Caterpillar Forklift E3000 Operation and Maintenance Manual

Format: PDF
Language: English
Brand: CAT Caterpillar
Machine type: Forklift
Manual Type: Operation and Maintenance Manual
Model: CAT E3000 Forklift
Date: 2021
Content:
Operation and Maintenance Manual E3000 E3000 E3500 EC4000 E4000 E5000 E5500 EX5000 E6000 E6500 99750-8C131 (148 pages)
99750-8C121-00 Foreword
99750-8C121-01 Safety rules for forklift operators
99750-8C121-02 Know your forklift
99750-8C121-03 How to avoid a rollover; How to survive a
99750-8C121-04 Operation
99750-8C121-05 Operating techniques
99750-8C121-06 Forklift storage
99750-8C121-07 Transportation Tips
99750-8C121-08 Special situations
99750-8C121-09 Maintenance
99750-8C121-10 Service data
99750-8C121-11 For the forklift owner
Cat List of Cat Publications (Service, Operator and Parts Manuals)
Mast Tilt Angles Mast Tilt Angles
REF-18-0001C How to determine the correct mast rails, lift cylinders and mast hoses
REF-18-0001C How to determine the correct mast rails, lift cylinders and mast hoses (Spanish)
REF-18-0002C How to locate fluid capacities
REF-18-0002C How to locate fluid capacities (Spanish)
REF-18-0003C How to use a selection list
REF-18-0003C How to use a selection list (Spanish)
REF-18-0007C List of abbreviations and acronyms
REF-18-0008C Diagnostic Trouble Codes (Error)

This parts manual includes all the spare parts you need on this model to make it easier for you to repair your forklift and replace new spare parts for high performance.
This service manual is a guide to performing maintenance on Cat forklifts. For your convenience, the instructions are grouped by system for easy reference.
This original operator's manual describes the operating procedures, daily checks and simple maintenance for the safe use of your Cat forklift.

SERVICE MANUAL

CHAPTER 1 GENERAL INFORMATION
1.1 Model view
1.2 Models covered
1.2.1 Nomenclatures and definitions of forklifts
1.3 Location of serial numbers
1.4 Dimensions
1.5 Technical data
1.6 Performance
CHAPTER 2 COOLING SYSTEM
2.1 Specifications
2.2 Structure
2.3 Disassembly and installation
2.3.1 Removing the fan belt
2.3.2 Suggestions for disassembly
2.3.3 Installation
2.4 Inspection and adjustment
2.4.1 Fan Belt Inspection
2.4.2 Fan belt tension
2.4.3 Connection hoses
2.4.4 Refrigerant
2.4.5 Radiator cap
CHAPTER 3 ELECTRICAL SYSTEM
3.1 Wiring diagram of electrical devices on the chassis
3.1.1 Harness arrangement
3.1.2 Component layout
3.2 Structure
3.2.1 Console box
3.2.2 Main electrical components
3.2.3 Lamp Table
3.3 Console Box
3.3.1 Disassembly
3.4 Battery Maintenance
3.4.1 State of Charge and Electrolyte Specific Gravity (SG) Adjustment
3.4.2 Specific Gravity and State of Charge Reading
3.4.3 Loading Precautions
3.5 Instrument Panel
3.5.1 Instrument Panel Display Element
3.5.2 Basic Screen
3.5.3 Basic Operation
3.5.4 When an Error Occurs
3.5.5 Warning Lamps
3.5.6 Optional Functions
3.5.7 Hour Counters
3.5.8 Troubleshooting
3.6 Cable Color
3.6.2 Cable Color List
3.7 Troubleshooting
3.7.1 Starting System
3.7.2 Meters
3.7.3 Lighting System
3.8 Electrical Schematic
CHAPTER 4 CONTROLLERS
4.1 Scheme
4.2 Main Functions
4.2.2 Instrument Panel
4.2.3 VCM (Vehicle Control Module)1-M
4.2.4 ECM (Gasoline Engine Control Module)
4.2.5 Remote input/output units
4.2.6 GSE Connector
4.3 Service Tool Functions
4.3.1 Tool menus
Service Tool Box 4.3.2 Service Tool Box
4.4 Mast interlock system
4.4.1 Function
4.4.2 Mast interlock system verification procedure, VCM1-M controller
4.4.3 Active Test Inspection Procedure
4.5 Driving interlock system
4.5.1 Function
4.5.2 Powershift T/M Forklift Driving Interlock System Check Procedure
4.5.3 Active Test Inspection Procedure
4.6 Seat belt warning lamp
4.6.1 Function
4.6.2 Seat belt warning lamp check procedure
4.7 Parking brake warning lamp and buzzer
4.7.1 Function
4.7.2 Parking brake warning lamp/buzzer check procedure
4.7.3 Parking brake warning light/buzzer check procedure with the key in the OFF position
4.8 Harness Codes
4.9 Controller Details
4.9.1 VCM1-M Controller
4.9.2 Seat switch/seat belt switch
4.9.3 Parking brake switch
4.9.4 Steering lever
4.9.5 Speed ​​sensor
4.9.6 T/M Solenoid
4.9.7 Dump solenoid
4.9.8 Lift lock solenoid
4.9.9 Warning buzzer
4.9.10 Warning Buzzer Relay
4.9.11 Warning Buzzer Circuit
4.9.12 Instrument panel
4.10 Error Codes and Troubleshooting
4.10.1 Displaying error codes
4.10.2 Diagnostic table (F code)
4.10.3 Error Codes and Troubleshooting
4.11 Sensor and switch locations
CHAPTER 5 POWERTRAIN
5.1 Removal and Installation (MC models)
5.1.1 Removing the engine and transmission assembly
5.1.2 Removing the engine and transmission assembly (for gasoline-powered forklifts)
5.2 Removal and installation (FC models)
5.2.1 Removing the engine and transmission assembly
CHAPTER 6 POWERSHIFT TRANSMISSION
6.1 Structure and functions
6.1.1 Transmission
6.1.2 Torque converter
6.1.3 Control valve
6.1.4 Powershift transmission hydraulic system diagram
6.2 Removal and installation
6.2.1 Extraction
6.2.2 Installation
6.3 Control valve
6.3.1 Disassembly
6.3.2 Reassembly
6.4 Input shaft assembly
6.4.1 Disassembly
6.5 Oil pump assembly 6.5.1
Disassembly
6.5.2 Reassembly
6.6 Inspection and adjustment
6.6.1 Oil pressure measurement
6.6.2 Clutch pedal adjustment (inching)
6.6.3 Slow feed cable, adjustment
6.7 Troubleshooting
6.8 Tightening torque
6.9 Service data
CHAPTER 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
7.1 Structure
7.1.1 Front axle
7.1.2 Reduction differential
7.2 Disassembly and installation
7.2.1 Front wheels
7.3 Front axle
7.3.2 Reduction differential
7.4 Disassembly and assembly
7.4.1 Front axle
7.4.2 Reduction differential
7.5 Troubleshooting
7.6 Service data
CHAPTER 8 REAR AXLE
8.1 Structure and functions
8.1.1 Rear axle in general
8.1.2 Structure of each component
8.1.3 Steering cylinder
8.2 Disassembly and installation
8.2.1 Rear wheel and rear axle assembly
8.3 Disassembly and assembly
8.3.1 Wheel hub, disassembly and assembly
8.3.2 Trunnion (king pin), disassembly and assembly
8.3.3 Steering cylinder, disassembly and reassembly
8.3.4 Tie rod, disassembly and reassembly
CHAPTER 9 BRAKE SYSTEM
9.1 Structure
9.1.1 Brake system
9.2 Disassembly and reassembly
9.2.1 Master cylinder
9.2.2 Wheel brakes
9.2.3 Wheel cylinder
9.3 Inspection and adjustment
9.3.1 Automatic adjuster test
9.3.2 Manual adjustment
9.3.3 Adjusting the parking brake cable
9.3.4 Adjusting the brake pedal
9.3.5 Bleeding the brake lines
9.3.6 Braking performance test
9.3.7 Parking brake lever
9.4 Troubleshooting
9.5 Service data
CHAPTER 10 STEERING SYSTEM
10.1 Structure and functions
10.1.1 Steering system
10.1.2 Steering valve
10.1.3 Steering column
10.2 Disassembly and reassembly
10.2.2 Steering wheel and valve, removal and installation
10.2.3 Steering wheel
10.2.4 Steering valve
10.2.5 Tilt lock lever
10.3 Steering valve
10.3.1 Disassembly
10.3.2 Reassembly
10.4 Troubleshooting
10.5 Service data
CHAPTER 11 HYDRAULIC SYSTEM
11.1 Structure and functions
11.1.1 Scheme
11.2 Hydraulic circuit diagram (for models with MC control valve)
11.3 Hydraulic circuit diagram (for models with FC control valve) 11.4 Hydraulic tank 11.5 Hydraulic pump (gear pump) 11.6 Control valve 11.7 Flow regulating valve (only for models with FC control valve) 11.8 Down safety valve 11.9 Lift cylinder 11.10 Tilt cylinder 11.11 Disassembly and reassembly 10.2.3 Steering wheel and steering valve, removal and installation
10.2.4 Steering valve 10.2.5 Tilt lock lever 10.3 Steering valve 10.3.1 Disassembly 10.3.2 Reassembly 10.4 Troubleshooting 10.5 Service data CHAPTER 11 HYDRAULIC SYSTEM 11.1 Structure and functions 11.1.1 Schematic 11.2 Hydraulic circuit diagram (for models with MC control valve) 11.3 Hydraulic circuit diagram (for models with FC control valve) 11.4 Hydraulic tank
11.5 Hydraulic pump (gear pump)
11.6 Control valve
11.7 Flow regulating valve (only for models with FC control valve)
11.8 Downstream safety valve
11.9 Lifting cylinder
11.10 Tilt cylinder
11.11 Disassembly and re-assembly
11.11.1 Hydraulic pump
11.11.2 Lifting cylinder
11.11.3 Tilt cylinder
11.11.4 Flow regulating valve
11.11.5 Pipeline
11.11.6 Suction and return filter
11.12 Inspection and adjustment
11.12.1 Hydraulic tank
11.12.2 Control valve
11.12.3 Descent test
11.12.4 Forward tilt test
11.13 Solution of
Problems 11.13.2 Cleaning the hydraulic system after a component failure
11.14 Service data
11.15 MC control valve
11.15.1 Structure and operation
11.15.2 Control valve, removal and installation
11.15.3 Disassembly and assembly
11.16 FC control valve
11.16.1 Structure and operation
11.16.2 Disassembly and assembly
CHAPTER 12 MAST AND FORKS
12.1 Single mast
12.1.1 Mast system
12.2 Structure and functions
12.2.1 Single mast (5A15C to 5A33C)
12.2.2 Mast Operation
12.3 Disassembly and installation
12.3.1 Mast and lifting bracket assembly
12.4 Disassembly and reassembly
12.4.1 Disassembling the single mast
12.4.2 Reassembly of the single mast
12.5 Removing and installing mast rollers and straps without removing
12.5.1 Single mast
12.6 Inspection and adjustment (single mast)
12.6.2 Forks
12.6.3 Inspection and adjustment of chain tension
12.6.4 Checking chain elongation
12.6.5 Adjusting the clearance between the lift support roller and the inner mast
12.6.6 Adjusting the mast roller clearance
12.6.7 Inspection and adjustment of mast strap clearance
12.6.8 Adjusting the tilt angle
12.6.9 Inspection and adjustment of the right and left lifting cylinder stroke
12.7 Troubleshooting (single mast)
12.8 Service data (single mast)
12.9 Duplex mast
12.9.1 Mast system
12.10 Structure and functions
12.10.1 Duplex mast (fully free double panoramic) (5B15C to 5B33C)
12.10.2 Mast operation
12.11 Removal and installation
12.11.1 Mast and lifting bracket assembly
12.12 Disassembly and reassembly
12.12.1 Disassembling the duplex mast
12.12.2 Duplex mast reassembly
12.13 Removing and installing mast rollers and straps without removing
12.13.1 Duplex mast
12.14 Inspection and adjustment (duplex mast)
12.14.1 Inspection and adjustment (duplex mast)
12.14.2 Forks
12.14.3 Inspection and adjustment of chain tension
12.14.4 Checking chain elongation
12.14.5 Adjusting the clearance between the lift support roller and the inner mast
12.14.6 Adjusting the mast roller clearance
12.14.7 Inspection and adjustment of mast strap clearance
12.14.8 Adjusting the tilt angle
12.14.9 Inspection and adjustment of the right and left lift cylinder stroke
12.15 Troubleshooting (duplex mast)
12.16 Service data (duplex mast)
12.17 Triplex mast
12.17.1 Mast system
12.18 Structure and functions
12.18.1 Triplex mast (unobstructed triple panoramic) (5C15C to 5C33C)
12.18.2 Mast operation
12.19 Removal and installation
12.19.1 Mast and lifting bracket assembly
12.20 Disassembly and reassembly
12.20.1 Disassembling the triplex mast
12.20.2 Reassembly of the triplex mast
12.21 Removing and installing mast rollers and straps without removing
12.21.1 Triplex mast
12.22 Inspection and adjustment (triplex mast)
12.22.2 Forks
12.22.3 Inspection and adjustment of chain tension
12.22.4 Checking chain elongation
12.22.5 Adjusting the clearance between the lift support roller and the inner mast
12.22.6 Adjusting the mast roller clearance
12.22.7 Inspection and adjustment of mast strap clearance
12.22.8 Adjusting the tilt angle
12.22.9 Inspection and adjustment of the right and left lift cylinder stroke
12.23 Troubleshooting (Triple Mast)
12.23.1 Troubleshooting (Triple Mast)
12.24 Service data (triple mast)
12.24.1 Triple mast
CHAPTER 13 SERVICE DATA
13.1 Maintenance program
13.2 Maintenance note
13.2.1 Brake system
13.2.2 Cooling system
13.2.3 Electrical system
13.2.4 Engine system
13.2.5 Frame and chassis
13.2.6 Fuel system
13.2.7 Hydraulic system
13.2.8 Ignition system
13.2.9 Intake system
13.2.10 Front section
13.2.11 Steering system and axle
13.2.12 T/M and transmission system
13.2.13 Wheels and tires
13.2.14 General
13.3 Tightening torque of standard bolts and nuts
13.4 Periodic spare parts
13.4.2 Location of periodic spare parts
13.5 Lubrication instructions
13.5.1 Lubrication table
13.5.2 Fuel and lubricant specifications
13.5.3 Adjustment value and oil quantities
13.6 Special service tools
13.6.1 Special service tools (standard tools for MC and FC forklifts)
13.6.2 Special service tools (FC forklifts only)
13.6.3 Special service tools (for Powershift transmission)

OPERATION MANUAL

CHAPTER 1 SAFETY RULES AND PRACTICES
1.1 SAFETY SIGNS AND MESSAGES
1.2 SYMBOLS AND WARNING LEVELS
1.3 OPERATOR QUALIFICATIONS
1.4 SECURITY PROTECTORS
1.5 PERSONAL PROTECTIVE EQUIPMENT FOR OPERATING A FORKLIFT
1.6 DAILY INSPECTION
1.7 OPERATOR RESPONSIBILITY
1.8 GENERAL
1.9 NON-PASSENGERS
1.10 TRANSFER
1.11 LOAD
1.12 DOCKS (BRIDGE PLATES), TRUCKS AND RAILWAY CARS
1.13 SURFACE AND CAPACITY
1.14 FUEL MANAGEMENT
1.15 INSTALLING ACCESSORIES
1.16 IN CASE OF ROLLOVER
1.17 FORKLIFT TRANSPORT
1.17.2 APPROACH ANGLE, DEPARTURE ANGLE AND GATEWAY
1.17.3 TRUCK LIFTING
1.18 FUNCTIONAL TESTS
1.19 PULL-UP BAR
1.20 POSITION OF DATA AND CAPACITY PLATES AND DECALS
1.21 DATA AND CAPACITY PLATES AND DECALS
1.21.2 DATA PLATE
1.21.3 IDENTIFICATION NUMBERS
1.21.4 DRIVING CAUTION DECAL (IN CASE OF ROLLOVER)
1.21.5 DRIVING WARNING DECAL (TRAINED AND AUTHORIZED)
1.21.6 CRUSH POINT DECAL
1.21.7 CAUTION DECAL ON FORK
1.21.8 MAST WARNING DECAL
1.21.9 DRIVING CAUTION DECAL (OPERATION)
1.21.10 RADIATOR WARNING DECAL
1.21.11 COOLING DECAL
FAN WARNING 1.21.12 LPG SETTING WARNING DECAL
1.21.13 LPG LATCH WARNING DECAL
1.21.14 LPG FUEL WARNING DECAL
CHAPTER 2 CONTROLS AND OPERATING FUNCTIONS
2.1 APPLICATIONS
2.2 APPLICATION FOR CAT FORKLIFTS
2.3 PROHIBITED APPLICATIONS FOR CAT FORKLIFTS
2.4 MAIN COMPONENTS
2.5 METERS, INDICATORS AND WARNING LIGHTS
2.5.2 LCD
2.5.3 OPERATION BUTTONS
2.5.4 ! MULTIPURPOSE WARNING LIGHT
2.5.5 MALFUNCTION INDICATOR LIGHT - CHECK ENGINE WARNING
2.5.6 OIL PRESSURE WARNING LIGHT
2.5.7 CHARGING WARNING LIGHT
2.5.8 PARKING BRAKE WARNING LIGHT
2.5.9 SEAT BELT WARNING LIGHT
2.5.10 METER SCREEN
2.5.11 WATER TEMPERATURE INDICATOR
2.5.12 FUEL GAUGE
2.5.13 TRANSMISSION POSITION
2.6 WARNING AND MALFUNCTION INDICATIONS
OPERATION 2.6.2 MAST INTERLOCK WARNING
2.6.3 LPG LEVEL WARNING/LPG SHELF BLOCKAGE WARNING
2.6.4 TORQUE CONVERTER FLUID TEMPERATURE WARNING
2.6.5 RADIATOR LEVEL WARNING
2.6.6 AIR FILTER WARNING
2.6.7 SERVICE REMINDER SCREEN
2.6.8 SCREENS WHEN A MALFUNCTION OCCURS
2.7 DRIVER RECOGNITION MODE
2.8 MANAGEMENT OF REMAINING LPG TIME
2.9 SWITCHES
2.9.2 HORN BUTTON
2.9.3 RIGHT REAR GRIP WITH HORN BUTTON
2.9.4 POWER SWITCH
2.9.5 LIGHTING AND TURN SIGNAL SWITCHES
2.9.6 MAXIMUM SPEED CHANGE SWITCH (OPTIONAL)
2.9.7 THROTTLE SENSITIVITY ADJUSTMENT SWITCH (OPTIONAL)
2.9.8 REVERSE OPERATION LIGHT SWITCH (OPTIONAL)
2.10 OPERATION CONTROLS
2.10.2 SELECTOR LEVER 2.10.3 LEVER
PARKING BRAKE
2.10.4 SLOW BRAKE PEDAL
2.10.5 BRAKE PEDAL
2.10.6 ACCELERATOR PEDAL
2.10.7 LOAD HANDLING CONTROL LEVERS 2.10.8
ANSI/ITSDF STANDARDS FOR FORKLIFT CLAMP ATTACHMENTS
2.10.9 ADDRESS FEATURES
CHAPTER 3 FORKLIFT OPERATION
3.1 OPERATION
3.2 PRE-OPERATION INSPECTION
3.3 FORKLIFT OPERATION PRECAUTIONS
3.4 PRECAUTIONS FOR COLD AND HOT CLIMATES
3.5 OPERATING PROCEDURES
3.6 STARTING THE LPG FORKLIFT
3.7 PROCEDURE FOR STARTING EFI ENGINES WITH DOORS
3.8 AUTOMATIC TRANSMISSION
3.9 LOAD
3.10 TRANSPORT OF CARGO
3.11 DOWNLOAD
3.12 ASCENT
3.13 STOPPING AND PARKING THE FORKLIFT
3.14 FORKS
3.15 SEAT ADJUSTMENT
3.15.1 ADJUSTING THE OPERATOR WEIGHT OF THE SUSPENSION SEAT
3.15.2 FORWARD AND REVERSE CONTROL LEVER
3.15.3 ADJUSTING THE BACKREST INCLINATION
3.15.4 LUMBAR ADJUSTMENT
3.15.5 SWIVEL SEAT
3.16 SEAT BELT
3.17 TOP PANEL
3.18 TILT STEERING WHEEL
3.19 SERVICE RELEASE LATCH
3.20 RADIATOR COVER
3.21 REARVIEW MIRROR (OPTIONAL)
3.22 LPG CYLINDER (TANK) SUPPORT
CHAPTER 4 GENERAL CARE AND MAINTENANCE
4.1 CARE AND MAINTENANCE OF WET CELL BATTERY
4.2 BATTERY SPECIFIC GRAVITY
4.3 DAILY INSPECTION
4.4 DAILY OPERATOR CHECKLIST (SAMPLE)
4.5 MAINTENANCE AND INSPECTION
4.5.1 ENGINE OIL LEVEL
4.5.2 FILLING ENGINE OIL
4.5.3 ENGINE COOLANT LEVEL
4.5.4 ENGINE COOLANT TOPPING
4.5.5 COOLING SYSTEM OPERATING INSTRUCTIONS
BLEEDING 4.5.6 BRAKE FLUID LEVEL
4.5.7 TOPPING BRAKE FLUID
4.5.8 AUTOMATIC TRANSMISSION FLUID LEVEL
4.5.9 FILLING AUTOMATIC TRANSMISSION FLUID
4.5.10 HYDRAULIC OIL LEVEL
4.5.11 HYDRAULIC OIL FILLING 4.5.12 CLEARANCE OF THE
STEERING WHEEL
4.5.13 WHEEL AND TIRE
4.5.14 REPLACING TYRES 4.5.15 CHECKING THE MAST 4.5.16 CHECKING THE LIFT CHAIN ​​4.5.17 INSPECTION OF THE FORKS 4.5.18 REPAIRING THE FORKS 4.5.19 CHECKING THE HORN 4.5.20 CHECKING THE LIGHTS 4.5.21 CHECKING THE LOAD HANDLING CONTROL LEVER(S) 4.5.22 CHECKING THE BRAKE PEDAL 4.5.23 PEDAL FREE PLAY 4.5.24 CHECKING THE PARKING BRAKE LEVER










4.5.25 CHECKING THE TOP PANEL LOCK
4.5.26 FUSES
4.5.27 CHECKING THE AIR FILTER
4.5.28 CHECKING THE BELT
FROM THE FAN 4.5.29 DRAINING TAR FROM THE VAPORIZER
4.5.30 PRECAUTIONS FOR THE USE OF LPG
4.5.31 RECOMMENDED LPG FUEL TYPE
4.5.32 CYLINDER (TANK) SIZE 4.5.33 REPLACEMENT
FROM THE LPG CYLINDER (TANK)
4.5.34 FILLING OF LPG CYLINDERS (TANKS)
4.5.35 PERIODIC MAINTENANCE AND LUBRICATION PROGRAM
4.5.36 PERIODIC MAINTENANCE AND LUBRICATION PROGRAM FOR THE EMISSION CONTROL SYSTEM
4.5.37 LUBRICATION CHART
4.5.38 RECOMMENDED LUBRICANTS
4.5.39 SAE RECOMMENDED VISCOSITY TABLE
4.5.40 FORKLIFT STORAGE
4.6 LATERAL DISPLACEMENT
4.6.1 OVERVIEW OF LATERAL DISPLACEMENT
4.6.2 MAIN TERMS USED IN THIS SECTION
4.6.3 SAFETY RULES AND PRACTICES
4.6.4 OPERATION OF THE SIDE SHIFT CONTROL LEVER
4.6.5 OPERATION OF LATERAL SHIFT
4.6.6 DAILY CHECKS AND SIMPLE MAINTENANCE
CHAPTER 5 SPECIFICATIONS
5.1 MODEL IDENTIFICATION
5.1.1 MODEL VARIATION BREAKDOWN (LONG MODEL CODE)
5.2 MAIN LIFT
5.2.1 MAIN FORKLIFT – 2C7000 AND 2C8000/2C8000-SWB
5.3 MAST
5.3.1 2C7000 AND 2C8000/2C8000-SWB
5.4 FUEL AND OIL CAPACITY
5.5 ENGINE
5.6 ENGINE OIL CAPACITY
5.7 NOISE LEVEL