||||||||||||||||||||||||||||||||||||||||||||||||||||||||| MAINTENANCE ||||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ General
Taking proper care of your lift truck is a vital
part of the overall planned maintenance
program.
Follow these rules to help save you from injury
Your participation in this program will provide
and to service your truck properly.
an early warning to help identify potential
maintenance problems.
Do-it-yourself maintenance does not include
repairs. If your truck requires any repairs,
consult your Cat lift truck dealer. The dealer’s
lift truck mechanics are well trained and know
how to safely make repairs.
! WARNING
Should the truck become unsafe during
operation in any way whatsoever, you
must report it immediately to the
designated authority. The truck must not
be used again until it has been restored to
safe operational condition.
76
! WARNING
• Make sure the service area is safe.
• Follow the recommended safe
procedures.
• Use only the right tools for the job.
• Park the truck on a level surface with
the forks lowered, parking brake
applied, forward-reverse lever in
NEUTRAL and battery disconnected.
! WARNING
Do not bypass any electrical switch on this
truck.
! WARNING
Lines, Tubes and Hoses
Do not bend or strike high pressure lines.
Do not install bent or damaged lines,
tubes or hoses.
Repair loose or damaged hydraulic oil
lines, tubes or hoses. Leaks can cause
fires. Contact your Cat lift truck dealer
for repair or replacement.
Check lines, tubes and hoses carefully. Do
not use your bare hands to check for
leaks, use a board or cardboard. Tighten
connections to the recommended torque.
If any of the following is found on a part,
replace the part:
• End fittings damaged or leaking.
• Outer covering chafed or cut and wire
reinforcing exposed.
• Outer covering ballooning locally.
• Evidence of kinked or crushed hose.
• Metal embedded in the outer cover.
• End fittings displaced.
Make sure that all clamps, guards and
heat shields are installed correctly to
prevent vibration, rubbing against other
parts, and excessive heat during
operation.
76
MAINTENANCE

◆ Inspection Precautions

A daily (Pre-Start) inspection is the key to

! WARNING ! CAUTION safety. At the beginning of each shift, check
If it is necessary to make an inspection • Avoid mixing lubricants. In some cases, your lift truck to make sure it is in safe
while the lift truck is turned on, ALWAYS different brands of lubricants are not operating condition.
USE TWO WORKERS—one, the compatible with each other and deterio- Always inspect your truck under the following
operator, at the controls and the other rate when mixed. It is best to stick with conditions.
checking where the operator can see him. the same brand at successive service
intervals.
• Before refilling, clean filler holes. After • Lift truck level
! WARNING filling, clean up spills. • Mast in vertical position
• Fork tips on ground
• Battery disconnected
• Wheels Blocked
ER
NG

op not
te
DA

era
do

If your truck requires any repair, attach a “DO

NOT OPERATE” or similar warning tag to the
steering wheel or other control, remove the key,
and contact your Cat lift truck dealer.

77 77
MAINTENANCE

◆ Maintenance Schedule
• Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First,
As the operator, you are responsible for the performance of daily pre-start
continued
inspection “Every 10 Service Hours or Daily.” You are also responsible for
those items listed under “Every 50 Service Hours or Weekly” whichever Item Service Page
comes first on the Lubrication and Maintenance Chart to keep your lift truck Brake Pedal Check 86
in proper working condition.
For periodic inspection and periodic change of rubber parts, however, rely on Damage or Faulty Operation
the expert knowledge of the factory-trained servicemen, and the service Found the Day Before Check 80
facilities at your Cat lift truck dealer’s workshop. Driving Interlock System Check 90
Forks Check 81
• Every 500 hours or 3 months
(Whichever Comes First) Front Wheel Nuts Check 80
Periodic Maintenance • Every 1000 hours or 6 months
Intervals (Whichever Comes First) Horn Check 86
• Every 2000 hours or 12 months Hour Meter Check 87
(Whichever Comes First)
Hydraulic Oil Level Check 81
Your pre-start inspection duties (Every 10 Service Hours or Daily) are Lift Chains Check and Adjust 89
covered in the remainder of this section.
Lights (if equipped) Check 81
• Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First Mast and Forks Check 84
Mast Interlock System Check 90
Item Service Page
Mast Operation Check 88
Accelerator Pedal Check 83
Oil or Battery Acid Leaks Check 80
Assist Grip Check 82
Optional Warning Devices (if installed) Check 88
Backrest (Load Backrest Extension) Check 81
Overhead Guard Check 82
Back-up Buzzer Check 85
Parking Brake Lever Check 86
Battery (Retention System) Check 85
Parking Brake Warning Buzzer and Light Check 91
Battery Charge Check 87
Seat Adjustment Check 83
Battery Discharge Indicator and
Speed/ Fault Code Display Check 87 Seat Belt and Seat Belt Switch Check 83
Battery Electrolyte Level Check 82 Seat Belt Warning Light Check 91
Battery Specific Gravity Check 85 Tilt Cylinder Socket Bolts Check 82
Battery Weight/Type Check 82 Tires Check 80
Brake Fluid Check 81 Vehicle Monitoring System Action Light Check 87

78 78
MAINTENANCE

• Every 50 Service Hours or Weekly, Whichever Comes First • Every 1000 Service Hours or 6 Months, Whichever Comes First
Item Service Page Item Service Page
Brake Hoses, Pipes and Joints Check 92 Differential Change Oil 96
Hydraulic Hoses, Pipes and Joints Check 92 Hydraulic System Change Return Oil Filter 96
Mast Supports Lubricate 92

• Every 2000 Service Hours or 1 Year, Whichever Comes First

• One Month After Delivery of a New Truck Item Service Page
Item Service Page Hydraulic Oil Change 98
Bolts, Nuts Retighten 93 Service Brake Fluid Change 98
Differential Check Oil Level 93
Hydraulic Tank Return Oil Filter Change 93

• Every 500 Service Hours or 3 Months, Whichever Comes First

Item Service Page
Brake Pedal Lubricate 95
Differential Check Oil Level 94
King Pins Lubricate 94
Lift Bracket Side Rollers Lubricate 95
Lift Chains Lubricate/Inspect 95
Mast Strip Roller Surfaces Lubricate 95
Rear Axle Center Pins Lubricate 94
Tie Rod Ends Lubricate 94
Tilt Socket Pins Lubricate 95
Wheel Nuts Retighten 94

79 79
MAINTENANCE

◆ Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First

• Damage or Faulty Operation Found the • Tires (Cushion) Check • Front Wheel Nuts Check
Day Before Check

1 inch
(2.5 cm)

Have repairs been made properly? Check the Is the tread area thickness more than 1 inch (25 • Are the front wheel nuts tightened properly?
pre-start inspection sheet. mm)?
If that thickness is less than 1 inch (25mm), the Tightening Torques for Front Wheel Nuts
tire must be replaced. For procedure on Unit: lbf•ft (kgf•m) [N•m]
replacing front tires, see the topic Changing
Tires. E3000–EC4000 Front 116 (16) [157]
E4000–E6500 Front 278 (38.5) [378]

• Oil or Battery Acid Leaks Check

! CAUTION
Changing the rear tires on your lift truck is a
specialized task. If these tires need
replacement contact your Cat lift truck
dealer.

Check on the floor for oil or battery acid leaks.

80 80
MAINTENANCE

• Brake Fluid (Truck level, floor plate • Hydraulic Oil Level (Truck level, floor • Backrest (Load backrest extension)
removed) Check plate removed) Check Check

B0007 970006A

Is the fluid level maintained between the MAX
and MIN marks on the reservoir?
Is the oil level maintained in the correct range of Have repairs been made properly? Check the
the dipstick? pre-start inspection sheet.
1. Remove the dipstick; wipe it clean, then
insert it all the way.
2. Again, remove the dipstick, and take the
reading.

• Lights (if equipped) • Forks Check

Are all the lights in safe working condition? Are Correct Level Range
their lenses clean and not defective? Do the tail
and head lights come on properly when you
switch them on?

970005A

If the level is low, see the topic Adding Are the forks free of distortion, cracks and other
Hydraulic Oil. defects?
Are the stopper pins properly engaged?

81 81
MAINTENANCE
• Tilt Cylinder Socket Bolts With the Battery Cover Opened • Battery Electrolyte Level Check

HIGH LEVEL
BOTTOM OF VENT WELL

LOW LEVEL

102706 970067

• Are the bolts tightened properly? • Battery Weight / Type Check Is the electrolyte level maintained between the
Use a wrench. Is the battery weight within the range specified UPPER LEVEL and LOWER LEVEL
NOTICE: After retightening the bolt, put a on the battery size label decal? The battery type specified by the battery manufacturer?
mark across the bolt and tilt must meet minimum requirements listed on the If the level is low, see the topic Adding Battery
cylinder socket. This permits truck capacity chart name plate. Electrolyte.
you to easily notice loosening of
the bolt.
Tightening Torque for the Bolts:
110 to 136 N•m (11.3 to 13.9 kgf•m) [82–100 lbf•ft]
• Overhead Guard Check
Refer to service manual for proper tilt angle
adjustment procedure if the tilt socket bolt is
found loose.
• Assist Grip

Battery Size
Label

1. Check the front and rear overhead guard

mounting bolts on each side. Tighten bolts to
124 to 166 N•m (12.5 to 16.9 Kgf•m) [91 to
Capacity Chart 122 lbf•ft].
Inspect the assist grip for damage or cracks and 2. Inspect overhead guard for bent or cracked
also check that it is secure. Tighten the screws sections. Contact your Cat lift truck dealer if
of the assist grip if necessary. repairs are needed.
82 82
MAINTENANCE

In Seat Check • Seat Adjustment Check • Accelerator Pedal Check

100700

Can you depress the pedals all the way? Can you depress the accelerator pedal
For seat adjustment, see the topic Operator’s smoothly? Does the pedal interfere with
Seat Adjustment. anything.

• Seat Belt and Seat Belt Switch

104274 B00090P

Is the seat belt in safe condition? Optional foot-operated directional control.

Replace the belt assembly if the belt is torn, cut,
or if the plate and/or buckle is defective.
Does the seat belt switch cause the warning
light and buzzer to come on? (Unbuckled)
Replace the belt if it does not operate correctly.

83 83
MAINTENANCE

101628 101629
• Mast and Forks Check
B

C
A

101064
– Does the mast move up and down smoothly
when you operate the lift control lever?
– Does the mast tilt forward and back
smoothly when you operate the tilt control
lever?
– Are there any oil leaks from the cylinders
and hydraulic lines?
If the truck is being used to carry maximum
capacity loads, the forks should be checked
daily.
1. Carefully inspect the forks for cracks.
Special attention should be given to the heel
section A, all weld areas and mounting
brackets B.
Forks with cracks should be removed from
service.
“Wet Test” magnetic particle inspection is
generally preferred due to its sensitivity and the
ease of interpreting the results. Portable
equipment is usually recommended so it can be
moved to the lift truck.
Contact your Cat lift truck dealer for further
information.
2. Check the difference in height of one fork
tip to the other when mounted on the fork
carrier. A difference in fork tip height can
result in uneven support of the load and
cause problems when entering loads.
The maximum allowable difference in fork tip
elevation C is 5 mm (0.19 in.) for pallet forks.
Replace one or both forks when the difference
in fork tip height exceeds the maximum
allowable difference.
101630
D

Unit: mm (in.) 3. Check the fork blade D. The fork should be

Tolerant thickness Std. Limit withdrawn from service if the thickness is
103444
reduced to less than the tolerant thickness.
E3000 40 (1.6) 31 (1.2)
– Are the stoppers properly engaged? Fork blade length may also be reduced by wear,
– Are the forks free of distortion and cracks? E3500-EC4000 40 (1.6) 31 (1.3) especially on tapered forks and platens. Remove
– Are the welds of the hangers free of cracks? E4000 45 (1.8) 36 (1.4) the forks from service when the blade length is
E5000-E5500 45 (1.8) 39 (1.5) no longer adequate for the intended loads.
E6500 45 (1.8) 40 (1.57)

84 84
MAINTENANCE

• Battery Specific Gravity Check • Battery (Retention System) Check Close the Battery Cover

Retention Plates
! WARNING

Retention Swing Arm

Using a battery hydrometer, check the specific 970002

gravity of the battery cells. Take the reading at
eye level. Keep your hand away from the pinch points
when closing the cover.
970091

Is the battery restrained from moving more than

1/2 inch (12.7 mm) in any horizontal direction?
If not, adjust battery retention swing arm or • Back-up Buzzer
Specific gravity retention plates to restrain the battery. See
corrected to Battery charge sections REMOVING THE BATTERY AND
27°C (80°F) INSTALLING THE BATTERY.
1.265 to 1.280 Normal operating range
1.225 to 1.240 Normal discharge range
(to be recharged)

! CAUTION
103907
Below 1.225 Operating the lift truck
Completely with a battery in this state Make sure the back-up buzzer sounds when
discharged of discharge may cause operating this truck in reverse.
permanent damage to the
lift truck components or
the battery.

85 85
MAINTENANCE

• Brake Pedal Check • Parking Brake Lever Check • Horn Check

B0006 B0005

Is the pedal free-play adjusted properly? Apply the brake pedal and then pull the brake Does the horn sound properly when you push
Brake pedal free-play lever all the way back with reasonable effort the switch?
until it clicks.
Unit: inch (mm)
For adjustment, see Service Manual or contact
E3000 – E6500 0.1 - 0.4 (3-10) your Cat lift dealer.

86 86
MAINTENANCE
! WARNING
Make sure the forward-reverse lever is in
NEUTRAL position, parking brake lever is set
and the accelerator is full-up.
• Battery Charge Check
Read the Battery Charge Indicator. Is the charge
enough for the day’s work? When the battery
symbol flashes, the battery is 80% discharged.
At 90% discharge, the battery symbol is solid.
87
With the Key in ON Position
OFF ON
• Battery Discharge Indicator and Speed /
Fault Code Display Check
Do the Battery Discharge Indicator bars appear
and does 188 momentarily show on the
Speed/Fault Code Indicator?
• Hour Meter Check
Is Hour Meter operating properly? The display
digits should cycle through truck hours, drive
motor hours, and hydraulic motor hours when
key switch is turned to the off position.
• Vehicle Monitoring System Action Lights
Check
Do the action lights chase from L to R and then
all but the park brake light and seat belt light
turn off? (The battery action light will flash if
the battery is 80% discharged and remain on at
the 90% discharged level.)
87
MAINTENANCE

• Optional Warning Devices Check • Mast Operation Check

(if installed)

Strobe

Does the mast move up and down smoothly

when you operate the lift control lever?
Does the mast tilt forward and back smoothly
Backup
Alarm when you operate the tilt control lever?
Are there any oil leaks from the cylinders and
hydraulic lines?
Do all installed optional warning devices
operate properly? Test the activation device for
each. Optional warning devices include such
items as:
• Lights—Turn signals, backup lights,
tail/stop lights, parking and clearance lights.
• Backup alarm.
• Strobe lamp.

88 88
MAINTENANCE

• Lift Chains Check and Adjust To Adjust

! WARNING Anchor Bolt

– Check the lift chains periodically and

determine if they are still in usable
condition.
– Check the lift chains for wear, cracks
and worn or seized link pins.
– Improper maintenance of the lift
chains could cause accidents. If
something is wrong with the chains,
consult your Cat lift truck dealer for
repair or replacement.
– DO NOT put your foot under the fork.
1. Check the lift chains for wear. Use the
following chart to determine if it is still in
usable condition.
Lift Chain Elongation Limit: (/20 links)
1.5 – 2.5 ton models 523 mm (20.6 in.)
3.0 – 3.3 ton models 654 mm (25.7 in.)
102009
2. Lift the forks high enough to put their full
weight on the carriage and chains.
3. Check to be sure the lift chains have equal
tension.
4. If the chains are loose or the tension is not
equal, have the chains adjusted.
➁ Upper Nut
➂ Double Nut (upper)
➀ Double Nut (lower) 102709
1. Loosen double nut (lower) ➀, then upper
nut ➁.
2. Turn double nut (upper) ➂ to adjust the
chain tension.
3. Hold the anchor bolt at two flats with a
wrench so as not to twist the chain, then
tighten the upper nut ➁ to the specified
torque.
4. Hold the double nut (upper) ➂ with a
wrench and tighten double nut (lower) ➀ to
the specified torque.
Tightening Torque
Unit: N•m (kgf•m) [lbf•ft]

1.5–2.5 ton models Upper nut 56.8–1 (5.8–0.1) [42–1]

Lower nuts 98.0+5 (10+0.5) [74+4]
102708
3.0–3.3 ton models Upper nut 84.3–11.6 (8.6–1.2) [62–11]
Lower nuts 147+49 (15+5) [108+36]

89 89
MAINTENANCE
• Mast Interlock System Check
Raise the forks high enough to see them from
the operator’s seat.
101416C
Apply the parking brake and place the direction
lever to the neutral position. Then, with the key in
the | (ON) position, half rise from the operator’s
seat and after approximately 2 seconds.
• Operate the lift lever and check that the
forks do not move up and down.
• Operate the tilt lever and check that the
mast does not tilt forward or backward.
90
• Driving Interlock System Check
Raise the forks a little from the floor.
! CAUTION
• Check this system on a level and hard
surface.
• Do not park the truck on a grade to
prevent it from traveling by itself.
• Make sure that the sufficient space is
available for the lift truck to move
around and that no one or obstacle is
around the truck.
101416B
With the key in the | (ON) position, place the
direction lever to the forward or reverse
position, and then half rise from the operator’s ! CAUTION
seat and after approximately 2 seconds.
• Verify that the power steering motor turns Make sure that nobody is around the lift
off. truck.
• Slightly press the accelerator pedal to check
that the truck does not move.
To restore the lift truck to its normal driving
condition, sit properly in the operator’s seat and
depress the brake pedal to hold the lift truck. Return
the direction lever to the neutral position, then place
the lever to the forward or reverse position.
NOTICE: If you are on a grade or slope the
truck will continue to roll because
the truck is in neutral. In this case, sit
properly in the operator’s seat and
depress the brake pedal to hold the
lift truck, return the direction lever to
the neutral position, and then place
the direction lever to the forward or
reverse position.
90
MAINTENANCE

• Parking Brake Warning Buzzer and
Light Check
Park the lift truck with the forks lowered until
fork tips touch the floor, parking brake applied,
direction lever in neutral and the key is in the
(OFF) position.
• Seat Belt Warning Light Check
Park the lift truck with the forks lowered until
! CAUTION
fork tips touch the floor, parking brake applied,
Check this system on a level and hard direction lever in neutral and the key is in the
surface. (OFF) position.

Release

103570A
102818
Remove the key from the key switch. Release
Turn the key switch to the I (ON) position and
the parking brake only and rise from the
buckle the seat belt.
operator’s seat and after approximately 2
seconds: • Unbuckle the seat belt. The warning light
• Check that the warning buzzer is sounding. should be lit and a buzzer should sound for
30 seconds.
Turn the key switch to the I (ON) position and
apply the parking brake.
• Check that the parking brake light is on.

91 91
MAINTENANCE

◆ Every 50 Service Hours or Weekly, Whichever Comes First

• Mast Supports
Lubricate
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.

• Hydraulic Hoses, Pipes, and Joints

– Check hoses, pipes and joints for damage,

cracks and hydraulic fluid leaks.

• Brake Hoses, Pipes, and Joints

102564 – Check hoses, pipes and joints for damage,

Lubricate 1 fitting on each support for a total of cracks and brake fluid leaks.
2 fittings.

92 92
MAINTENANCE

◆ One Month After Delivery of a New Truck

You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.

• Hydraulic Tank Return Oil Filter

Change

– Filter should be changed.

See Hydraulic System, Change Return Oil

Filter in the Every 1200 Service Hours.

• Bolts, Nuts
Retighten

– Bolts and nuts, such as bolts for the

overhead guard, should be retightened.

• Differential
Check Oil Level

– Check differential oil level. See

Differential, Check Oil Level in the Every
500 Service Hours.

93 93
MAINTENANCE

◆ Every 500 Service Hours or 3 Months, Whichever Comes First

You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.
• Wheel Nuts 3. Remove the level/fill plug. Maintain • Rear Axle Center Pins
Retighten lubricant level to the bottom of the level/fill Lubricate
hole.
– Nuts should be retightened. 4. Clean the level/fill plug and put it back in
place.
See Wheel Nuts, Check – Tighten, when 5. Remove the blocking. Lower the lift bracket.
required.
Adding Oil
• Differential See the topic, Differential, Change Oil under
Check Oil Level Every 1000 Service Hours or 6 Months,
Whichever Comes First.
Park the lift truck on a level surface, parking 102576
brake applied. • Tie Rod Pins
Lubricate 1 fitting on each pin for a total of 2
1. Raise the lift bracket high enough to gain Lubricate
fittings.
access to the level/fill plug.
2. Use blocking under the inner mast to secure
the lift bracket in this position.

103849

Lubricate 1 fitting on each pin for a total of 4

fittings.
102565

94 94
MAINTENANCE

• Mast Strip Roller Surfaces • Lift Chains • Brake Pedal

Lubricate Lubricate and Inspect Lubricate

102570 102572 103493

Lubricate 1 fitting on each side of the inner mast Lubricate each chain on the left and right of the Lubricate 1 fitting.
for a total of 2 fittings. mast.

• Lift Bracket Side Rollers • Tilt Socket Pins

Lubricate Lubricate
1. Brush a film of engine oil onto the chain
links, or spray with chain and cable
lubricant.
2. Raise and lower the lift bracket a few times
to work lubricant into the chain links.
NOTICE: Lubricate chains more frequently
than normal where the
atmosphere can cause corrosion
of components or when the truck
102571 104230
must work in rapid lift cycles.
Lubricate 1 fitting on each side roller for a total 3. Inspect the chain anchors and individual Lubricate 1 fitting on each pin for a total of 2
of 2 fittings. links for wear, loose pins or cracked leaves. fittings.

95 95
MAINTENANCE
◆ Every 1000 Service Hours or 6 Months, Whichever Comes First
• Differential
Change Oil
Park the lift truck on a level surface, parking
brake applied, direction lever in NEUTRAL,
forks lowered, lubricant warm and the key is in
the (OFF) position.
1. Raise the lift bracket high enough to gain
access to the level/fill plug ➁.
2. Use blocking under inner mast to secure the
lift bracket in this position.
3. Remove the drain plug ➀ and the level/fill
plug ➁.
4. Allow the oil to drain. Clean and reinstall
the drain plug.
➁ 12. Refill the tank.
➀ 102580
5. Fill with oil to the bottom of the level/fill
hole.
6. Put the level/fill plug back in place.
7. Remove blocking. Lower the lift bracket.
96
• Hydraulic System
Change Return Oil Filter and Wash Strainer
! WARNING
Hot oil components could cause personal
injury. Do not allow hot oil or components
to contact your skin.
At operating temperature, the hydraulic
tank is hot and can be under pressure.
Park the lift truck with the forks lowered on a
level surface, parking brake applied,
transmission in NEUTRAL and the key is in the
(OFF) position.
1. Raise the hood.
2. Remove the battery and tank cover.
3. Drain the hydraulic tank. See Hydraulic
Oil Change in Every 2000 Service Hours.
4. Remove the hoses.
➀
➁
103461
5. Remove the gasket and strainer ➀.
6. Remove the gasket and return oil filter ➁.
Discard the filter element.
7. Clean the filter parts and replace the seal
and gasket, if necessary. Install a new filter
element.
8. Put the filter body assembly back in place
and tighten the retaining bolts.
9. Wash the strainer in clean, nonflammable
solvent.
10. Inspect the gasket and replace it, if
necessary.
11. Put the strainer, gasket, hoses, and drain
plug back in place.
13. Remove the filler cap. Check the oil level.
14. Add oil, if needed, to reach the correct level
range on the dipstick.
15. Put the dipstick and filler cap back in place.
16. Check for oil leaks.
17. Install the battery.
18. Close and secure the hood.
Correct level range
100698
96
MAINTENANCE

◆ Every 2000 Service Hours or 1 Year, Whichever Comes First

You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.
• Hydraulic Oil
Change
4. Remove the hydraulic tank drain plug.
Allow the oil to drain. Clean and put the
! WARNING plug back in place.
Hot oil and components could cause
serious injury. Do not allow hot oil or
components to contact your skin.
Correct level range
The truck has been stopped and the filler
cap is cool enough to remove with your
hand.
Remove the filler cap slowly to relieve
pressure.
102586 100698

1. Operate the lift truck to warm the oil.
2. Park the lift truck with the forks lowered on
a level surface with parking brake applied,
direction lever in NEUTRAL and key is in
the (OFF) position.
3. Remove the filler cap.
5. Fill the hydraulic tank. See Refill 9. Put the dipstick and the filler cap back in
Capacities. Put the filler cap back on. place.
6. Operate the hydraulic controls and the
steering system through a few cycles to fill
the filters and lines.
• Service Brake Fluid
7. Retract all hydraulic cylinders and stop the
Change
truck.
8. Remove the filler cap and the dipstick. Keep NOTICE: When changing fluid consult with
the oil level at the HIGH mark on the your Cat lift truck dealer.
dipstick.

970058 970054 970006

97 97
MAINTENANCE

◆ Adding Hydraulic Oil

970058 970054 970006

1. Park the truck on a level surface, lower the
forks all the way, turn off the key and unplug
the battery.
2. Remove the floor plate.
3. Remove the hydraulic tank filler cap by turn-
ing it counterclockwise.
4. Add oil to the hydraulic tank. 5. After adding oil, make sure the level is in the
For hydraulic oil, see topic: Recommended correct range on the dipstick.
Oils and Lubricants.
Correct level range

100698

6. Replace the filler cap.

7. Replace the floor plate.

! CAUTION
When adding hydraulic oil:
• Clean the filler hole to prevent dirt from
dropping into the tank.
• DO NOT overfill.
• Clean up spillage.

98 98
MAINTENANCE
• Brake Operation Check
Slowly Drive the Truck in a Safe Area
STOP
970036
Does the truck pull to one side when braking? Is
the pedal soft or spongy? Is there poor braking
action requiring excessive pedal effort? Are the
brakes too sensitive or do they grab?
• Mast Strip Sliding Surfaces
102570
Inspect the mast strip sliding surface and roller
for wear and crack.
– Does the mast and roller move smoothly?
If not, lubricate on each side of the inner
mast.
99
• Steering Wheel Operation Check
100710
Is the free-play 0.6 to 1.2 inches (15 to 32 mm)?
Check the play at the rim of the wheel by
rotating the wheel in both directions.
Is the wheel assembly tight? Check by shaking
the wheel up and down.
How is the steering response? Does the truck
wander? Shimmy? Is the steering stiff or
sloppy?
• Parking Brake Application Check
970035
Can you hold your truck on a grade by applying
the park brake lever?
Now Your Truck is Ready to Operate.
! WARNING
Fill out a pre-start inspection sheet. Remember,
a complete and thorough pre-start inspection is
the best insurance against personal injury and
property damage.
99
MAINTENANCE

◆ Adding Battery Electrolyte

1. If the electrolyte level is low, remove the
! WARNING filler caps and add distilled water to the cells. ! WARNING
When a battery is being charged, an Before removing the caps, clean the top of
explosive gas mixture forms within and the battery.
around each cell. If the area is not 2. After adding the water, replace the caps, and
properly ventilated, this explosive gas can tighten the caps securely.
remain in or around the battery for
several hours after charging. An open
flame or spark can ignite this gas,
! WARNING
resulting in serious personal injury or
property damage.
Do not get acid in eyes, on skin or clothing. In
case of contact, flush immediately and
! CAUTION thoroughly with clean water.
Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
your clothing or skin, flush the area
Always charge the battery in a well ventilated
immediately with cold water. should the
solution get on your face or in your eyes
area. DO NOT smoke, and keep flames away. ! WARNING
DO NOT use equipment in this area that is If acid gets in your eyes, FLUSH THEM
flush the area with cold water and
liable to produce sparks. IMMEDIATELY WITH LARGE
immediately get medical attention.
AMOUNTS OF WATER AND OBTAIN
MEDICAL ATTENTION AT ONCE.
• Battery
Check Electrolyte Level Bicarbonate of soda (baking soda) solution (one
1. If the electrolyte level is low, remove the pound to a gallon of water) will neutralize any
filler caps and add distilled water to the cells. acid accidentally spilled on clothing or material.
Before removing the caps, clean the top of Apply the solution until bubbling stops, then
the battery. rinse with clean water.
2. After adding the distilled water, tighten the
caps securely.

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MAINTENANCE

◆ Removing the Battery

! WARNING

970071 B0005

Never operate the lift truck without the correct Park the lift truck on level ground, apply the Use a battery spreader bar of greater capacity
size and weight of battery in the lift truck. parking brake, remove key and disconnect the than the weight of the battery to remove or
battery. replace batteries.

! WARNING
Never use chain or other items for lifting a
battery that is not specifically designed for
the task.
Tabs

970004
Handle

Swing the latch over the lock down tabs and

open the battery cover using the lifting handle
on the right side and place the battery cables on
top of the battery.

101 101
MAINTENANCE

◆ Installing the Battery

! WARNING ! WARNING

Retention Plates

Retention Swing Arm

970073 102539

To prevent injury, always keep your body out 3. Remove the battery spreader bar and plug
from between the battery and the truck. the battery into the truck.
970091 2. Use a battery spreader bar of greater capaci- 4. Using the battery cover lifting handle, close
ty than the weight of the battery to lift the the battery cover.
1. When installing a battery, always check that
battery and place it in the truck. Make sure
the battery retention system is adjusted cor-
that the battery is all the way down inside the
rectly. The battery retention swing arm and
truck.
adjustment plate(s) should be positioned to
limit the battery from moving more than
12mm (1/2 inch) in any horizontal direction.
The swing arm located at the front of the bat- ! CAUTION ! CAUTION
tery compartment can be adjusted by swing-
When moving a battery always place battery When closing the battery cover, be careful
ing it to the desired location and inserting the
cables on top of the battery. This will prevent not to pinch your hand. Use the battery cover
pin into the appropriate hole. This arm will
damage to the battery cables, battery lifting handle.
restrict the front-to-back movement of the
connector, or battery.
battery when adjusted correctly. The reten-
tion plate(s) shipped with your lift truck
should be attached with the provided spacers
and bolts. If correctly adjusted, the plate(s)
will limit side-to-side movement of the bat-
tery.
Consult your Cat lift truck dealer for
special instructions about the battery slide
option, available on your model lift truck.

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MAINTENANCE

◆ Charging the Battery

• Make sure the correct charger is used for the battery you are using. The most accurate check of specific gravity is obtained after
• Check – Voltage of charger. the equalizing charge is complete.
– Voltage of battery. • Check the battery charge
– Size or power output of charger is correct. – Use a hydrometer.
• Type of Charge – Complete the pre-start inspection procedure.
– Daily charge
This should be done every day and normally takes
eight hours to fully charge a battery.
– Equalizing charge
This charges the battery at a slow rate and balances the
charge in all the cells. This should normally be done
once per week.

! WARNING ! WARNING ! CAUTION

Always charge the battery in a well ventilated
area. DO NOT smoke and keep flames away.
DO NOT use equipment in this area that is
liable to produce sparks.
Explosive gases are generated when batteries
are being charged. Always ensure adequate
ventilation for battery charging. Do not smoke,
keep flames and sparks away.
• Always turn off charger before connect-
ing or disconnecting the battery.
• Always check the water level before
charging to make sure the plates are cov-
ered.
• Never overfill before charging. The elec-
trolyte will expand during charging and
may overflow.
• After charging, add water to the battery
manufacturer’s full mark.
• Never plug the lift truck into the charger.

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MAINTENANCE

◆ Parking Brake Lever Check

Adjustment Release

Rod

103628

The parking brake is a double action type.

To Apply Parking Brake

- Apply pedal brake and then pull the brake
lever all the way back until it clicks.

To Release Parking Brake

- Apply pedal brake, and then press the top
button while pushing the brake lever all
the way forward.

104 104
MAINTENANCE

◆ Jacking the Lift Truck for Changing Tires

Raising Front Tires Raising Rear Tires
! WARNING

C970064 970065 101107

Jacking Method Jacking Method Stop raising the truck when the tire just clears
Position the jack under the frame and raise the Position the jack under the counterweight and the surface.
front tire. raise the rear tire. DO NOT raise the truck more than necessary to
avoid the possibility of personal injury.

Other method
! WARNING

970031 100832 100833

“Self-Jacking” Method BE SURE to get off the truck when raising the DO NOT put any portion of your body under
Tilt the mast all the way backward, place blocks front or rear tire. the truck being raised. SECURELY SUPPORT
under the mast, and tilt the mast forward. by blocks after jacking.

105 105
MAINTENANCE

◆ Changing Tires (Front Tires) Removing Tires

101105 100830 970061

DO NOT attempt to change the tire with the
truck loaded.
1. Park the truck in a safe level area and discon-
nect the battery.
2. Put the park brake on.
3. Prepare tools, jack, and wheel blocks.
THE CAPACITY OF THE JACK
SHOULD BE 12,000 LB. (6 TON)
MINIMUM.
4. Block the diagonally opposite wheel to the
one you are going to change.
1. Loosen the wheel nuts about two rotations.
Only loosen the wheel nuts. DO NOT
remove them.
2. Position the jack under the truck at the spe-
cific jack point.
3. Raise the truck by operating the jack until
the tire is just clear of the surface.

106 106
MAINTENANCE
100834
4. Remove the wheel nuts by hand.
5. Firmly grip the wheel with both hands and
remove it from the truck.
100880
Change the tire if its height measures less than 1
inch (2.5 cm). Do not replace the tire yourself.
Consult your Cat lift truck dealer for tire
replacement.
! CAUTION
Changing the rear tires on your lift truck is a
specialized task. If these tires need
replacement contact your Cat lift truck
dealer.
107
Counterbore
970069
Installing Tires
1. Install the tire and tighten the wheel nuts so
that the tire will not rattle. Tighten each
wheel nut until its tapered portion comes
into full-face contact with the counterbore in
the rim.
Make sure the clamping surfaces of the
wheel nuts and counterbores are free of dirt.
! CAUTION
Use the same size and brand of tire as
indicated on name plate and specifications
per manufacturer.
970068
2. Lower the truck by operating the jack until
the tire just touches the surface. Then tight-
en the wheel nuts in the sequence shown, in
two or three steps, to the specified torque.
Tightening Torques for Front Wheel Nuts
Unit: lbf•ft (kgf•m) [N•m]
E3000–EC4000 Front 116 (16) [157]
E4000–E6500 Front 278(38.5)[378]
3. Lower the truck fully and remove the jack.
After tire replacement, drive the truck for a
while and check the wheel nuts again for the
correct torque.
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MAINTENANCE

◆ Parts to be Changed Periodically

The following parts should be periodically

changed as noted below. 5
These parts are made of materials which will
deteriorate over time. Further, it is difficult to
determine visually whether or not they are still
in good condition. Changing at proper intervals
will reduce the chance of injury to the operator 2
and damage to the truck.

4
Ref.
No. Parts to be changed Interval
1 Rubber parts of brake master 2000 service hours or 1 year, 6 3
cylinder whichever comes first
2 Rubber parts of brake calipers 2000 service hours or 1 year,
whichever comes first 6
3 High-pressure hoses of 2000 to 4000 service hours or
hydraulic system 1 or 2 years, whichever comes first
4 Power steering hose 4000 service hours or 2 years,
whichever comes first 1
5 Inner rubber parts of the power 4000 to 8000 service hours or 3
steering cylinders 2 to 4 years, whichever comes first
6 Lift chains 4000 to 8000 service hours or
2 to 4 years, whichever comes first

NOTICE: Periodic changes of these parts are not covered by Warranty.

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MAINTENANCE

◆ Tightening Torque for Standard Bolts

Nominal
Pitch
size
mm in. mm in. kgf•m (lbf•ft) [N•m]
6 0.24 1 0.04 0.70 5.0 6.9
8 0.32 1.25 0.05 1.70 12.3 16.7
10 0.39 1.25 0.05 3.40 24.6 33.3
Metric fine thread

12 0.47 1.25 0.05 6.09 44.1 59.8

14 0.55 1.5 0.06 9.89 71.6 97.0
16 0.63 1.5 0.06 14.8 107.0 145.0
18 0.71 1.5 0.06 21.4 154.7 209.7
20 0.79 1.5 0.06 29.7 214.8 291.1
22 0.87 1.5 0.06 39.2 284.2 385.1
24 0.95 1.5 0.06 49.7 359.5 487.1
27 1.06 1.5 0.06 81.0 585.9 794.3
30 1.18 1.5 0.06 112.2 811.5 1100.3
33 1.30 1.5 0.06 149.6 1082.1 1467.1
36 1.42 1.5 0.06 195.6 1414.8 1918.2
39 1.54 1.5 0.06 251.0 1815.5 2461.5

Remarks:
1. This chart gives the torques for standard bolts and nuts.

2. The tolerance for these torques is:

137.2 or below ± 20 (%)
over 137.2 ± 15 (%)

3. Unless otherwise specified, use these torques.

4. These torques are for “dry” condition.

109 109
MAINTENANCE

Nominal
Pitch
size
10
mm 0.39
in. 1.5
mm 0.06
in. kgf3.29
•m 23.8
(lbf•ft) 32.3
[N•m]
12 0.47 1.75 0.07 5.79 42.0 56.8
14 0.55 2 0.08 9.49 68.7 93.1
16 0.63 2 0.08 10.48 102.7 139.2
Metric coarse thread

18 0.71 2.5 0.10 19.8 143.2 194.0

20 0.79 2.5 0.10 27.6 200.3 271.5
22 0.87 2.5 0.10 36.9 267.6 362.6
24 0.95 3 0.12 47.68 345.0 467.5
27 1.06 3 0.12 73.9 534.5 724.7
30 1.18 3.5 0.14 98.9 715.3 969.9
33 1.30 3.5 0.14 135.5 980.1 1328.8
36 1.42 4 0.16 170.9 1236.1 1676.0
39 1.54 4 0.16 226.3 1636.8 2219.2
42 1.65 4.5 0.18 280.9 2031.8 2754.7

110 110