Caterpillar Forklift E4000

1. Removing hose guard: With the lift bracket raised to the maximum height, remove each hose guard from the front side of the mast.

CAUTION: Be careful not to touch the lift control lever

2. Lowering lift bracket: Lower the lift bracket by carefully operating the lift control lever.

3. Disconnecting high-pressure hoses: Disconnect the high-pressure hoses at the joints indicated by arrows. Use a container to catch oil flowing out of the hoses.

1. Remove the set bolt at the top of each lift cylinder. Lift the inner mast to separate the cylinder rod ends. To lift the inner mast, clove-hitch a sling to the mast with protective wad.

NOTE; The rod end of either lift cylinder is shimadjusted to eliminate the difference in stroke between the cylinders. Before removing the stopper bolts, make a record of the number of shims and the cylinder to which the shims are fitted.

1. Check for oil leaks from the joint between adjacent valve housings sealed by O-ring.

2. Check for oil leaks from the scrapers sealed by O-rings.

3. Check for oil leaks from the screw connections.

It is not practical to check the control valve alone for internal leakage. The correct way to check the control valve in place under normal operating conditions follows.

The internal leakage to be checked includes leakage occurring at the lift spool, tilt spool, tilt lock valve, and check valves.

[Test oil temperature: approx. 50°C (122°F)]

1. Inspect the body bore cut-in where gears wipe into the body.

2. The body can only be reused if the cut-in is bright and polished in appearance and the depth does not exceed .08 mm.

3. The body should be replaced if the surface is scored, has a matte appearance, or shows signs that the tips of the gears have dug in and torn away the surface material.

4. The body should be inspected to ensure that there is no superficial damage which may adversely affect performance or sealing. Pay particular attention to the port threads and body O-ring seal recesses.

1. The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the regions where the body O-rings and bush seals contact, which could result in external leakage.

2. Check the shaft seal recess for scoring or damage that could result in oil leakage around the outer diameter of the shaft seal. A replacement shaft seal can be refitted with Loctite hydraulic sealant to overcome slight damage in this area.

1. Check the bore wall for wear, grooving, scratch marks, and rusting.

1. Check for deflection in the manner shown.

2. Check for surface flaws such as grooving, scratch marks, rusting, and wear. The rod must be replaced if its threads show signs of stripping or any other damage.

1. Remove the floorplates and the front dashboard cover.

2. Tilt the mast to vertical position, lower the forks all the way, and relieve the pressure in the hydraulic lines.

4. Disconnect the wire leads to the valve switches.

5. Disconnect the hydraulic lines per the listed sequence solenoid, and lower switch.

6. Remove the 3 mounting bolts from the front of the dash.

7. Remove the valve from the truck;