Operation & Maintenance Manual MC EC22N2
ATB30-0001 A TB30-00011-up 1-up
EC25N2
ATB30-50001-up A TB30-50001-up
EC25EN2
ATB31-0001 A TB31-00011-up 1-up
EC25LN2
ATB31-30001-up A TB31-30001-up
EC30N2
ATB31-50001-up A TB31-50001-up
EC30LN2
ATB32-0001 A TB32-00011-up 1-up
Keep this manual in your lift truck as a ready reference
99750-8N100
FOREWORD The Occupational Safety and Health Administration (OSHA) prohibits employees under the age of 18 years old from operating lift trucks, and is now mandating operator training for all lift truck operators. SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness of the operator. To develop the skill, the operator should read this manual to understand the following points: (1) Working capabilities and limitations of the lift truck (2) Make-up of the lift truck (3) Safe driving and load handling procedures It is the employer's responsibility to make sure the operator can see, hear, and has the physical and mental ability to operate the lift truck safely. It is also important that a qualified person experienced in lift truck operation should guide new operators through several driving and load handling operations before they attempt to operate the lift truck on their own. Note: -
This manual contains information necessary for the operation and "Do-it-yourself" maintenance of standard lift trucks.
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Optional equipment is sometimes installed; it can change some operating characteristics described in this manual. Before operating such a lift truck, make sure the necessary instructions are available and understood.
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Lift truck operator training is provided through your authorized Cat® lift dealer. They will be glad to help you and answer any questions you may have about operating your new lift truck. Lift trucks are NOT intended for use on public roads.
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If you resell a lift truck, be sure to attach the original Operation & Maintenance Manual to the lift truck. In some countries, strict regulations do not allow imported lift trucks for resale. For resale information, contact your authorized Cat lift truck dealer.
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If a lift truck is resold from another country, an Operation & Maintenance Manual attached to the lift truck may not meet your country's rules and regulations. For manual information, contact your authorized Cat lift truck dealer.
How to Use This Manual The following safety signs and NOTE are used in this manual to emphasize important and critical instructions:
R
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Be sure to read these precautionary instructions and all safety related decals installed on your lift truck before you operate it.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or s erious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
R CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Note:
Note indicates important matters and useful information on operation and maintenance.
i
FOREWORD
Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method, or operating technique not specifically recommended by MCFA is used, you must satisfy yourself that it does not pose a safety hazard to yourself and others. You should also ensure the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures you choose.
DIRECTIONAL TERMS:
The directions "Left", "Right", "Front", and "Rear" are given from the viewpoint of the operator facing forward.
All information, specifications, and illustrations in this manual are based on the latest data available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the most complete and current information from your authorized Cat lift truck dealer before starting any job. Additional manuals are available from your authorized Cat lift truck dealer. Truck Models Covered in This Manual
Truck Model
Serial Number
EC22N2
ATB30-00011-up
EC25N2
ATB30-50001-up
EC25EN2
ATB31-00011-up
EC25LN2
ATB31-30001-up
EC30N2
ATB31-50001-up
EC30LN2
ATB32-00011-up
Abbreviation
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ii
MC is short for manual control.
Control Lever
MC
TABLE OF CONTENTS
1. SAFETY RULES FOR LIFT TRUCK OPERATORS .......................1-1 General ................................................................................1-1 Location............................................................................... 1-2 Decals, Description................................................................ 1-4 Fasten Seat Belt Decal ...................................................................... 1-4 Survive in a Tipover Decal ................................................................. 1-4 Danger Electric ................................................................................. 1-5 Overhead Guard ................................................................................ 1-5 Operation Warning Decal ................................................................. 1-6 Fuse Warning ................................................................................... 1-6 Parking Brake Adjustment Decal ...................................................... 1-7 No One under / on Forks / P inch Points ............................................. 1-7 Crush and Pinch Points ..................................................................... 1-7 With Backrest Extension ................................................................... 1-8 No Riders Decal ................................................................................. 1-8 Back-up Alarm Decal ........................................................................ 1-8 Capacity Plate ................................................................................... 1-8 Designated Tire Type ........................................................................ 1-9 Safety Rules ....................................................................... 1-10 Operating Precautions ........................................................ 1-20 Working Precautions........................................................... 1-25 2. KNOW YOUR LIFT TRUCK ..................................................2-1 Serial Number and Capacity Plate ..........................................2-1 Electrical Components...........................................................2-2 Controller ......................................................................................... 2-2 Motor ............................................................................................... 2-3 Model View .......................................................................... 2-4 Driving Switches and Controls................................................ 2-6 Key Switch ........................................................................................ 2-7 Direction Lever ................................................................................. 2-7 Light Switch ..................................................................................... 2-7 Steering Column Tilt Lever ............................................................... 2-8 Meter Panel ......................................................................... 2-9 Configuration of Meter Panel ........................................................... 2-9 Meter Panel Screen Transition ........................................................ 2-12 Diagnostic Code .............................................................................. 2-13 Password Entry ............................................................................... 2-14 User Setting Function ..................................................................... 2-15 Presence Detection System.................................................. 2-16 Mast Interlock System .................................................................... 2-16 Driving Interlock System ................................................................. 2-17 Controlled Rollback Function .......................................................... 2-17 Neutral Lock ................................................................................... 2-18 Seat Belt Warning .......................................................................... 2-18 Parking Brake Warning Buzzer ....................................................... 2-19 Parking Brake Warning Buzzer and Icon ............................... 2-20 Operating Switches and Controls (MC Model) ........................ 2-21 Lift Lever ........................................................................................ 2-21 Tilt Lever ......................................................................................... 2-21 Attachment Lever ........................................................................... 2-21 Operator Seat ..................................................................... 2-22 Seat Adjustment ............................................................................. 2-22 Forward and Back Adjustment ....................................................... 2-22 Adjustment of Suspension .............................................................. 2-22 How To Tip the Seat Forward .......................................................... 2-23 Pocket for the Manual .................................................................... 2-23 Operator Presence Switch and Buzzer ............................................ 2-23
Seat Belt ............................................................................ 2-24 Fork Locking Pins ................................................................ 2-25 Changing Forks................................................................... 2-26 Assist Grip .......................................................................... 2-26 Battery Cover ..................................................................... 2-27 Hydraulic Tank Oil Level / Filler Hole .................................... 2-30 Brake Reservoir Tank Fluid Level ......................................... 2-31 Drawbar Pin (Option) .......................................................... 2-31 3. HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE ..............3-1 Know What Lift Truck Stability Is ........................................... 3-1 Center of Gravity (CG)............................................................ 3-1 Stability and Center of Gravity (Top View) .............................. 3-1 Stability and Center of Gravity (Side View) ............................. 3-2 Lift Truck Stability Base.........................................................3-2 Capacity (Weight and Load Center) ........................................ 3-2 Capacity Plate ...................................................................... 3-3 Sample .............................................................................................3-3 Do’s and Don’ts to Avoid Tipover ............................................ 3-4 How to Survive in a Tipover ...................................................3-9 4. OPERATION ....................................................................4-1 New Lift Truck Break-In......................................................... 4-1 Before Starting..................................................................... 4-1 Starting .............................................................................................4-2 Mast Interlock System .......................................................................4-2 Seat Adjustment ...............................................................................4-3 Before Moving Lift Truck ....................................................... 4-4 Lift Truck Operation.............................................................. 4-5 Changing Speed ................................................................................ 4-6 Changing Direction ...........................................................................4-6 Operating Techniques .......................................................................4-6 Steering (Turning) ............................................................................4-7 Stopping Lift Truck ............................................................... 4-9 Parking Lift Truck (After Stopping)....................................... 4-10 Leaving Lift Truck .............................................................. 4-11 5. OPERATING TECHNIQUES ................................................. 5-1 Stacking Methods.................................................................5-1 Stacking Different Size Loads ............................................................5-1 Stacking Small Identical Loads ..........................................................5-1 Stacking Large Identical Loads ..........................................................5-1 Handling Loads Safely........................................................... 5-2 Flickering of the Interlock Indicator Icons............................... 5-3 Lifting the Load.................................................................... 5-4 Traveling with the Load ........................................................ 5-6 Unloading ............................................................................ 5-8 Working on Grades ............................................................. 5-11 Normal Travel Position ....................................................................5-11 Traveling on a Grade .......................................................................5-11 Stopping on a Grade .......................................................................5-11 6. STORING THE LIFT TRUCK ................................................. 6-1 End of Each Shift Storage ...................................................... 6-1 Long Term Storage ............................................................... 6-1 Hydraulic System ..............................................................................6-1 Battery ..............................................................................................6-1 Controller ..........................................................................................6-1 Other ................................................................................................6-1 TOC-1
TABLE OF CONTENTS
7. TRANSPORTATIONS HINTS ............................................... 7-1 Lift Truck Loading and Shipping ............................................ 7-1 Lift Truck Lifting and Tie Down Information ........................... 7-1 8. SPECIAL SITUATIONS ....................................................... 8-1 Care in Cold Weather ............................................................ 8-1 Battery ..............................................................................................8-1 Care in Hot Weather ............................................................. 8-1 Battery ..............................................................................................8-1 9. TROUBLESHOOTING ........................................................ 9-1 Fuses and Lights................................................................... 9-1 How to Check Fuses and Lights .........................................................9-1 Diagnostic Code List.............................................................. 9-2 10. MAINTENANCE ............................................................. 10-1 General.............................................................................. 10-1 Inspection Precautions ....................................................... 10-3 Maintenance Schedule........................................................ 10-4 Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First 10-4 Every 50 Service Hours or Weekly, Whichever Comes First .............. 10-6 One Month (30 days) or 200 Service Hours After Delivery of a New Truck, Whichever Comes First ................................................................... 10-7 Every 500 Service Hours or 3 Months, Whichever Comes First ......... 10-8 Every 1000 Service Hours or 6 Months, Whichever Comes First ....... 10-9 Every 2000 Service Hours or 1 year, Whichever Comes First .......... 10-11 Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First .......................................................10-12 Faulty Operation Found the Day Before ........................................10-1 2 Motor ............................................................................................10-12 Battery Electrolyte ........................................................................ 10-12 Battery Charge Level ..................................................................... 10-14 Key Switch .................................................................................... 10-15 Oil or Battery Electrolyte Leaks ..................................................... 10-15 Accelerator Pedal ..........................................................................10-16 Tires and Rims ..............................................................................10 -16 Steering Wheel and Steering Column ........................................... 10-16 Wheel Nuts ................................................................................... 10-17 Brake Pedal ................................................................................... 10-17 Brake Fluid Level ..........................................................................10-18 Parking Brake Lever ...................................................................... 10-18 Brake Hose and Pipes ....................................................................10-19 Forks .............................................................................................10-19 Outer and Inner Masts .................................................................. 10-20 Tilt Cylinder and Masts .................................................................. 10-20 Outer Masts and Cylinder Support ................................................ 10-21 Lift Bracket ................................................................................... 10-21 Lift Cylinder Mounting Bolts .........................................................10-21 Mast .............................................................................................10-22 Lift Bracket Main Rollers and Side Rollers ..................................... 10-22 Mast Strip Sliding Surfaces and Rollers ......................................... 10-22 Tilt Cylinder Socket Bolts ..............................................................10-23 Mast Support ................................................................................10 -23 Lift Chains ..................................................................................... 10-23 Load Backrest Extension, Lift Bracket ............................................10-24 Cylinders (Lift Cylinders, Tilt Cylinders, and Steer Cylinder) .......... 10-24 Oil Pump ....................................................................................... 10-25 Operation Levers ...........................................................................10 -25 Control Valves ...............................................................................10 -25 TOC-2
Hydraulic Oil ..................................................................................10-25 Hydraulic Hoses, Pipes, and Joints .................................................10-27 Overhead Guard ............................................................................10-27 Assist Grip .....................................................................................10-27 Front Lights and Rear Working Light (If equipped) .......................10-27 Meter Panel ..................................................................................10-28 Operator Seat ................................................................................10-28 Seat Belt ........................................................................................10-29 Horn ..............................................................................................10-29 Mast Interlock System ...................................................................10-29 Driving Interlock System ...............................................................10-30 Driving Control System (Traction Motors, Steering System and Brake System) .........................................................................................10-30 Every 50 Service Hours or Weekly, Whichever Comes First.....10-31 Battery Electrolyte Spec ific Gravity ................................................10-31 One Month (30 days) or 200 Service Hours After Delivery of a New Truck, Whichever Comes First .............................................10-32 Rear Axle Mounting Bushing .........................................................10-32 Rear Axle King Pins .......................................................................10-32 Rear Axle Tie Rod Pins ...................................................................10-32 Lift Bracket Main Roller and Side Rollers .......................................10-33 Mast Strip Sliding Surfaces and Rollers .........................................10-33 Mast Support ................................................................................10-33 Tilt Cylinder End ............................................................................10-33 Every 500 Service Hours or 3 Months, Whichever Comes First 10-34 Differential ....................................................................................10-34 Every 1000 Service Hours or 6 Months, Whichever Comes First.......................................................10-35 Wheel Bearings .............................................................................10-35 Mast Supports ...............................................................................10-35 Tilt Sockets ....................................................................................10-35 Chain Wheel ..................................................................................10-35 Lift Chains .....................................................................................10-36 Every 2000 Service Hours or 12 Months, Whichever Comes First.......................................................10-36 Service Brakes ...............................................................................10-36 Hydraulic Oil ..................................................................................10-37 Hydraulic System ..........................................................................10-38 Parts to Be Changed Periodically ........................................10-39
11. SERVICE DATA ...............................................................11-1 Recommended Oils and Greases ...........................................11-1 Specifications (Standard Models)..........................................11-2 Capacities and Lift Truck Weight (Standard Models)...............11-2 12. TO THE CAT LIFT TRUCK OWNER .......................................12-1 The Importance of Genuine Parts .........................................12-1 Proper Disposal of Your Lift Truck .........................................12-1 Instructions for Ordering Parts .............................................12-2 Service Registration ............................................................12-3 Transfer of Ownership Report for Cat Lift Trucks Customers Only ..............................................12-4 13. APPENDIX .....................................................................13-1 Description of Circuit Diagrams ............................................13-1 Schematic diagram .........................................................................13-1 Connector Diagrams ........................................................................13-1 How to Read Circuit Diagrams ..............................................13-2 Symbols ..........................................................................................13-3
Sheet Symbol ................................................................................. 13-6 Connecting Lines ............................................................................ 13-7 Equipment ...................................................................................... 13-8 Relay Contactor and Coil ................................................................. 13-9 Connectors ..................................................................................... 13-9 Indication of Connecting Line ...................................................... 13-10 Indication of GND (Earth) .............................................................. 13-10 Indication of Another Specification ............................................... 13-11 How to Read Connector Diagrams ...................................... 13-12 Circuit Diagram................................................................. 13-14
