This manual covers the Caterpillar EP20K, EP25K, EP30K, and EP35K series electric pneumatic tire forklift trucks. These robust machines are engineered for demanding indoor warehouse operations, manufacturing facilities, and general material handling. With lift capacities ranging from 2,000 kg to 3,500 kg, they feature efficient AC drive motors for precise operation and high starting torque. Caterpillar's legacy in industrial equipment ensures a focus on durability and reliability, making these forklifts a dependable choice for various material handling needs. This comprehensive service manual provides detailed information for the maintenance, repair, and diagnostics of your Caterpillar EP Series forklift. It covers all major systems, including the electric powertrain, hydraulics, electrical system, chassis, and operator compartment. Inside, you will find preventive maintenance schedules, troubleshooting procedures, component overhaul instructions, electrical schematics, and safety guidelines. This manual is an essential resource for owners, mechanics, and technicians to ensure the optimal performance and longevity of these industrial trucks. 🏷️ Basic Information Identification Make: Caterpillar (CAT) Model: EP20K, EP25K, EP30K, EP35K PAC Forklift Trucks Product Name: EP20K-EP25K-EP30K-EP35K-Forklift-Trucks-Service Manual PDF Download Serial Number Range Ep20K: ETB8C-00011 and up Serial Number Range Ep25K: ET...... (Specific range not fully provided, but implies ET prefix) Codes Model Code Ep20K: EP20K Model Code Ep25K: EP25K Model Code Ep30K: EP30K Model Code Ep35K: EP35K 👋 Introduction Market Position Segment: Electric Pneumatic Tire Counterbalance Forklift Trucks Application: Designed for indoor warehouse operations, manufacturing facilities, and general material handling Competitive Analysis Competitors: Toyota, Mitsubishi, Crown, Hyster-Yale, Komatsu, Nissan Forklift Key Features Power Source: Electric (Battery-powered) Lift Capacities: Ranges from 2,000 kg (EP20K) to 3,500 kg (EP35K) Drive System: AC drive motors for efficient and precise operation 📋 Manual Details Coverage Areas Main Coverage: Comprehensive service and repair for Caterpillar electric pneumatic tire forklift trucks Page Count Estimated Page Count: Highly comprehensive, likely exceeding 1000 pages due to technical depth Manual Type Type: Service Manual / Repair Manual / Technical Manual Language Language: English (Standard for Caterpillar service documentation) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Electric drive motors, control systems, reduction gears, hydraulic pump drive (if applicable) Hydraulics: Lift/tilt system, steering system, auxiliary functions (if equipped), hydraulic pump, valves, cylinders, hoses, filters Electrical System: Battery system, charging system, controller (AC/DC), motor controllers, sensors, wiring diagrams, lighting, operator controls, diagnostics Chassis And Frame: Frame construction, mast assembly, overhead guard, counterweight, drive axle, steer axle, tires Operator Compartment: Seating, controls, dashboard, safety features, access panels Brakes: Service brakes (typically electric regenerative and hydraulic), parking brake system Procedures Included Diagnostics: Troubleshooting charts, fault code interpretation, electrical system diagnostics, hydraulic system diagnostics Maintenance: Preventive maintenance schedules, lubrication, fluid checks/changes, filter replacements, battery maintenance Repair: Component removal and installation (e.g., drive motor, hydraulic pump, mast components), system adjustments, seal replacement Overhaul: Detailed procedures for overhauling major components like drive motors, hydraulic pumps, and cylinders Calibration: Calibration procedures for control systems, sensors, and hydraulic functions Safety Precautions: Specific safety instructions for working on electric and hydraulic systems Technical Depth Depth: Extremely high, covering detailed internal component procedures, schematics, and specifications Diagnostics Level: Advanced, including electrical schematics, diagnostic codes, and signal tracing Component Rebuild: Comprehensive, with exploded views, part breakdowns, and assembly/disassembly instructions for major components 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable if generated from a digital source, allowing quick information retrieval Print Quality Printability: Printable for workshop use Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Electric Motor (AC) Power Output: Variable depending on model and specific configuration, but designed for demanding lift cycles. Performance Torque: High starting torque characteristic of AC electric motors, enabling smooth acceleration and load handling. Fuel System Energy Source: Lead-acid or Lithium-ion battery packs (configuration dependent) Charging System: On-board or off-board battery chargers (compatibility specified in manual) 🔧 Transmission Standard Type: Direct drive to drive axle via reduction gears (no traditional gearbox) Optional Features: Regenerative braking controlled by the AC drive system Features Control: Electronic speed control via operator's accelerator pedal and direction control 📐 Dimensions Exterior Lift Height Max: Varies by mast type and configuration (e.g., 3m, 4m, 5m, 6m+). Specific details in manual. Fork Length: Standard lengths typically 1070mm or 1220mm, specified by model and options. Weights Operating Weight: Includes battery, varies significantly by model capacity and configuration. Refer to specific model data plates. Axle Loading: Specific front and rear axle loads under various load conditions detailed in the manual for safe operation. 🛡️ Safety Features Ratings Design Standards: Adherence to relevant ISO, ANSI/ITSDF, and European safety standards for industrial trucks. Active Features Speed Control: Operator-controlled acceleration and deceleration, regenerative braking. Anti-Roll Back: Built into the drive system, preventing unintended movement on inclines. Passive Features Overhead Guard: Standard for operator protection from falling loads. Seatbelt: Standard operator restraint system. Mast Guard: Protects operator's...