
6 Assembly and commissioning 60
6 1 Assembly and commissioning 60
7 Batteries 61
7 1 Safety regulations concerning the handling of lead-acid batteries 62
7 2 Battery maintenance 63
7 2 1 Daily maintenance 63
7 2 2 Weekly maintenance 63
7 2 3 Monthly maintenance 63
7 2 4 Annual maintenance 64
7 3 Requirements for the battery recharging areas 64
7 4 Recharge the battery 65
7 5 Measure the specific gravity of the battery 68
7 6 Acquire a new battery 68
7 7 Replace the battery 69
7 7 1 Replace the battery with the standard equipment 70
7 7 2 Guide the battery cable 72
7 7 3 Battery sideway exchange 73
8 Before operation 74
8 1 Daily checks before operation 74
8 2 Adjust the arm rest 74
Copyright© 2014 by MCFE All rights reserved Revision: A Document ID: 623322 5 (172)
EP25-35(C)N Operation and Maintenance Manual
8 2 1 Adjust the distance of the arm rest 75
8 2 2 Adjust the height of the arm rest 75
8 3 Adjust the operator’s seat 76
8 3 1 Adjust the seat suspension according to the weight of the operator 76
8 3 2 Adjust the backrest 78
8 3 3 Adjust the seat distance 79
8 3 4 Adjust the lumbar support 79
8 3 5 Clean the operator’s seat 79
8 3 6 Seat belt 80
8 4 Adjust the steering wheel 81
8 5 Before you start 82
9 Operating instructions 83
9 1 How to activate the truck 83
9 1 1 Activate the truck with a PIN code 83
9 1 2 Switch the truck off 85
9 1 3 Program a new PIN code 85
9 2 Brakes 85
9 2 1 Service brake 85
9 2 2 Parking brake 85
9 3 How to operate the truck 86
9 3 1 How to enter and exit the operator’s cabin 86
9 3 2 Operating position 87
9 3 3 Driving direction 89
9 3 4 How to use the operating devices of the truck 90
9 3 5 General operating instructions 91
9 3 6 Traffic rules 91
9 3 7 How to avoid accidents 92
9 3 8 In case the truck turns over 93
9 4 How to handle loads 93
9 4 1 Lifting capacity 94
9 4 2 How to stack 95
9 4 3 How to unstack 96
9 4 4 Broken pallets 96
9 5 Speed 96
9 6 How to stop the truck 97
9 7 How to park the truck 97
10 Maintenance 98
10 1 Safety instructions for maintenance 98
10 2 Daily maintenance 99
10 3 Weekly maintenance 100
10 4 Monthly maintenance 101
10 5 Annual (or 1,000 h) maintenance 101
10 6 Lubrication of the drive axle 102
10 7 Lubricant recommendation 104
10 7 1 Hydraulic oil 104
10 7 2 Transmission oil 104
10 7 3 Mast chains 104
Copyright© 2014 by MCFE All rights reserved Revision: A Document ID: 623322 6 (172)
EP25-35(C)N Operation and Maintenance Manual
10 7 4 Mast channels 104
10 8 Order spare parts 104
10 9 Service operations 105
10 9 1 Truck covers 105
10 9 1 1 Open the cover of the hydraulic valve block 107
10 9 1 2 Remove the pedal plate 107
10 9 1 3 Remove the floor plate 108
10 9 1 4 Open the battery door 109
10 9 1 5 Open the battery cover 110
10 9 1 6 Remove the back cover 111
10 9 1 7 Remove the steering wheel cover 111
10 9 1 8 Remove the control panel 111
10 9 1 9 Remove the step cover 112
10 9 1 10 Remove the side plate 113
10 9 1 11 Remove the cup holder 113
10 9 1 12 Remove the steering wheel front cover 113
10 9 2 Location of the fuses in the electric panel 114
10 10 Dangerous waste and disposal 115
10 11 Maintenance check list 115
10 12 Troubleshooting 121
11 Transportation and storage 123
11 1 Lifting points 123
11 1 1 Jack points 123
11 1 2 Hoist points 123
11 2 How to tow the truck 124
11 2 1 How to release the brake of the drive axle 125
11 3 Transportation 126
11 4 Storage 128
11 4 1 Return the truck to operation 128
11 5 Decommissioning 128
12 Options 129
12 1 Accessory clamp 130
12 2 A4 size paper holder 130
12 3 Smart backup alarm 131
12 4 Road light kit 132
12 4 1 Brake light 133
12 5 Amber strobe 134
12 6 Auto light switch 135
12 7 Blue spot rear light 136
12 8 Current output 137
12 9 12 V connector 137
12 10 Automated performance reduction based on lift height 138
12 11 Tilt angle sensor / display status indication with FC 139
Copyright© 2014 by MCFE All rights reserved Revision: A Document ID: 623322 7 (172)
EP25-35(C)N Operation and Maintenance Manual
12 12 Load weight indicator and overload warning system 139
12 13 Operator’s seat options and accessories 141
12 13 1 Arm rest 141
12 13 2 Backrest extension for MSG65/MSG75 142
12 13 2 1 Backrest extension adjustment 142
12 14 Fire extinguisher 143
12 15 Battery sideway exchange tools 143
12 15 1 Installation of the battery sideway exchange tool 144
12 15 2 Replace the battery with the battery sideway exchange tools 145
12 15 3 Guide the battery cable 150
12 16 Rear view mirror 151
12 17 External rear view mirrors 152
12 18 Wide view mirror 152
12 19 Dead angle mirror overview 153
12 20 Hydraulic accumulator 153
13 Technical specifications 154
13 1 EP25N, EP25CN, EP30N, EP30CN and EP35N 155
13 2 Mast heights 158
14 EC Declaration of Conformity 159
15 Index 160
APPENDIX A: Stickers 163

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CATERPILLAR EP35N LIFT TRUCK OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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