Cat forklift p30000 schematic service operation maintenance manual

CAT Forklift P30000 Schematic, Service, Operation & Maintenance Manual

CAT Forklift P30000 Schematic, Service, Operation & Maintenance Manual To download the complete and correct content, please visit: https://manualpost.com/download/cat-forklift-p30000-schematic-service-operationmaintenance-manual/

**CAT Forklift P30000 Schematic, Service, Operation & Maintenance Manual** Size: 51.9 MB Format: PDF Language: English, Spanish Brand: CAT Caterpillar Type of Machine: Forklift Type of Manual: Schematic, Service Manual, Operation & Maintenance Manual Model: CAT P30000 Forklift Date: 2011 Content: 99709-61100-00 Engine 6M60 Diesel: Foreword 99709-61100-01 Engine 6M60 Diesel: General 99709-61100-02 Engine 6M60 Diesel: Engine 99709-61100-03 Engine 6M60 Diesel: Lubrication 99709-61100-04 Engine 6M60 Diesel: Fuel and Engine Control 99709-61100-05 Engine 6M60 Diesel: Electronically Controlled Fuel System 99709-61100-06 Engine 6M60 Diesel: Cooling 99709-61100-07 Engine 6M60 Diesel: Intake and Exhaust 99709-61100-08 Engine 6M60 Diesel: Emission Control 99709-61100-09 Engine 6M60 Diesel: Electrical 99709-61100-10 Engine 6M60 Diesel: Special Equipment 99799-83100-00 Chassis and Mast: Foreword 99799-83100-01 Chassis and Mast: General Information 99799-83100-02 Chassis and Mast: Cooling System 99799-83100-03 Chassis and Mast: Electrical System 99799-83100-03a Chassis and Mast: Wiring Schematic 99799-83100-04 Chassis and Mast: Controller 99799-83100-05 Chassis and Mast: Cab Tilt System 99799-83100-06 Chassis and Mast: Power Train 99799-83100-07 Chassis and Mast: 3-Speed Powershift Transmission 99799-83100-08 Chassis and Mast: Front Axle and Differential 99799-83100-09 Chassis and Mast: Rear

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Axle 99799-83100-10 Chassis and Mast: Brake System 99799-83100-11 Chassis and Mast: Steering System 99799-83100-12 Chassis and Mast: Hydraulic System 99799-83100-12a Chassis and Mast: Hydraulic Schematic 99799-83100-13 Chassis and Mast: Mast and Forks 99799-83100-14 Chassis and Mast: Fork Positoners 99799-83100-15 Chassis and Mast: Service Data 99790-82102-00 Operation & Maintenance Manual: Foreword 99790-82102-01 Operation & Maintenance Manual: Safety Rules for Lift Truck Operators 99790-82102-02 Operation & Maintenance Manual: Know Your Lift Truck 99790-82102-03 Operation & Maintenance Manual: How to Avoid a Tipover; How to Survive One 99790-82102-04 Operation & Maintenance Manual: Refueling 99790-82102-05 Operation & Maintenance Manual: Operation 99790-82102-06 Operation & Maintenance Manual: Operating Techniques 99790-82102-07 Operation & Maintenance Manual: Storing the Lift Truck 99790-82102-08 Operation & Maintenance Manual: Transportation Hints 99790-82102-09 Operation & Maintenance Manual: Special Situations 99790-82102-10 Operation & Maintenance Manual: Troubleshooting 99790-82102-11 Operation & Maintenance Manual: Maintenance 99790-82102-12 Operation & Maintenance Manual: Service Data 99790-82102-13 Operation & Maintenance Manual: To the CAT Lift Truck Owner 99790-82102-14 Operation & Maintenance Manual: Index 99790-82H02-00 PREFACE 99790-82H02-01 SAFETY REGULATION FOR FORKLIFT OPERATORS 99790-82H02-02 KNOW YOUR FORKLIFT 99790-82H02-03 HOW TO AVOID A TIP AND HOW TO SURVIVE IT IF IT OCCURS 99790-82H02-04 RESUPPLAY OF FUEL 99790-82H02-05 OPERATION 99790-82H02-06 OPERATING TECHNIQUES 99790-82H02-07 FORKLIFT STORAGE 99790-82H02-08 TRANSPORTATION SUGGESTIONS 99790-82H02-09 SPECIAL SITUATIONS 99790-82H02-10 LOCALIZATION AND FAILURE CORRECTS 99790-82H02-11 MAINTENANCE 99790-82H02-12 SERVICE DATA 99790-82H02-13 INFORMATION TO THE OWNER OF CAT FORKLIFT 99790-82H02-14 INDEX Cat Pub List Publication List (Service, Operator, & Parts Manuals) Mast Tilting Angles Mast Tilting Angles REF-18-0001C How To Determine Correct Mast Rails Lift Cylinders And Mast Hosing REF-18-0001C How To Determine Correct Mast Rails Lift Cylinders And Mast Hosing (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 Pick List REF-18-0003C How To Use A Pick List (Spanish) REF-18-0007C Abbreviations And Acronyms List REF-18-0008C Diagnostic Trouble (Error) Codes Schematic HARNESS A MAIN HARNESS This part manual inlcude all spare parts number you need inside this model, for you easier in fixing your forklift replace new spare part hight performance. This service manual is a guide for servicing Cat Lift Trucks. For your convenience the instructions are grouped by systems as an easy reference. This Original Instructions (Operator's) Manual describes operating procedures, daily checks and simple maintenance for safe usage of your Cat lift truck. SERVICE MANUAL CHAPTER 1 GENERAL INFORMATION 1.1 Model View 1.2 Models Covered 1.2.1 Lift Truck Nomenclatures and Definitions 1.3 Serial Number Locations 1.4 Dimensions 1.5 Technical Data 1.6 Performance CHAPTER 2 COOLING SYSTEM 2.1 Specifications 2.2 Structure 2.3 Removal and Installation 2.3.1 Fan Belt Removal 2.3.2 Suggestions for Removal 2.3.3 Installation 2.4 Inspection and Adjustment 2.4.1 Fan Belt Inspection 2.4.2 Fan Belt Tension 2.4.3 Connecting Hoses 2.4.4 Coolant 2.4.5 Radiator Cap CHAPTER 3 ELECTRIC SYSTEM 3.1 Chassis Electrical Devices Wiring Outline 3.1.1 Harnesses Layout 3.1.2 Components Layout 3.2 Structure 3.2.1 Console Box 3.2.2 Major Electrical Components 3.2.3 Table of Lamps 3.3 Console Box 3.3.1 Disassembly 3.4 Battery Maintenance 3.4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment 3.4.2 Specific Gravity Reading and State of Charge 3.4.3 Charging Precautions 3.5 Instrument Panel 3.5.1 Instrument Panel Screen Element 3.5.2 Basic Screen Display 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 Meters 3.5.8 Troubleshooting

3.6 Wire Color 3.6.2 List of Wire Colors 3.7 Troubleshooting 3.7.1 Starter System 3.7.2 Gauges 3.7.3 Lighting System 3.8 Electrical Schematic CHAPTER 4 CONTROLLERS 4.1 Outline 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 Service Tool Menus 4.3.2 Service Tool Box 4.4 Mast Interlock System 4.4.1 Function 4.4.2 VCM1-M Controller, Mast Interlock System Checking Procedure 4.4.3 Active Test Inspection Procedure 4.5 Driving Interlock System 4.5.1 Function 4.5.2 Driving Interlock System Checking Procedure for Powershift T/M Lift Trucks 4.5.3 Active Test Inspection Procedure 4.6 Seat Belt Warning Lamp 4.6.1 Function 4.6.2 Seat Belt Warning Lamp Checking Procedure 4.7 Parking Brake Warning Buzzer and Lamp 4.7.1 Function 4.7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure 4.7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in 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 Direction Lever 4.9.5 Speed Sensor 4.9.6 T/M Solenoid 4.9.7 Unload 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 Troubleshootings 4.10.1 Error Code Display 4.10.2 Diagnosis Table (F Code) 4.10.3 Error Codes and Troubleshooting 4.11 Locations of Sensors and Switches CHAPTER 5 POWER TRAIN 5.1 Removal and Installation (MC Models) 5.1.1 Removal of Engine and Transmission Assembly 5.1.2 Removal of Engine and Transmission Assembly (for Gasoline-Engine Lift Trucks) 5.2 Removal and Installation (FC Models) 5.2.1 Removal of 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 Hydraulic System Schematic of Powershift Transmission 6.2 Removal and Installation 6.2.1 Removal 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 (Inching) Pedal Adjustment 6.6.3 Inching 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 Removal and Installation 7.2.1 Front Wheels 7.3 Front Axle 7.3.2 Reduction Differential 7.4 Disassembly and Reassembly 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 Removal and Installation 8.2.1 Rear Wheel and Rear Axle Assembly 8.3 Disassembly and Reassembly 8.3.1 Wheel Hub, Disassembly and Reassembly 8.3.2 Knuckle (King Pin), Disassembly and Reassembly 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 Parking Brake Cable Adjustment 9.3.4 Brake Pedal Adjustment 9.3.5 Brake Lines Bleeding 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 Steering 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 Outline 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 Regulator Valve (for Models with FC Control Valve Only)

11.8 Down Safety Valve 11.9 Lift Cylinder 11.10 Tilt Cylinder 11.11 Disassembly and Reassembly 11.11.1 Hydraulic Pump 11.11.2 Lift Cylinder 11.11.3 Tilt Cylinder 11.11.4 Flow Regulator Valve 11.11.5 Piping 11.11.6 Suction Strainer 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 Troubleshooting 11.13.2 Hydraulic System Cleaning 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 Simplex Mast 12.1.1 Mast System 12.2 Structure and Functions 12.2.1 Simplex Mast (5A15C to 5A33C) 12.2.2 Mast Operation 12.3 Removal and Installation 12.3.1 Mast and Lift Bracket Assembly 12.4 Disassembly and Reassembly 12.4.1 Simplex Mast Disassembly 12.4.2 Simplex Mast Reassembly 12.5 Removal and Installation of Mast Rollers and Strips without Removing 12.5.1 Simplex Mast 12.6 Inspection and Adjustment (Simplex Mast) 12.6.2 Forks 12.6.3 Chain Tension Inspection and Adjustment 12.6.4 Checking Chain Elongation 12.6.5 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 12.6.6 Mast Roller Clearance Adjustment 12.6.7 Mast Strip Clearance Inspection and Adjustment 12.6.8 Tilt Angle Adjustment 12.6.9 Right and Left Lift Cylinder Stroke Inspection and Adjustment 12.7 Troubleshooting (Simplex Mast) 12.8 Service Data (Simplex Mast) 12.9 Duplex Mast 12.9.1 Mast System 12.10 Structure and Functions 12.10.1 Duplex (Dual Full-Free Panoramic) Mast (5B15C to 5B33C) 12.10.2 Mast Operation 12.11 Removal and Installation 12.11.1 Mast and Lift Bracket Assembly 12.12 Disassembly and Reassembly 12.12.1 Duplex Mast Disassembly 12.12.2 Duplex Mast Reassembly 12.13 Removal and Installation of Mast Rollers and Strips 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 Chain Tension Inspection and Adjustment 12.14.4 Checking Chain Elongation 12.14.5 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 12.14.6 Mast Roller Clearance Adjustment 12.14.7 Mast Strip Clearance Inspection and Adjustment 12.14.8 Tilt Angle Adjustment 12.14.9 Right and Left Lift Cylinder Stroke Inspection and Adjustment 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 (Triple Full-Free Panoramic) Mast (5C15C to 5C33C) 12.18.2 Mast Operation 12.19 Removal and Installation 12.19.1 Mast and Lift Bracket Assembly 12.20 Disassembly and Reassembly 12.20.1 Triplex Mast Disassembly 12.20.2 Triplex Mast Reassembly 12.21 Removal and Installation of Mast Rollers and Strips without Removing 12.21.1 Triplex Mast 12.22 Inspection and Adjustment (Triplex Mast) 12.22.2 Forks 12.22.3 Chain Tension Inspection and Adjustment 12.22.4 Checking Chain Elongation 12.22.5 Adjusting Clearance between Lift Bracket Roller and Inner Mast 12.22.6 Mast Roller Clearance Adjustment 12.22.7 Mast Strip Clearance Inspection and Adjustment 12.22.8 Tilt Angle Adjustment 12.22.9 Right and Left Lift Cylinder Stroke Inspection and Adjustment 12.23 Troubleshooting (Triplex Mast) 12.23.1 Troubleshooting (Triplex Mast) 12.24 Service Data (Triplex Mast) 12.24.1 Triplex Mast CHAPTER 13 SERVICE DATA 13.1 Maintenance Schedule 13.2 Maintenance Note 13.2.1 Brake System 13.2.2 Cooling System 13.2.3 Electric 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 End Section 13.2.11 Steering and Axle System 13.2.12 T/M and Drive System 13.2.13 Wheels and Tires 13.2.14 General 13.3 Tightening Torque for Standard Bolts and Nuts 13.4 Periodic Replacement Parts 13.4.2 Location of Periodic Replacement Parts 13.5 Lubrication Instructions 13.5.1 Lubrication Chart 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 Both MC and FC LiftTrucks) 13.6.2 Special Service Tools (for FC Lift

Truck Only) 13.6.3 Special Service Tools (for Powershift Transmission) OPERRATION MANUAL CHAPTER 1 SAFETY RULES AND PRACTICES 1.1 SAFETY SIGNS AND SAFETY MESSAGES 1.2 WARNING SYMBOLS AND LEVELS 1.3 OPERATOR QUALIFICATIONS 1.4 SAFETY GUARDS 1.5 PERSONAL PROTECTIVE EQUIPMENT FOR OPERATING LIFT TRUCK 1.6 DAILY INSPECTION 1.7 OPERATOR RESPONSIBILITY 1.8 GENERAL 1.9 NO RIDERS 1.10 TRAVELING 1.11 LOADING 1.12 DOCKBOARDS (BRIDGE PLATES), TRUCKS AND RAILROAD CARS 1.13 SURFACE AND CAPACITY 1.14 FUEL HANDLING 1.15 INSTALLATION OF ATTACHMENTS 1.16 IN CASE OF TIP-OVER 1.17 TRANSPORTING LIFT TRUCK 1.17.2 APPROACH ANGLE, DEPARTURE ANGLE AND GANGWAY 1.17.3 HOISTING (LIFTING) UP THE TRUCK 1.18 FUNCTION TESTS 1.19 TRACTION 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 CAUTION DRIVE DECAL (IN CASE OF TIP-OVER DECAL) 1.21.5 WARNING DRIVE DECAL (TRAINED AND AUTHORIZED) 1.21.6 PINCH POINT DECAL 1.21.7 CAUTION FORK DECAL 1.21.8 MAST WARNING DECAL 1.21.9 CAUTION DRIVE DECAL (OPERATION) 1.21.10 RADIATOR WARNING DECAL 1.21.11 COOLING FAN WARNING DECAL 1.21.12 ADJ LPG WARNING DECAL 1.21.13 LPG LATCH WARNING DECAL 1.21.14 LPG FUEL WARNING DECAL CHAPTER 2 OPERATING CONTROLS AND FUNCTIONS 2.1 APPLICATIONS 2.2 APPLICATION FOR CAT LIFT TRUCKS 2.3 PROHIBITED APPLICATIONS FOR CAT LIFT TRUCKS 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-ENGINE CHECK WARNING 2.5.6 OIL PRESSURE WARNING LIGHT 2.5.7 CHARGE WARNING LIGHT 2.5.8 PARKING BRAKE WARNING LIGHT 2.5.9 SEAT BELT WARNING LIGHT 2.5.10 METER DISPLAY 2.5.11 WATER TEMPERATURE GAUGE 2.5.12 FUEL GAUGE 2.5.13 TRANSMISSION POSITION 2.6 MALFUNCTION AND WARNING INDICATIONS 2.6.2 MAST INTERLOCK WARNING 2.6.3 LPG LEVEL WARNING/LPG RACK LOCK WARNING 2.6.4 TORQUE CONVERTER FLUID TEMP WARNING 2.6.5 RADIATOR LEVEL WARNING 2.6.6 AIR CLEANER WARNING 2.6.7 SERVICE REMINDER DISPLAY 2.6.8 DISPLAYS WHEN MALFUNCTION OCCURS 2.7 DRIVER RECOGNITION MODE 2.8 LPG REMAINING TIME MANAGEMENT 2.9 SWITCHES 2.9.2 HORN BUTTON 2.9.3 REAR RIGHT GRIP WITH HORN BUTTON 2.9.4 IGNITION SWITCH 2.9.5 LIGHTING AND TURN SIGNAL SWITCHES 2.9.6 MAXIMUM SPEED CHANGE SWITCH (OPTION) 2.9.7 THROTTLE SENSITIVITY ADJUST SWITCH (OPTION) 2.9.8 BACK-UP OPERATION LIGHT SWITCH (OPTION) 2.10 OPERATING CONTROLS 2.10.2 SELECTOR LEVER 2.10.3 PARKING BRAKE LEVER 2.10.4 INCHING BRAKE PEDAL 2.10.5 BRAKE PEDAL 2.10.6 ACCELERATOR PEDAL 2.10.7 CARGO-HANDLING CONTROL LEVERS 2.10.8 ANSI/ITSDF STANDARDS FOR LIFT TRUCK CLAMP ATTACHMENTS 2.10.9 STEERING CHARACTERISTICS CHAPTER 3 OPERATING THE LIFT TRUCK 3.1 OPERATION 3.2 INSPECTION BEFORE OPERATING 3.3 LIFT TRUCK OPERATING PRECAUTIONS 3.4 PRECAUTIONS FOR COLD AND HOT WEATHER 3.5 OPERATIONAL PROCEDURES 3.6 LPG LIFT TRUCK STARTING 3.7 PROCEDURE FOR JUMP STARTING EFI ENGINES 3.8 AUTOMATIC TRANSMISSION 3.9 LOADING 3.10 TRANSPORTING LOADS 3.11 UNLOADING 3.12 CLIMBING 3.13 STOPPING AND PARKING THE LIFT TRUCK 3.14 FORKS 3.15 SEAT ADJUSTMENT 3.15.1 SUSPENSION SEAT OPERATOR'S WEIGHT ADJUSTMENT 3.15.2 FORWARD AND BACKWARD CONTROL LEVER 3.15.3 BACKREST INCLINATION ADJUSTMENT 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 (OPTION) 3.22 LPG CYLINDER (TANK) HOLDER CHAPTER 4 GENERAL CARE AND

CAT Forklift P30000 Schematic, Service, Operation & Maintenance Manual

MAINTENANCE 4.1 WET CELL BATTERY CARE AND MAINTENANCE 4.2 BATTERY SPECIFIC GRAVITY 4.3 DAILY INSPECTION 4.4 OPERATOR'S DAILY CHECKLIST (SAMPLE) 4.5 MAINTENANCE AND INSPECTION 4.5.1 ENGINE OIL LEVEL 4.5.2 REFILLING ENGINE OIL 4.5.3 ENGINE COOLANT LEVEL 4.5.4 REFILLING ENGINE COOLANT 4.5.5 COOLING SYSTEM BLEEDING INSTRUCTIONS 4.5.6 BRAKE FLUID LEVEL 4.5.7 REFILLING BRAKE FLUID 4.5.8 AUTOMATIC TRANSMISSION FLUID LEVEL 4.5.9 REFILLING AUTOMATIC TRANSMISSION FLUID 4.5.10 HYDRAULIC OIL LEVEL 4.5.11 REFILLING HYDRAULIC OIL 4.5.12 STEERING WHEEL PLAY 4.5.13 WHEEL AND TIRE 4.5.14 TIRE REPLACEMENT 4.5.15 CHECKING MAST 4.5.16 CHECKING LIFT CHAIN 4.5.17 FORK INSPECTION 4.5.18 FORK REPAIR 4.5.19 CHECKING HORN 4.5.20 CHECKING LIGHTS 4.5.21 CHECKING CARGO-HANDLING CONTROL LEVER(S) 4.5.22 CHECKING BRAKE PEDAL 4.5.23 PEDAL FREE PLAY 4.5.24 CHECKING PARKING BRAKE LEVER 4.5.25 CHECKING TOP PANEL LOCK 4.5.26 FUSES 4.5.27 CHECKING AIR CLEANER 4.5.28 CHECKING FAN BELT 4.5.29 DRAINING OF TAR FROM THE VAPORIZER 4.5.30 PRECAUTIONS FOR USING LPG 4.5.31 RECOMMENDED LPG FUEL TYPE 4.5.32 CYLINDER (TANK) SIZE 4.5.33 LPG CYLINDER (TANK) REPLACEMENT 4.5.34 REFILLING LPG CYLINDERS (TANKS) 4.5.35 PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE 4.5.36 PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE FOR EMISSION CONTROL SYSTEM 4.5.37 LUBRICATION CHART 4.5.38 RECOMMENDED LUBRICANTS 4.5.39 RECOMMENDED SAE VISCOSITY CHART 4.5.40 PUTTING LIFT TRUCK IN STORAGE 4.6 SIDE SHIFT 4.6.1 OVERVIEW OF SIDE SHIFT 4.6.2 MAIN TERMS USED IN THIS SECTION 4.6.3 SAFETY RULES AND PRACTICES 4.6.4 SIDE SHIFT CONTROL LEVER OPERATION 4.6.5 SIDE SHIFT OPERATION 4.6.6 DAILY CHECKS AND SIMPLE MAINTENANCE CHAPTER 5 SPECIFICATIONS 5.1 MODEL IDENTIFICATION 5.1.1 MODEL VARIATION (LONG MODEL CODE) BREAKDOWN 5.2 MAIN TRUCK 5.2.1 MAIN TRUCK 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 Download all on: manualpost.com.

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Of all the variations of the French Defence I like this best, because it gives Black more chances to obtain the initiative.

5. P - K 5 Though I consider P × P the best move, there is much to be said in favour of this move, but not of the variation as a whole, which White adopted in this game.

5. ........

6. B - Q 2 7. P × B 8. Q - Kt 4

P-KR3 B × Kt Kt - K 5 K-B1

The alternative, P - K Kt 3; leaves Black's King's side very weak.

White by playing P - K R 4 would force Black to play P - K R 4; and later, on White's Bishop by going to Q 3, would threaten the weakened K Kt P. By the text move Black gives up Castling, but gains time for an attack against White's centre and Queen's side.

9. B - B 1

P-QB4

Threatening Q - R 4 and stopping thereby White's threat of B - R 3.

It demonstrates that White's last move was a complete loss of time and merely weakened his position.

10. B - Q 3 11. Kt - K 2 12. O - O 13. B × Kt 14. Q × P

Q-R4 P×P P×P P×B Kt - B 3

Black has come out of the opening with a Pawn to the good. His development, however, has suffered somewhat, and there are Bishops of opposite colour, so that it cannot be said as yet, that Black has a won game; but he has certainly the best of the position, because, besides being a Pawn to the good, he threatens White's K P, which must of course be defended, and this in turn will give him the opportunity to post his Knight at Q 4 via K 2. When the Black Knight is posted at Q 4, the Bishop will be developed to B 3 via Q 2, as soon as the opportunity presents itself, and it will be Black that

will then have the initiative, and can consequently decide the course of the game.

15. R - Q 1 To prevent Kt - K 2; which would be answered by Kt × P, or still better by B - R 3. The move, however, is strategically wrong, since by bringing his pieces to the Queen's side, White loses any chance he might have of making a determined attack on the King's side before Black is thoroughly prepared for it.

15. ........

16. P - B 4 17. B - K 3

P - K Kt 3 K - Kt 2

Better would have been P - Q R 4, in order to play B - R 3. The White B would be much better posted on the open diagonal than here, where it acts purely on the defensive.

17. ........

18. B - B 2

Kt - K 2 Kt - Q 4

This Knight completely paralyses the attack, as it dominates the whole situation, and there is no way to dislodge it. Behind it Black can quietly develop his pieces. The game can now be said to be won for Black strategically.

19. R - Q 3 B - Q 2 20. Kt - Q 4 Q R - Q B 1 21. R - Kt 3 K - R 2 22. P - K R 4 K R - Kt 1 23. P - R 5 Q - Kt 5 In order to pin the Knight and be ready to come back to either K 2 or B 1. Also to prevent Q R - Kt 1. In reality nearly all these precautions are unnecessary, since White's attack amounts to nothing. Probably Black should have left aside all these

considerations, and played Q - R 5 now, in order to follow it up with P - B 4, as he did later, but under less favourable circumstances.

24. R - R 3

24. ........

P-B4

Not the best, as White will soon prove. Q - B 1 would have avoided everything, but Black wants to assume the initiative at once and plunges into complications. However, as will soon be seen, the move is not a losing one by any means.

25. P × P e.p.Kt × P (B 3)

26. P × P ch R × P

27. R × P ch This wins the Queen.

27. ........

K×R 28. Kt - B 5 chP × Kt 29. Q × Q

The position looks most interesting. I thought it would be possible to get up such an attack against the White King as to make it impossible for him to hold out much longer, but I was wrong, unless it could have been done by playing B - B 3 first, forcing P - Kt 3 and then playing K - R 4. I followed a similar plan, but lost a very important move by playing Q R - K Kt 1; which gave White time to play R - Q 1. I am convinced, however, that B - B 3 at once was the right move. White would be forced to play P - Kt 3, and Black would reply with either K - R 4; as already indicated, which looks the best

(the plan, of course, is to play R - K R 1; and follow it up with K - Kt 5; threatening mate, or some other move according to circumstances. In some cases, of course, it will be better first to play K - Kt 5), or Kt - K 5, which will at least give him a draw. There are so many possibilities in this position that it would be impossible to give them all. It will be worth the reader's time to go carefully through the lines of play indicated above.

29. ........

Q R - K Kt 1

As stated B - B 3 was the best move.

30. P - Kt 3 31. R - Q 1

B-B3 K-R4

The plan, of course, as explained above, is to go to Kt 5 in due time and threaten mate at K R 8, but it is now too late, the White Rook having come in time to prevent the manœuvre. Instead of the text move, therefore, Black should have played Kt - K 5; which would have given him a draw at the very least. After the text moves the tables are turned. It is now White who has the upper hand, and Black who has to fight for a draw.

32. R - Q 6

B-K5

Kt - K 5 was still the right move, and probably the last chance Black had to draw against White's best play.

33. Q × B P Kt - Q 4 34. R × R K×R Kt × Q; R × R, Kt × P was no better.

35. Q - K 5 36. P - B 4 37. Q - Kt 2 38. B - Q 4 39. Q - Kt 5

K-B2 R-K1 Kt - B 3 R-KR1 R - R 8 ch

40. K - B 2 P - R 3 41. Q - Kt 6 R - R 7 ch 42. K - K 1 Kt - Q 2 43. Q - Q 6 B - B 3 44. P - Kt 4 P × P 45. P - K B 5 R - R 8 ch 46. K - Q 2 K - K 1 47. P - B 6 R-R2 48. Q - K 6 chK - B 1 49. B - K 3 R - B 2 50. B - R 6 chK - Kt 1 Most players will be wondering, as the spectators did, why I did not resign. The reason is that while I knew the game to be lost, I was hoping for the following variation, which Chajes came very near playing: 51 Q × P ch, K - R 2; 52 Q - R 5, R × P; 53 B - Kt 5 ch, K - Kt 2; 54 B × R ch, K × B; and while White has a won game it is by no means easy. If the reader does not believe it, let him take the White pieces against a master and see what happens. My opponent, who decided to take no chances, played 51 B - Kt 7, and finally won as shown below.

51. B - Kt 7 P - Kt 6 52. K - K2 P - Kt 7 53. K - B 2 Kt - B 1 54. Q - Kt 4 Kt - Q 2 55. K - Kt 1 P - R 4 56. P - R 4 B × P 57. Q - R 3 R × P 58. B × R Kt × B 59. Q × P ch K - B 1 60. Q × P and after a very few more moves Black resigned.

A very fine game on Chajes' part from move 25 on, for while Black, having the best of the position, missed several chances, White, on the other hand, missed none.

GAME 7. RUY LOPEZ (San Sebastian, 1911) White: J. R. Capablanca.

Black: A. Burn

1. P - K 4 P - K 4 2. Kt - K B 3Kt - Q B 3 3. B - Kt 5 P - Q R 3 4. B - R 4 Kt - B 3 5. P - Q 3 This is a very solid development, to which I was much addicted at the time, because of my ignorance of the multiple variations of the openings.

5. ........

6. P - B 3

P-Q3 B-K2

In this variation there is the alternative of developing this Bishop via Kt 2, after P - K Kt 3.

O-O 7. Q Kt - Q 2 8. Kt - B 1 P - Q Kt 4 9. B - B 2 P - Q 4 10. Q - K 2 P × P 11. P × P B-QB4 Evidently to make room for the Queen at K 2, but I do not think the move advisable at this stage. B - K 3 is a more natural and effective

move. It develops a piece and threatens B - B 5, which would have to be stopped.

12. B - Kt 5

B-K3

Now it is not so effective, because White's Q B is out, and the Knight, in going to K 3 to defend the square Q B 4, does not block the Q B. 13. Kt - K 3 14. O - O

R-K1 Q-K2

This is bad. Black's game was already not good. He probably had no choice but to take the Knight with the Bishop before making this move.

15. Kt - Q 5 B × Kt 16. P × B Kt - Kt 1 in order to bring it to Q 2, to support the other Knight and also his King's Pawn. White, however, does not allow time for this, and by taking advantage of his superior position is able to win a Pawn.

17. P - Q R 4 P - Kt 5 Since he had no way to prevent the loss of a Pawn, he should have given it up where it is, and played Q Kt - Q 2, in order to make his

position more solid. The text move not only loses a Pawn, but leaves Black's game very much weakened.

18. P × P B×P 19. B × Kt Q×B 20. Q - K 4 B - Q 3 21. Q × P ch K - B 1

With a Pawn more and all his pieces ready for action, while Black is still backward in development, it only remains for White to drive home his advantage before Black can come out with his pieces, in

which case, by using the open K R file, Black might be able to start a strong attack against White's King. White is able by his next move to eliminate all danger.

22. Kt - R 4

Q-R3

This is practically forced. Black could not play P - Kt 3 because of B × P, and White meanwhile threatened Q - R 8 ch followed by Kt - B 5 ch and Q × P. 23. Q × Q P×Q 24. Kt - B 5 P - K R 4 25. B - Q 1 Kt - Q 2 26. B × P Kt - B 3 27. B - K 2 Kt × P 28. K R - Q 1 Kt - B 5 29. B - B 4 K R - Q 1 30. P - R 4 P - R 4 Black must lose time assuring the safety of this Pawn.

31. P - Kt 3 32. B × Kt 33. Kt - K 3 34. Kt - B 4

Kt - K 3 P×B K R - Kt 1 K-K2

Black fights a hopeless battle. He is two Pawns down for all practical purposes, and the Pawns he has are isolated and have to be defended by pieces.

35. Q R - B 1 R - R 2 White threatened Kt × B, followed by R - B 7 ch.

36. R - K 1 37. R - K 4 38. P - Kt 4

K-B3 R - Kt 5 R-R3

If R × R P; Kt × B of course would win a piece 39. R - B 3 B - B 4 40. R - B 3 chK - Kt 2 41. P - Kt 3 B - Q 5 42. K - Kt 2 R - R 1 43. P - Kt 5 R - R 3 44. P - R 5 R × Kt 45. P × R R-B3 46. P - Kt 6 Resigns.

GAME 8. CENTRE GAME (Berlin 1913) White: J. Mieses.

Black: J. R. Capablanca.

1. P - K 4 2. P - Q 4 3. Q × P 4. Q - K 3

P-K4 P×P Kt - Q B 3 Kt - B 3

B - Kt 5 5. Kt - Q B 3 6. B - Q 2 O - O 7. O - O - O R - K 1 In this position, instead of the text move, P - Q 3 is often played in order to develop the Q B. My idea was to exert sufficient pressure against the K P to win it, and thus gain a material advantage, which would, at least, compensate whatever slight advantage of position White might have. The plan, I think, is quite feasible, my subsequent difficulties being due to faulty execution of the plan.

8. Q - Kt 3 Kt × P

9. Kt × Kt R × Kt 10. B - K B 4

10. ........

Q-B3

White's threat to regain the Pawn was merely with the idea of gaining time to develop his pieces. Black could have played P - Q 3; opening the way for his Q B, when would have followed, 11 B - Q 3, R - K 1; 12 Kt - B 3, and White would soon start a powerful direct attack against Black's King. With the text move Black aims at taking

the initiative away from White in accordance with the principles laid down in this book.

11. Kt - R 3 If B × P, P - Q 3; and White's Bishop would be completely shut off, and could only be extricated, if at all, with serious loss of position.

The text move aims at quick development to keep the initiative.

11. ........

P-Q3

This now is not only a developing move, but it also threatens to win a piece by B × Kt. 12. B - Q 3

Kt - Q 5

This complicates the game unnecessarily. R - K 1; was simple, and perfectly safe.

13. B - K 3

13. ........

B - Kt 5

This is a serious mistake. The position was most interesting, and though in appearance dangerous for Black, not so in reality. The right move would have been 13...R - Kt 5, when we would have 14 B × Kt, R × B; 15 P - Q B 3, B × P; 16 P × B, R - K Kt 5; 17 Q - K 3 (best), Q × P ch; 18 B - B 2, Q × Q; 19 P × Q, R × P, and Black has the best of the game with four Pawns for a Knight, besides the fact that all the White Pawns are isolated.

14. Kt - Kt 5 !R × B There was nothing better.

15. Q × B !

Kt - K 7 ch

16. B × Kt ! R × B 17. Kt - K 4 ! R × Kt 18. Q × R Q - Kt 4 ch 19. P - K B 4 Q - Kt 4 20. P - B 3 B - B 4

21. K R - K 1 Q - B 3 22. R - Q 5 Q × Q would have given White a decided advantage, enough to win with proper play. Mieses, however, feared the difficulties of an ending where, while having the exchange, he would be a Pawn minus. He preferred to keep the Queens on the board and keep up the attack. At first sight, and even after careful thought, there seems to be no objection to his plan; but in truth such is not the case.

From this point the game will gradually improve in Black's favour until, with the exchange ahead, White is lost.

22. ........

23. P - B 5 24. R - Q 2

Q-Q2 P-QB3 P-Q4

My plan for the moment is very simple. It will consist in bringing my Bishop around to B 3. Then I shall try to paralyse White's attack against my King by playing P - K R 3, and also prevent White from ever playing P - K Kt 5. Once my King is safe from attack I shall begin to advance my Queen's side Pawns, where there are four to three; and that advantage, coupled with the enormous attacking power of my Bishop at B 3, will at least assure me an even chance of success.