Cat Lift Trucks. For use with K21/K25 and S4S Engine Service Manuals (2007)

FOREWORD

This service manual is a guide for servicing

Lift Trucks. For your convenience the

instructions are grouped by systems as a ready reference.

Long productive life of your

depends on regular and proper servicing. Servicing

consistent with what you will learn by reading this service manual. Read the respective sections

of this manual carefully and familiarize yourself with all of the components before attempting

to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual are

trucks with

serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to change

specifications or design without notice and without incurring obligation.

The trucks listed in this manual are powered by

gasoline engines or

diesel

engines. For the engine servicing, please refer to the applicable engine service manual.

Safety Related Signs

The following safety related signs are used in this service

manual to emphasize important and critical instructions:

result in death or serious injury.

Indicate a potentially hazardous

situation which, if not avoided, may

result in minor or moderate injury, or

to your machine.

Indicates a condition that can cause

(NOTE)

damage to, or shorten service life of,

the machine.

Pub. No. 99719-89120

rication and

maintenance for these lift trucks,

read and understood the instructions in the

recommended by Cat Lift Trucks, are outlined

OPERATION

MAINTENANCE MANUAL.

in the

MANUAL.

truck

is dangerous and

Improper performance of lubrication or

could result in injury or death.

maintenance procedures is dangerous and

Lower the forks or other implements to the ground

could result in injury or death. Read and

before performing any work on the truck. If this

understand the OPERATION & MAINTENANCE

cannot be done, make sure the forks or other

MANUAL before performing any lubrication or

implements are blocked correctly to prevent them

maintenance on these trucks.

from dropping unexpectedly.

The serviceman or mechanic may be unfamiliar with

Use steps and grab handles (if applicable) when

many of the systems on this truck. This makes it

mounting or dismounting a truck. Clean any mud

or debris from steps, walkways or work platforms

important to use caution when performing service

before using. Always face truck when using steps,

work. A knowledge of the system

components

is important before the removal or disassembly of any

ladders and walkways. When it is not possible to

component.

use the designed access system, provide ladders,

scaffolds, or work platforms to perform safe repair

Because of the size of some of the truck components,

operations.

the serviceman or mechanic should check the weights

noted in this Manual. Use proper lifting procedures

To avoid back injury, use a hoist when lifting

when removing any components.

components which weigh 23 kg (50 lb.) or more.

Make sure all chains, hooks, slings, etc., are in

Following is a list of basic precautions that should

good condition and are of the correct capacity. Be

always be observed.

sure hooks are positioned correctly. Lifting eyes

Read and understand all warning plates and decals

are not to be side loaded during a lifting operation.

on the truck before operating, lubricating or

To avoid burns, be alert for hot parts on trucks

repairing the product.

which have just been stopped and hot fluids in

2. Always wear protective glasses and protective

lines, tubes and compartments.

shoes when working around trucks. In particular,

Be careful when removing cover plates. Gradually

wear protective glasses when pounding on any part

back off the last two bolts or nuts located at

of the truck or its attachments with a hammer or

opposite ends of the cover or device and pry cover

sledge. Use welders gloves,

apron

loose to relieve any spring or

pressure, before

and other protective clothing appropriate to the

removing the last two bolts or nuts completely.

welding job being performed. Do not wear

Be careful when

filler caps, breathers and

fitting or torn clothing. Remove all rings from

plugs on the truck. Hold a rag over the cap or plug

fingers when working on machinery.

to prevent being sprayed or splashed by liquids

3. Do not work on any truck that is supported only by

under pressure. The danger is even greater if the

lift jacks or a hoist. Always use blocks or jack

truck has just been stopped because fluids can be

stands to support the truck before performing any

hot.

disassembly.

10. Always use tools that are in good condition and be

19. Tighten connections to the correct torque. Make

sure you understand how to use them before

sure that all heat shields, clamps and guards are

performing any service work.

installed correctly to avoid excessive heat,

vibration or rubbing against other parts during

11. Reinstall all fasteners with same part number. Do

operation. Shields that protect against oil spray

not use a lesser quality fastener if replacements are

onto hot exhaust components in event of a line,

necessary.

tube or seal failure, must be installed correctly.

12. If possible, make all repairs with the truck parked

20. Relieve

pressure in air, oil or water systems

on a level, hard surface. Block truck so it does not

before any lines, fittings or related items are

roll while working on or under truck.

disconnected or removed. Always make sure all

13. Disconnect battery and discharge any capacitors

raised components are blocked correctly and be

(electric trucks) before starting to work on truck.

alert for possible pressure when disconnecting any

Hang "Do not Operate" tag in the Operator's

device from a system that utilizes pressure.

Compartment.

21. Do not operate a truck if any rotating part is

14. Repairs, which require welding, should be

damaged or contacts any other part during

performed only with the benefit of the appropriate

operation. Any high speed rotating component that

reference information and by personnel adequately

has been damaged or altered should be checked for

trained and knowledgeable in welding procedures.

balance before reusing.

Determine type of metal being welded and select

correct welding procedure and electrodes, rods or

wire to provide a weld metal strength equivalent at

least to that of parent metal.

15. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it

be damaged in operation by contacting sharp

corners, or by rubbing against

object or hot

surface. Place wiring away form oil pipe.

16. Be sure all protective devices including guards and

shields are properly installed and functioning

correctly before starting a repair. If a guard or

shield must be removed to perform the repair work,

use extra caution.

17. Always support the

and carriage to keep

carriage or attachments raised when maintenance

or repair work is performed, which requires the

mast in the raised position.

18. Loose or damaged fuel, lubricant and hydraulic

lines, tubes and hoses can cause fires. Do not bend

or strike high pressure lines or install ones which

have been bent or damaged. Inspect lines, tubes

and hoses carefully. Do not check for leaks with

your hands. Pin hole (very small) leaks can result

in a high velocity oil stream that will be invisible

close to the hose. This oil can penetrate the skin

and cause personal injury. Use cardboard or paper

to locate pin hole leaks.

GROUP

Model view, Truck models covered, Serial number locations,

GENERAL INFORMATION

Dimensions, Technical data

Fan removal and installation, Fan belt inspection and adjustment

COOLING SYSTEM

Console box, Chassis electrical devices, Battery maintenance, Electrical

ELECTRICAL SYSTEM

system schematic

Main functions, Service tool functions,

monitor, Error

codes and troubleshooting

POWER TRAIN

Removal and installation

Torque converter, 1 -speed transmission, Control valve,

Automatic 2-speed transmission

FRONT

AND

Front tires, Front axle, Reduction and differential

REDUCTION DIFFERENTIAL

Rear tires, Rear axle, Toe-in,

turning radius

REAR AXLE

Master cylinder, Wheel cylinders, Wheel brakes, Brake booster

Steering gear, Power cylinder, Flow divider

STEERING SYSTEM

Hydraulic tank, Gear pump, Control valve, Lift and tilt cylinders,

HYDRAULIC SYSTEM

Flow regulator valve, Down safety valve

Simplex mast, Duplex mast, Triplex mast

MAST AND FORKS

Maintenance standards, Periodic service chart, Periodic replacement

SERVICE DATA

parts, Lubrication instructions, Special tools

GENERAL INFORMATION

Truck Models Covered

This Service Manual contains servicing and maintenance information for the following trucks:

Gasoline-engine models

Dual fuel gasoline-engine models

Truck class

Engine

Truck model

Serial number

Truck model

Serial number

mounted

1 ton class

2 ton class

3 ton class

LPG-engine models

Diesel-engine models

Truck class

Engine

Truck model

Serial number

Truck model

number

mounted

1 ton class

AT35-10121-UP

2 ton class

AT35-10121-up

AT36-10121

AT1

3 ton class

AT13F-60121

Note: Characters at the end of truck model should be read as follows:

C: Short body model

GENERAL

Technical Data

Unit: mm (in.)

Ref.

Model Gasoline-engine

No.

Truck

,.,,,,..,

,.,.

Item

Maximum lift

3000 (118)

Free lift

115 (4.5)

Fork spread (outside)

Fork length

920 (36.2)

Tilt angle (forward - backward)

Overall length

3180 (125.2)

3321 (126.8)

3279 (129.1)

Single tire

1065 (41.9)

Overall width (outside of tires)

Dual tire

1330 (52.4)

Overall height (to top of mast lowered)

1995 (78.5)

Overall height (to top of overhead guard)

2065 (81.3)

Overall height (mast extended)

4055 (159.6)

Single tire

890 (35)

Tread (front)

Dual tire

1025 (40.4)

Tread (rear)

900 (35.4)

Wheelbase

1400 (55.1)

SYSTEM

Inspection and Adjustment

Fan Belt Inspection

(1) Check the belt for contamination

oil, grease or

dust. Replace the belt if required. When the

Fan pull

contamination is slight, clean the belt with a rag or

paper towel. Do not use gasoline, oil or any other

solvent to clean

(2) During the engine overhaul or belt tension adjustment,

check the condition of the belt. Replace the belt if it

has any damage.

Fan Belt Tension

Apply a force of 98 N (10 kgf) [22

perpendicularly to

the belt at a point midway between the fan pulley and

tension pulley. Adjust the tension until belt deflection is

between to 13 mm (0.43 to 0.51 in.).

Connecting Radiator Hoses

When connecting the hoses to the radiator, fit their ends

Hose

fully on the fittings and secure them with clamps. Make

sure that each hose is correctly connected and over the flare

of the fitting.

Unit Layout

COOLING SYSTEM

Coolant

Fill the radiator with coolant containing antifreeze. After

starting the engine and letting it warm up during operation,

check for abnormal noises. Check the coolant level in the

reserve tank to ensure it meets specifications.

Quantity of coolant

Unit: liter (U.S. gal.)

1 ton class

2 ton class

3 ton class

Engine

3.95

(1.04)

Radiator

2.2

(0.58)

Reserve tank (FULL level)

0.65

(0.17)

0.65

(0.17)

0.65

(0.17)

Total quantity of coolant

(including coolant in hoses)

Oil cooler

0.094

(0.02)

Radiator Cap

Opening pressure

(0.92

0.15 kgf/crn²)

psi]

to 5

Vacuum valve

to 0.05

to 0.73 psi]

ELECTRICAL SYSTEM

Function of Instrument Panel

i3 i4

Description of function

When illuminated

Code

Name of monitor

When not illuminated

Remarks

or flashing

Parking brake released

Parking brake applied

warning lamp

level

ECM warning lamp

Normal

ECM abnormal

Gasoline-engine truck

Engine oil pressure warning lamp

Normal oil pressure

Low oil pressure

Seat belt reminder warning lamp

Fastened

Not fastened

Multi-purpose warning lamp (illuminates when

warnings indicated by printed symbols occur or minor

Normal

Malfunction

Printed symbol

failures occur)

Abnormal charging

Charge warning lamp

Normal charging

system

Engine being

Glow pilot lamp

Preheating completed

Diesel-engine truck

preheated

LPG fuel level

LP-Gas warning lamp

Normal

pressure low

Loadiunload interlock

Free

Fr, Re interlock lamp

Free

Locked (flashing)

Neutral lamp

For R

Neutral

Fuel gauge

Indicates remaining

amount with key in "ON" position.

Water temperature gauge

Indicates "Overheat" condition if pointer enters the red zone.

Liquid crystal (normally acting as hour meter)

Indicates operating hours with key in "ON" position.

L4 Clogged air cleaner element warning lamp

Normal element

Clogged

Option

When major failures occur, bulbs A, C, D, E, and H simultaneously flash.

Inspection method of blown bulbs for Instrument panel

All warning and indicator lamps are normal if they illuminate when the starter switch is turned ON, and no bulbs are

blown.

3-4

ELECTRICAL SYSTEM

Major Electrical Components

Starter switch

The diesel-engine truck, which uses a distributor type injection pump, is provided with an engine automatic stop

mechanism of the fuel cut off system located by the starter switch.

The gasoline-engine truck also has an engine automatic stop mechanism of the fuel cutoff system.

Starter switch (with

Lock)

This switch has a built-in anti-restart lock, so the key cannot be turned from (ON) to

(START) position while

the engine is running. This prevents starter breakage or flywheel damage caused by an operator re-starting the truck

when the engine is running. The gasoline- and diesel-engine models use the

starter switch. In the diesel-engine

models, (ON) position of the switch is for energizing the glow plugs.

(START)

Connection Table

Gasoline-engine truck

Diesel-engine truck

Key position

OFF

ELECTRICAL SYSTEM

Sender unit (engine coolant temperature)

1. Apply an

between the terminal and body of

the sender unit and check for continuity (resistance

Terminal

value).

2. Replace the sending unit if there is no continuity or the

measured resistance value is outside the standard

resistance value.

Note: The illustration is for a gasoline-engine truck.

Gasoline-engine truck

Temperature

Standard resistance

136

27.2

20.5

17.2

value (ohm)

Diesel-engine truck

Temperature

100

106

120

(122)

(140)

(176)

(212)

(222.8)

(248)

Standard

resistance

(80)

56.3

(29.5)

(16.5)

14.3

(10)

value (ohm)

3. When installing the sending unit, tighten it to the

specified torque.

19.6 to 27.4

Sending unit tightening

(2.0 to 2.8

torque

to 20.2

ELECTRICAL SYSTEM

Thermoswitch

oil)

Apply an ohmmeter between the terminal and body and

Terminal

Body

check for continuity (resistance value). Replace the

thermoswitch if the measured insulation resistance value is

not more than the value listed in the table below.

ohm or more

Insulation resistance value

(with contact OFF)

(at 500 V megger)

Internal resistance: 0.5 ohm or less (with contact ON)

Allowable load: 0.5 A

Note: When installing the thermoswitch, tighten it to the

specified torque.

Tightening torque

Replace the thermoswitch if it was dropped or

abused.

Main specifications

Operating temperature

Insulation resistance

1 M ohm or more

(with contact OFF)

ELECTRICAL SYSTEM

Power relay (Backup lamps)

Inspection of coil

Apply an ohmmeter across terminal 1 and terminal 2 and

measure the resistance value of the relay coil. If there is no

continuity or the resistance value measured is outside the

standard resistance value, replace coil.

Resistance value of coil

Inspection of contact

1. Measure the insulation resistance value between

terminal 3 and terminal 4. Replace the contact if the

measured insulation resistance value is not more than

the value listed in the table below.

10 M ohm or more

Insulation resistance value

(at 500 V megger)

Connection diagram

2. Apply an ohmmeter across terminal 3 and terminal

3. When applying a voltage of 12 V ON and OFF across

terminal 1 and terminal 2 under the above condition,

Diode

check to see if the relay activates to cause continuity

between terminal 3 and terminal 4. Replace the relay if

it was dropped or abused.

terminals, be careful about the polarity when

inspecting. Replace the relay if an impact is given

to it or if it is dropped.

SYSTEM

Glow timer (diesel-engine truck)

Inspection of output time when starter switch is

turned to ON

3 (1.25 Br: MTM truck)

(1.25 BY: ATM truck)

When an ohmmeter is applied to terminal 2 and terminal 1

4 (1.25 WL)

and a voltage of 12 V is applied between terminal 3 and

1 (0.85 B)

terminal 1 , there is continuity between terminal 2 and

2 (1.25 BR)

terminal 1 for 1.5 seconds at room temperature. Replace

the glow timer with a new one if it does not operate

properly.

Inspection of output time when starter switch is

turned to START

Starter switch

When an ohmmeter is applied to terminal 2 and terminal 1

and a voltage of 12 V is applied between terminal 4 and

timer

terminal 1 , there is continuity between terminal 2 and

terminal 1 for 5 seconds. Replace the glow timer with a

new one if it does not operate properly.

Glow

indicator

lamp

Rated voltage: DC 12 V

ELECTRICAL SYSTEM

Glow relay (diesel-engine truck)

lnspection of coil

Apply an ohmmeter across terminal 3 and terminal 4 and

measure the resistance value of the relay coil. If there is no

continuity or the measured resistance value is outside the

standard resistance value. Replace the coil.

Resistance value of coil

52 ohm

[at 20

(68

lnspection of contact

1. Measure the insulation resistance value between

terminal 1 and terminal 2. Replace the contact with a

new one if the measured insulation resistance value is

not more than the value listed in the table below.

ohm or more

Insulation resistance valve

(at 500 V megger)

Connection diagram

Apply a tester to terminal 1 and terminal 2.

3. When applying a voltage of 12 ON and OFF across

terminal 3 and terminal 4 under the above condition,

check to see if the relay activates to cause continuity or

not between terminal 1 and terminal 2. Replace the

relay with a new one if it does not activate properly.

Coil rating [in case of 20°C

Rated operating voltage: DC 12 V

Coil resistance: 52 ohm

Rated exciting current:

Fuel pump (gasoline-engine truck)

ELECTRICAL SYSTEM

Solenoid valve (for speed selector valve)

This is an

valve (normal open type).

The valve opens the

circuit in a non-energized

condition.

Rated operating voltage: DC 12V (gasoline-engine truck,

resin color: grey)

: DC 12V (diesel-engine truck,

resin color: brown)

Solenoid valve (for SR-SF selector valve)

This is an

valve (normal open type).

The valve opens the

circuit in a non-energized

condition.

Rated operating voltage: DC 12V

OUT

Wiring to the solenoid valve terminal on

side

Wire gauge and color 1.25 Br

tag is attached.

Wiring to the solenoid valve terminal on SF side

Mark of 12 V NO

Wire gauge and color 1.25

is attached.

208536

The valve has an identification mark "1 2 V NO" on

the body side.

Be careful not to supply DC 24 to the valve to

avoid damage.

ELECTRICAL SYSTEM

Battery Maintenance

1. State of charge and electrolyte specific gravity

adjustment

Specific gravity reading

State of charge

Adjustment

at 20°C

1.280 to 1.265

Fully charged

If difference in S.G. between any two cells is 0.020 or more,

discharge the battery to minimize the difference and then

recharge battery. Adjust S.G. during recharging.

1.260 to 1.225

One-half charged

Recharge battery and adjust electrolyte S.G. Make sure there

is neither faulty components, loosely connected cord or

corroded connection.

1.220 or below

Discharged

Recharge battery. If difference in S.G. is large, adjust it

during recharging.

If difference in S .G. is

A cell with a low S.G.

Recharge until voltage and S.G. stabilize and have remained

more than 0.040

is in

condition.

constant for more than 2 hours.

Electrolyte leakage,

During recharging, adjust S

to 1.280 to 1.265.

If difference in S.G. is more than 0.040 and a low S

electrolyte.

found in certain cells only, replace battery. After leaving

battery for 12 to 96 hours, conduct a high current discharge

test.

2. Specific gravity reading and state of charge

To check the battery for state of charge, take

Be sure to turn

hydrometer readings on its electrolyte. The battery may

switch before disconnecting or connecting the

be fully charged if the S.G. reading is 1.280 to 1.265 at

battery cables to prevent the IC regulator from

20°C (68°F). The state of charge can be told from the

way the electrolyte level goes down to expose the cell

plates. If addition of distilled water is necessary every

month or so, the battery is overcharged. If addition is

not required for more than 3 months, it is likely that the

battery is inadequately charged.

3. Charging precautions

(1) In slow charging, the charging current should be

about 1/10 the capacity of the battery to be charged.

000000

(2) In quick charging, the battery capacity in ampere

should not be exceeded.

(3) During charging, adjust the charging current to

prevent the electrolyte temperature from rising

beyond 45°C (113°F).

(4) When connecting the cables to the battery, begin by

installing the cable to the positive (+) terminal.

When disconnecting them from the battery, begin

by removing the cable for the negative (-) terminal.

209650

ELECTRICAL SYSTEM

Wire Color

Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first

color shows a base color and the second color a marking color.

Example: The wire color of BW shows that its base color is B with a marking W.

Marking color

Base color

Note: For wiring identification, the same color, in principle, must be used for the circuit from the power supply to the

load.

Be careful that allowable current differs between solid wires and stranded wires even if they are of the

, same gauge.

List of wire colors

Wire color

Color

BLACK

WHITE

RED

GREEN

BROWN

BLUE

LIGHT GREEN

ORANGE

PINK

GRAY

LIGHT BLUE

DARK GREEN

CHOCOLATE

ELECTRICAL SYSTEM

Troubleshooting

Starter System

Weak or dead battery

Recharge or replace.

Short or open circuit

Repair or replace.

Starter will not crank

Poor continuity in starter switch

Replace.

Starter or starter relay defective

Replace.

Forward-reverse lever not in neutral

Move lever to neutral

Starter switch

position

position.

Open or short circuit

Repair or replace.

switch will not stop

Engine stop solenoid defective

Replace or readjust.

engine

Control timer defective

Replace.

Gauges

Rigid board defective

Replace.

Open or short circuit

Repair or replace

all

Gauge internally defective

Replace.

Gauge unit defective

Replace.

Gauge or gauge unit not of the type

Replace to a correct

Water

Will not indicate

called for

one.

temperature

Loose terminal connection

Repair.

Circuit between gauge and gauge unit

Repair.

grounded

temperature

Gauge internally defective

Replace.

Rigid board defective

---- Replace.

Will not indicate at

Open or short circuit

Repair or replace.

Gauge internally defective

- Replace.

Gauge unit defective

Replace.

Gauge or gauge unit not of the type

Replace to a correct

Will not indicate

called for

one.

accurately

Loose terminal connection

Repair.

Fuel gauge

Circuit between gauge and gauge unit

Repair.

Will indicate "full"

open or short

regardless of amount

Gauge internally defective

Replace.

of fuel left in tank

Gauge unit defective

Replace.

Circuit between gauge and gauge unit

Repair.

Will indicate

grounded

"empty" regardless

of amount of fuel

Gauge unit defective

Replace.

left in tank

Gauge internally defective

Replace.

ELECTRICAL SYSTEM

Lighting System

Weak or dead battery

Recharge or replace.

Fuses blown out

Check and replace.

Open or short circuit

Repair or replace.

Will not light

---

Clean ground

and

re-make connection.

Switch defective

Replace.

Bulbs burnt out

- Replace.

Weak battery

Check and recharge.

Contact points in switches defective

- Repair or replace.

Loose terminals

Repair.

Dirty lenses

Clean.

Waterdrops inside lenses

Dry and replace packings.

Bulbs expired in service life

- Replace.

Lighting switch defective

Replace.

Bulbs burnt out

Replace.

Turn signal switch defective

Replace.

Will not flicker

Turn signal relay defective

Replace.

Turn signal relay defective

Replace.

Will not go out

Bulbs burnt out

Replace.

Turn signals

Low wattage of bulbs

Replace to a correct one.

Will flicker too

Bulbs burnt out

Replace.

slow

Turn signal relay defective

- Replace.

Will flicker too

High wattage of bulbs

--- Replace to a correct one.

Turn signal relay defective

Replace.

Backup

switch defective

Repair or replace.

will not light

Bulbs burnt out

Replace.

Other lamps

License number

Lighting switch defective

- Replace.

plate lamp will

Bulb burnt out

Replace.

not light

Alarm Unit

Fuse blown out

Check and replace.

Open or short circuit

Repair or replace.

Will not sound

Horn switch defective

Replace.

Horn defective

Replace.

Horn button defective

- Repair or replace.

Horn switch defective

Replace.

offensive blast

Horn defective

-- Replace.

of sound

ELECTRICAL SYSTEM

Battery

Drive belt slipping

- Readjust.

Alternator

Stator coil grounded or open-circuited

Repair or replace.

Rotor coil open

- Replace.

Brushes poorly seating on slip rings

- Replace brushes if worn.

Clean holder and polish

slip rings.

Diode ruptured

Replace.

Regulator

Regulated voltage setting too low

Replace.

Tends to run down

Battery

rapidly

Not enough electrolyte or wrong concentration of acid

- Refill and check specific

to water

gravity.

Battery cell plates deteriorated (forming, possibly

Replace.

internal short-circuit)

Terminal connections loose

Clean and retighten.

Wiring

Open or loose connection between starter switch and

Repair,

regulator IC terminal

Fuse blown, or loosely set in holder

- Replace and repair.

Open or loose connection between F terminals of

Repair.

regulator and alternator

Wiring

Regulator IC and terminals shorted or miswired

- Repair.

Poor grounding of regulator F terminal

Repair.

Tends to get

Regulator

overcharged

Pressure coil open-circuited

--- Replace.

Regulated voltage too high

Replace.

CONTROLLERS

Tool Functions

Monitor

Monitors input and output of sensors and switches.

Monitor: Mast control

Unload Sol

Feedback [Hex

monitor

Sol

Feedback [Hex

Unload Sol

Sol

OFF

Sol

OFF

Lowering Speed SW

ONIOFF

Lowering Speed SW

Lift Operation SW

ONIOFF

Lift Operation SW

Mast High SW

ONIOFF

Tilt Operation SW

Mast Hight SW

Snow Mode SW

ONIOFF

Snow Mode SW

Tilt Auto-stop SW

ONIOFF

Tilt Auto-stop SW

Tilt Operation SW

ONIOFF

Tilt Angle

2. VCM-1

Monitor: Engine and

control

Speed limit SW

monitor

Direction lever F

Speed limit SW

Outside

Direction lever N

Direction lever

Direction lever R

Direction lever N

Direction lever

Accel SW

sig

0 FF

sol

TIM

ONIOFF

sol

0FF

TIM sol cur

sol F

ONIOFF

Speed sensor

TIM sol R

ONIOFF

Speed sensor err

TIM sol cur

[Hex

Speed sensor

[Hex ,Hz

Speed sensor err

Note: "Hex" denotes hexadecimal digit.

CONTROLLERS

Monitor:

control

Oil press MAIN

[Hex

monitor

Oil press LIFT

[Hex

Oil press MAIN

Oil press LIFT

Weight set SW

ONIOFF

Enter SW

ONIOFF

Weight set SW

OFF

Enter SW

OFF

Next SW

ONIOFF

Next SW

Auto light sig

ONIOFF

Auto light OUT

ONIOFF

Seat SW

Seat SW timer

Seat SW

ONIOFF

Seat SW timer

ONIOFF

Monitor:

control 2

Park brake alarm

monitor

Over load alarm

Park brake alarm

OFF

Over speed alarm

Over load alarm

OFF

Over speed alarm

OFF

Coolant low SW

ONIOFF

Coolant low SW

OFF

Air cleaner SW

OFF

Air cleaner SW

ONIOFF

warning SW

ONIOFF

Fuel warning SW

OFF

Park brake SW

OFF

Fuel warning SW

ONIOFF

Park brake SW

ONIOFF

AUX

OFF

AUX

AUX in2 ON

AUX out2 OFF

AUX out3 OFF

AUX

ONIOFF

AUX in2

ONIOFF

AUX

ONIOFF

AUX out2

ONIOFF

AUX out3

ONIOFF

CONTROLLERS

Error Codes and

Error Code Display

All the error codes detected by VCM are displayed.

Troubleshooting

Tapping a displayed error code or error name reads the text file

which can be edited with a Windows application)

corresponding to the error code and displays the troubleshooting

screen specific to the error code. If one screen cannot

accommodate all data, the screen can be scrolled. The screen

specifications are shown below. The table in the following pages

lists the probable causes and check points for error codes.

Error code F34 (speed sensor error)

Estimated cause

Connector contact error

Troubleshooting

2. Harness error

F34 Speed sensor err

3. Speed sensor error

Estimated cause

4. Controller error

1 .Connector contact bad

bad

Check items

sensor bad

1. Connector connection

bad

continuity

Check item

3. Sensor continuity

1.Connector connection check

connection check

CONTROLLERS

Error Codes and Troubleshootings are shown below.

Refer to "Locations of Sensors and Switches" on later pages.

Description

Probable cause

Check point

Memory err

1. Controller bad

1. Connector contact bad

Connector connection check

2. Harness bad

2. Harness connection check

3. Controller bad

F03

VCM communication err

1. Connector contact bad

Connector connection check

2. Harness bad

2. Harness connection check

3. VCM Controller bad

3. Communication line check

. Connector contact bad

2. Harness bad

2. Harness connection check

3. Meter panel bad

3. Communication line check

4. Controller bad

Connector contact bad

1. Connector connection check

F16 Shift lever fault

1. Connector contact bad

. Connector connection check

. Harness connection check

3. Shift lever check

3. Shift lever bad

4. Controller bad

CONTROLLERS

Probable cause

Check point

1. Connector contact bad

1. Connector connection check

2. Harness bad

2. I-Iarness connection check

3. Speed sensor bad

3. Sensor connection check

4. Controller bad

1. Connector contact bad

1. Connector connection check

2. Harness bad

. Harness connection check

4. Controller bad

1. Connector contact bad

1. Connector connection check

2. Harness bad

2. Harness connection check

3. Speed sensor bad

3. Sensor connection check

1. Connector contact bad

1. Connector connection check

2. Harness bad

2. Harness connection check

3. Wheel sensor bad

3. Sensor connection check

4. Joint and link bad

4. Joint and link check

5. Controller bad

CONTROLLERS

Description

Probable cause

Check point

F38 Tilt sensor err

Connector contact bad

Link

and damage check

2. Connector connection check

2. Harness bad

3. Harness connection check

3. Tilt sensor bad

4. Sensor connection check

4. Controller bad

1. Connector contact bad

Connector connection check

2. Harness bad

2. Harness connection check

3. Wheel sensor bad

3. Sensor connection check

4. Controller bad

Unload sol err

1. Connector contact bad

1. Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

4. Unload sol bad

4. Unload sol connection check

5. Controller bad

sol err

1. Connector contact bad

1. Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

sol bad

sol connection check

. Controller bad

CONTROLLERS

Err

Description

Probable cause

Check point

code

F79

Unload sol leak

I. Connector contact bad

Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

4. Unload sol bad

4. Unload sol connection check

Controller bad

Knob pos sol err

Connector contact bad

1. Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

4. Knob pos sol bad

4. Knob pos sol connection check

sol err

I.Connector contact bad

1. Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

sol bad

sol connection check

5. Controller bad

Knob pos sol leak

1. Connector contact bad

1. Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

4. Knob pos sol bad

4. Knob pos sol connection check

CONTROLLERS

Err

Description

Probable cause

Check point

code

TIM FW sol err

Connector contact bad

Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

4. TIM FW sol bad

FW sol connection check

5.Controller bad

TIM

sol err

Connector contact bad

Connector connection check

Diode bad

Diode connection check

3. Harness bad

3. Harness connection check

TIM BW sol bad

BW sol connection check

. Controller bad

TIM sol leak

Connector contact bad

1. Connector connection check

2. Diode bad

2. Diode connection check

3. Harness bad

3. Harness connection check

4. TIM sol bad

sol connection check

Error Codes and Explanation

Contact your Cat lift truck dealer when the error code is displayed.

POWER TRAIN

and Installation

Removal of Engine and Transmission Assembly (for Gasoline-engine Trucks)

The engine and transmission are installed as an

assembled unit. The engine may be removed

independently of the transmission, but the transmission

can only be removed together with the engine.

Overhead Guard, Covers, Air Cleaner and Other Components

1 Overhead guard, Headlamps

6 Radiator cover

2 Batteries, Cables

Floor plate, Floor mat

3 Steering wheel

8 Air hose, Air cleaner

4 Gas springs

9 Exhaust pipe

5 Engine cover, Seat

10 Fuel hoses (without LPG engine models)

Suggestions for Removal

(1) When removing the batteries 2, be sure to

(4) Before removing the fuel hose 10, make sure to

disconnect the ground (negative) cable first.

close the cock on the fuel tank.

(2) Remove the floor plate and mat 7 together with the

(5) After disconnecting the harness connectors from

accelerator pedal after disconnecting the pedal from

the sockets and terminals on the engine and

the linkage rod.

transmission they should be attached to the main

harness, in order to avoid damaging them.

(3) Disconnect the exhaust pipe 9 from the engine.

POWER TRAIN

Radiator and Pipes

Sequence

1 Reserve tank

7 Cooler hose (between radiator and powershift

2 Hose (upper)

transmission)

3 Hose (lower)

8 Cooling fan

4 Hose (between hydraulic tank and control

9 Fan belt

valve)

10 Fan guard

5 Hose (between hydraulic tank and oil pump)

11 Universal joint (between transmission and

6 Hose (between oil pump and steering control

gears)

valve)

Start by:

Installation

(a) Drain the coolant from the engine by removing the

Follow the removal sequence in reverse.

drain plug (note that the position of the drain plug

differs by engine type).

(b) Drain the coolant from the radiator by loosening

the cock at the bottom of the radiator.

Suggestion for Removal

Disconnect the cooler hose 7 from the transmission side

and temporarily attach it to the right side of the frame.

POWER

Engine and Transmission Assembly

Sequence

1 Transmission mounting bolt

3 Engine and transmission assembly

2 Engine mounting bolt

Start by:

(a) Lifting the engine and transmission assembly with a

hoist and slings.

Suggestions for Removal

(1) Lift the engine and transmission assembly just the

amount necessary to remove the load on the mounting

cushion before removing the mounting bolts 1 and 2.

Remove the engine support mounting bolts.

(2) Slowly lift the engine and transmission assembly 3 out

by moving it backwards while maintaining its balance.

Note:

With the engine and transmission suspended,

drain the transmission oil and clutch oil.

(2) There is only one drain plug in the powershift

transmission.

POWER TRAIN

Follow the removal sequence in reverse.

Suggestions for Installation

(1) Engine and transmission assembly

(a) Slowly lift the assembly.

(b) On the transmission side, tighten the bolts of the

left and right mounts after aligning them with the

holes in the differential case.

right engine supports after aligning them with the

holes in the engine mounts.

engine mount

(2) For powershift transmission trucks, check that the

clutch valve plunger is pushed out completely when the

cable is connected between the inching pedal and the

transmission.

(3) Bleed the air out of the brake fluid circuit after

connecting the brake pipe.

(4) When installing the exhaust pipe, use a new gasket.

(5) Connect the ground (negative) cable to the battery only

after making sure that all wiring is connected properly.

(6) Refill the engine, radiator, and transmission with

and check for leakage. Unless otherwise

specified, use soft water (tap water) mixed with

antifreeze at a concentration of 35%.

(7) Bleed the air out of the fuel circuit of the engine.

(8) After checking the parts, start the engine and check

that the clutch booster functions properly (wet-type

clutch transmission trucks only). Operate the mast

and steering, and check the hydraulic oil

level. Also recheck the engine oil, coolant and

transmission oil levels.

POWER TRAIN

Removal of Engine and Transmission Assembly (for Diesel-engine Trucks)

The engine and transmission are installed as an

Note: There are two types of transmission, namely the

assembled unit. The engine may be removed

torque converter drive type (powershift

independently of the transmission, but the transmission

transmission) and the direct drive type (manual

can only be removed together with the engine.

transmission). Removal procedures vary for

direct drive type transmissions according to

whether they have a dry-type clutch or a

type clutch.

Overhead Guard, Covers, Air Cleaner and Other Components

Sequence

1 Overhead guard, Headlamps

6 Radiator cover

2 Batteries, Cables

7 Floor plate, Floor mat

3 Steering wheel

8 Air hose, Air cleaner

4 Gas springs

9 Exhaust pipe

5 Engine cover, Seat

10 Fuel hose

Suggestions for Removal

(1) When removing the batteries 2, be sure to

(4) Before removing the fuel hose 10, make sure to

disconnect the ground (negative) cable first.

close the cock on the fuel tank.

(2) Remove the floor plate and mat 7 together with the

(5) After disconnecting the harness connectors from

accelerator pedal after disconnecting the pedal from

the sockets and terminals on the engine and

the linkage rod.

transmission they should be attached to the main

harness, in order to avoid damaging them.

(3) Disconnect the exhaust pipe 9 from the engine.

POWER TRAIN

Radiator and Pipes

Sequence

1 Reserve tank

7 Cooler hose (between radiator and powershift

2 Hose (upper)

transmission)

3 Hose (lower)

fan

4 Hose (between hydraulic tank and control

9 Fan belt

valve)

10 Fan guard

5 Hose (between hydraulic tank and oil pump)

11 Universal joint (between transmission and

6 Hose (between oil pump and steering control

gears)

valve)

Start by:

Installation

(a) Drain the coolant from the engine by removing the

Follow the removal sequence in reverse.

drain plug (note that the position of the drain plug

differs by engine type).

(b) Drain the coolant from the radiator by loosening

the cock at the bottom of the radiator.

Suggestion for Removal

Disconnect the cooler hose 7 from the transmission side

and temporarily attach it to the right side of the frame.

POWER TRAIN

Engine and Transmission Assembly

Sequence

1 Transmission mounting bolt

3 Engine and transmission assembly

2 Engine mounting bolt

Start by:

Installation

(a) Lifting the engine and transmission assembly with

This section describes only removal and installation

a hoist and slings.

procedures specific to diesel-engine trucks. Follow the

instructions for the gasoline-engine trucks in the

preceding sections for the common procedures.

Suggestions for Removal

(1) Lift the engine and transmission assembly just the

Suggestion for Installation (those not shared with

amount necessary to remove the load on the

gasoline-engine trucks)

mounting cushion before removing the mounting

bolts

and 2. Remove the engine support

Connect the accelerator pedal linkage on the floor plate

mounting bolts.

to the throttle cable. Check that the injection pump

lever at the full-open position when the accelerator

(2) Slowly lift the engine and transmission assembly 3

pedal is fully depressed.

out by moving it backwards while maintaining its

balance.

Note: Drain the powershift transmission oil with the

engine and transmission assembly suspended.

TRANSM

Structure and Function

Transmission

Torque Converter

Control System of Powershift Transmission

Hydraulic System Schematic of Powershift Transmission

and Installation

Removal

Disassembly and Reassembly

Transmission External Parts and Torque Converter Assembly

Transmission Housing and Output Gear

Output Gear Assembly and

Shaft

Oil Pump Assembly

Reassembly

Disassembly and Reassembly of Other Components

Control Valve

Input Shaft Assembly

Disassembly

Reassembly

Oil Pump Assembly

Disassembly

Reassembly

................................................... 6. 29

Inspection and Adjustment

6 - 31

Oil Pressure Measurement

Clutch (Inching) Pedal Adjustment

6 - 34

Inching Valve Adjustment

6 - 36

Troubleshooting

6 -

TRANSMISSION

This transmission consists of one forward gear and one

Three-element, single-stage,

reverse gear. The forward-reverse changeover is

two-phase

accomplished by a powershift

that uses

Range

Power path

hydraulically controlled multiple-disc clutches. The

F (Forward)

same transmission parts, except for the torque

converter, clutch valve, output flange, and universal

R (Reverse)

joints, are used in all the 1 to 3.5 ton class trucks. The

transmission housing and torque converter housing can

Transmission reduction ratio

be separated from each other.

The torque converter shell is made of steel-plates

F (Forward)

welded in one body. For this reason, torque converter

parts can be replaced as an assembled unit only.

R (Reverse)

Removal and Installation

Removal

(1) Remove the engine and transmission as an assembly

from the truck.

Note: Removal and installation procedures for the engine

and transmission are covered in the "GROUP 5

POWER TRAIN." Drain oil out of the transmission

housing when removing the engine and

transmission.

(2) Remove the bolts securing the flexible plate through

the access hole in the torque converter housing.

(3) Separate the torque converter and transmission

assembly from the engine.

Couple the torque converter and transmission assembly

to the engine. To do this, push the torque converter

toward the transmission as far as it goes so that the

distance between the end surface of the torque

converter housing and the flywheel connecting surface

of the flexible plate is 50 mm (1.97 in.).

(2) Connect the flexible plate to the flywheel with the bolts

through the access hole in the torque converter

housing.

Note: Tighten the bolts evenly

progressively. Avoid

giving strain to the flexible plate.

TRANSMISSION

Transmission Housing and Output Gear

Disassembly

Sequence

1 Servo case assembly, O-ring, Steel ball

3 Output gear, Ball bearing

2 Transmission housing, Oil seal

Suggestions for Disassembly

(1) Place transmission assembly with the torque

(4)

the transmission housing and place it with

converter hosing end facing down. Remove the

its mating flange facing down.

bolts fastening the transmission housing to the

Note: (a) Do not remove any steel balls or sealing caps

torque converter housing.

that are fitted in the transmission housing

(2) Remove the servo case assembly. Lift the

and torque converter housing.

transmission housing using wire rope, lifting

(b) Inspect the oil seal in the transmission

hardware, and the holes for the hardware and the

housing. It must not be removed unless

mounting bolt holes on the housing.

defective.

(3) Keeping the wire ropes slightly taught, remove the

transmission housing by tapping the area around

the dowel-pin holes evenly with a plastic hammer.

TRANSMISSION

Suggestions for Reassembly

(1) Applying grease

(a) Apply grease to the lips of the oil seals in the

transmission housing.

(2) Installing oil pump assembly

(a) Place the torque converter housing with its

weighted flange facing down.

(b) Install the relief valve and spring into the torque

converter housing.

torque converter housing. Then, install the oil

pump assembly.

(3) Installing transmission housing

(a) Reinstall the transmission housing while hoisting it

in the same procedure during disassembly. Pay

attention that the input shaft is not yet stable at the

center line.

(4) Installing torque converter

(a) Install the torque converter by aligning its splines

with the splines on the stator shaft and input shaft

of the transmission and the grooves in the oil pump

drive gear.

(1.97 in.)

(b) After the torque converter is installed, check the

distance between the end surface of the torque

converter housing and the flywheel fitting surface

of the flexible plate referring to

specification

below.

Distance between torque converter

housing end surface and flywheel

(1.97 in.)

fitting surface of flexible plate

part of the flexible plate to the torque converter

housing using suitable wires until the assembly is

fixed to the engine.

(5) Shim adjustment

(a) Thrust the clutch pack, the input shaft and the

support bearing toward the torque converter and

measure the concave dimension between the

contact surface of the servo case and the outer edge

of bearing 1 .

(b) Calculate the shim 2 thickness required as follows:

Concave dimension 1 - 4.8 mm (0.18912 in .)

shim thickness.

Example; (5.1 mm - 4.8 mm

0.3 mm)

in. - 0.18912 in.

0.01182 in.]

supporting clutch pack and servo case and

assemble servo case. (This clearance axially is 0.3

to 0.4 mm

to 0.01576 in.])

Shims

NO.

Thickness

- 05100

0.1 mm (0.00394 in.)

- 05300

0.3 mm (0.01182 in.)

- 05500

0.5 rnm (0.01970 in.)

- 05600

0.6 mm (0.02364 in.)

(6) Refilling transmission with oil

(a) Refill the transmission with oil only after the

transmission is installed in the truck and the engine

is ready to be started.

(b) Check the oil level using the level gauge.

about 3 minute and then stop the engine.

(d)

for about 30 second after stopping the engine,

and then start the checking procedure.

(e) The checking procedure must be completed within

5 minutes after the engine has stopped.

Cat Lift Trucks. For use with K21/K25 and S4S Engine Service Manuals (2007) - page 1