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

MAST AND FORKS

2. installing mast rollers (all mast models)

0.1 to 0.5 mm

0.1 to 0.5 rnm

to 0.020 in.)

(0.004 to 0.020 in.)

(0.04 in.)

rnrn (0.04 in.) or less

0.1 to 0.5 mm

in.)

(0.004 to 0.020 in.)

in.)

mm (0.04 in.) or less

Lift bracket

Mast Roller for Simplex Mast

Mast Roller for Triplex Mast

and Duplex Mast

209375

Mast rollers are identical in shape and size with lift

Installation of mast rollers follows the same

bracket lower rollers.

procedures for the lift-bracket rollers.

Therefore:

(2) Measure clearance between the rollers and masts.

If the measured clearances exceed the standard

Clearance F should be

mm (0.04 in.) or less.

value, increase the thicknesses of shims (e) -

Clearance G should be 0.1 to 0.5 mm (0.004 to 0.020

under the roller seats as required.

in.).

Remarks: At the assembly plant, shims (e) -

are

(1) Measure clearance F between the rollers' rolling

usually adjusted to the values shown in the

contact surfaces and masts. If the measured

table below for the shipment.

clearances do not conform to the standard value,

replace with rollers of correct diameters listed in

the table below

(in.)

Note: For measuring procedures, refer to "Inspection

and Adjustment."

classes

Unit : mm (in.)

Shim (e)

2 (0.079)

1 (0.039)

2,3 ton

Shim (f)

2 (0.079)

1 (0.039)

classes

Shim (g)

1 (0.039)

(0.039)

Shim (h)

2 (0.079)

1 (0.039)

Shim (i)

2 (0.079)

1 (0.039)

Shim

MAST AND FORKS

3. Installing mast strip (all mast models)

Simplex Mast

Measuring and adjusting clearance G2 between mast

strip and inner mast (all mast models)

0.1 to 0.5 mm

(0.004 to 0.020 in.)

Measurement

Make a clearance between the mast strip and inner mast.

Insert a thickness gage to measure the clearance G2.

Clearance G2

0.1 to 0.5 mm (0.004 to 0.020 in.)

Adjustment

If clearance G2 is excessive, add a proper amount of shims

under the mast strip. Check the smooth movement by

209377

moving slowly up and down the bracket. Usually, a 1.0

(0.04 in.) thick shim is used in a new truck.

4. Installing second lift cylinders (all mast models)

Note: Second lift cylinders have basically the same

structure across all mast models, except that some

details are different illustration.

(1) Install the cylinder brackets to the lift cylinders as

Simplex Mast

shown in the right illustration.

(2) Place the lift cylinders complete with the brackets

between the outer and inner masts.

(3) Install the lift cylinder rods to the inner mast as shown

in the illustration. If shims (I) are used, be sure to

reinstall them. Usually shims (I) are not used.

(4) With the cylinder rods fully retracted and the cylinders

set vertically, measure clearance H. Adjust the

clearance at 1.6 mm (0.063 in.) or less by adding or

removing shims (m).

Clearance H

1.6 mm (0.063 in.) or less

Adjustment

Simplex Mast

If clearance H is excessive, add shims (m). Normally on a

new truck, the second lift cylinders are not fitted with

shims (m). If the clearance is 3.2 mm (0.126 in.) or more,

make sure to include a 3.2 mm (0.126 in.) thick sheet in the

shim pack that is to be installed.

(5) After reassembly, perform an operation test to check if

the stroke of the left and right cylinders is the same.

For the checking procedure, refer to page 12-39.

MAST AND FORKS

first lift cylinders

With the masts set vertically and fully lowered,

temporarily install the first lift cylinder complete with

the original shims to the inner mast.

First

cylinder

(2) Set the first lift cylinders vertically, and measure the

Shims

clearance, if any, between the cylinder brackets and the

cylinder mounts on the inner mast. Remove any

clearance by adding shims.

Mounting

The perpendicularity of each cylinder in the lateral

direction can be checked by measuring the parallelism

between the cylinder and the side face of the inner mast.

Error of the

should be

1 mm

0.04 in.).

209126

The perpendicularity of each cylinder in the longitudinal

direction can be checked by visually inspecting for the

parallelism between the cylinder and the front face of the

inner mast. The cylinder slightly inclined to the rear is

acceptable. The cylinder should not be inclined forward

even slightly.

Each shim is 1 mm (0.04 in.) thick.

Remarks: At the manufacturing facility, a shim pack of 2.0

mm (0.08 in.) is usually inserted between the

cylinder bracket and the inner mast for the

shipment.

(3) After shimming is completed, install and tighten the

mounting bolts.

Note: Depending on the truck model, the direction in

which the mounting bolts are inserted may be

different from what is shown in the illustration.

6. Connecting chain (Simplex mast, 1 ton class)

Upper chain anchor kit

The lift chain is connected to the lift bracket by assembling

Chain

the upper chain anchor kit as shown in the right illustration.

Make sure that link plate 3 with a stamped mark is installed

on the outside of the chain.

Lower chain anchor kit

1 Link

2 Center plate (without stamped mark)

3 Link plate (with stamped mark)

4 Sprit pin

MAST

FORKS

7. Installing hydraulic lines

General precautions

Use care not to let abrasive dust or dirt to enter the

For assembling Elbow Connector (a fitting with

hydraulic system.

straight threads and O-ring seal) indicated by

Apply a film of oil to O-rings before installation.

follow the procedure "Installation of a fitting with

straight threads and 0-Ring seal" shown below.

Simplex Mast

Return hose

(for mast of 3.5 m in height or higher)

Return line connector

Tightening torques

Unit :

3 ton

class

58.8t5.9

Nut

Installation of a fitting with straight threads and

Different in shape

O-ring seal

between fitting types

1. Apply grease or hydraulic oil to O-ring and O-ring

seat in the housing side.

2. Turn lock nut 3 to move it as close to fitting body 2

as possible. Place washer 4 and O-ring seal 5

against the lock nut.

3. Tighten the fitting by hand. Once O-ring 5 is

placed in the position of housing and washer 4

Elbow body assembly

comes in contact with the surface of housing, turn it

1 End of fitting

4 Backup washer

back to adjust the mounting direction. Never loose

body

5 O-ring seal

more than turn.

(connects to tube)

6 End of fitting that

4. Tighten lock nut 3 to the specified torque.

2 Fitting body

goes into other part

3 Locknut

MAST AND FORKS

Removal and

of Mast Rollers and Strips without Removing Mast

from

Simplex Mast

cylinder set bolt

The mast rollers and strips can only be removed

installed when the inner mast is positioned lower than

the outer mast. This can be achieved as follows:

(I) Disconnect the lift bracket assembly.

(2) Lift the front of the truck by 15 to 20 cm (5.9 to 7.9

in .), and place blocks to support the truck.

(3) Remove the set bolts at the top of the lift cylinders.

Place a sling around the inner mast. Lift the inner mast

using a hoist connected to the sling in order to

disengage the lift cylinders' piston rods from the inner

mast. Remove the hose guard.

(4) Remove the lift cylinder clamp bolts, and separate the

lift cylinders from the outer mast. Pull out the lift

cylinders from the seats at the bottom of the outer

mast. Tilt the cylinders until they rest on the outer

mast cross member. Using a rope, fix the cylinders

onto the cross member.

(5) Using the hoist, slowly lower the inner mast until the

mast contacts the lift cylinders.

(6) The main rollers of the inner and outer masts can now

Parts for

cylinder

be removed. It is recommended that before attempting

to remove the main rollers, remove the mast strips and

shims as they tend to drop easily.

(7) Adjust shims for the main rollers and mast strips as

required.

Reassembly follows the above-described disassembly

procedures in reverse.

MAST AND FORKS

2. Duplex Mast

(1) Disconnect the lift bracket assembly.

(2) Remove the first lift cylinders as follows:

(a) For each of the cylinders: Place a sling around the

cylinder. Using a hoist connected to the sling,

slightly lift the cylinder. The sling should be

hitched firmly around the cylinder to prevent the

cylinder from slipping down.

(b) Remove the cylinder mounting bolts. Using the

hoist, slowly lift and remove the cylinder.

Note: The remaining procedures are exactly the same as

those for the simplex mast models.

(3) Place the inner mast lower than the outer mast as

follows:

(a) Lift the front of the truck by 15 to 20 cm (5.9 to

7.9 in.), and place blocks to support the truck.

(b) Remove the set bolts at the top of the second lift

cylinders. Place a sling around the inner mast.

Lift the inner mast using a hoist

to the

sling in order to disengage the lift cylinders' piston

rods from the inner mast. Remove the hose guard.

separate the cylinders from the outer mast. Pull

out the lift cylinders from the seats at the bottom of

the outer mast. Tilt the cylinders until they rest on

the outer mast cross member. Using a rope, fix the

cylinders onto the cross member.

202961

(d) Using the hoist, slowly lower the inner mast until

the

contacts the second lift cylinders fixed to

the cross member.

(e) The main rollers of the inner and outer masts can

now be removed. It is recommended that before

attempting to remove the main rollers, remove the

mast strips and shims as they tend to drop easily.

Adjust shims for the main rollers and mast strips as

required.

Reassembly follows the above-described disassembly

procedures in reverse.

MAST AND FORKS

Mast

Disconnect the lift bracket assembly.

Remove the first lift cylinders as follows:

(a) For each of the cylinders: Place a sling around the

cylinder. Using a hoist connected to the sling,

slightly lift the cylinder. The sling should be

hitched firmly around the cylinder to prevent the

cylinder from slipping down.

(b) Remove the cylinder mounting bolts. Using the

hoist, slowly lift and remove the cylinder.

Place the inner mast lower than the middle mast as

follows:

(a) Lift the front of the truck by 15 to 20 cm (5.9 to

7.9 in.), and place blocks to support the truck.

(b) Place a sling around the upper cross member of the

inner mast. Using a hoist connected to the sling,

slightly lift the inner mast.

wheels.

(d) Disconnect the second lift chains at the outer mast

ends, and place the loose ends on the floor beyond

the inner mast.

(e) Lower the inner mast to such a height that allows

the mast rollers to be removed.

Support the inner mast with wood blocks.

(g) The main rollers of the inner and middle masts can

now be removed. It is recommended that before

attempting to remove the main rollers, remove the

mast strips and shims as they tend to drop easily.

(h) Adjust shims for the main rollers and mast strips as

required.

With the mast disassembled as above, it is not

, possible to remove the second lift cylinders.

MAST AND FORKS

(4) Place the middle mast lower than the outer mast as

follows:

(a)

Lift the inner mast to the height of the middle

mast, then place wood blocks for support.

(b)

Hitch slings to both middle mast and inner mast,

and lift them with a hoist.

(c)

Remove set bolts

the upper sections of the

second lift cylinders, then lift the middle mast and

inner mast to separate the second lift cylinder from

the middle mast.

(d)

Remove two lift cylinder clamps, dismount the

second lift cylinders from the mounting sections at

the lower outer mast section. Tilt the cylinders by

moving the top sections towards the center of the

truck. Using a rope, fix the cylinders onto the

cross member.

(e)

Lower the middle mast and inner mast until mast

rollers (outer mast upper roller and middle mast

lower roller) can be moved.

(f)

Support the middle mast and inner mast with wood

blocks.

(g)

The

rollers of the inner and outer masts can

now be removed. It is recommended that before

attempting to remove the main rollers, remove the

mast strips and shims as they tend to drop easily.

(h)

Adjust shims for the main rollers and mast strips as

required.

For reassembling, follow the disassembly sequence in

reverse.

MAST AND FORKS

Inspection and Adjustment

The inspection and adjustment in this chapter can be done

without dismounting or disassembling. Conduct inspection

whenever a defect is suspected.

Forks (all mast models)

(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 shall be removed

service.

Magnetic particle inspection is generally preferred due

to its sensitivity and the ease of interpreting the results.

For correct inspection, remove the painting from the

inspecting portion.

(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 loaded.

The maximum allowable difference in fork tip

elevation is 5 mm (0.20 in.) for pallet forks.

Replace one or both forks when the difference in fork

tip height exceeds the maximum allowable difference.

(3) Check the fork blade

The fork should be withdrawn

from service if the thickness is reduced to less than the

allowable thickness.

630

A: Standard value B: Repair or service limit

Fork thickness

31 (1.22)

32 (1.26)

35 (1.38)

40 (1.57)

45 (1.77)

MAST AND FORKS

2. Chain Tension lnspection and Adjustment

(Simplex Mast)

Turn the

key to the

(OFF) position

before making the inspection or adjustment of lift

chains, anchor bolts and nuts. Place blocks below

the forks when they are lifted.

Inspection of chain tension

(1) Place the mast vertical on a level ground, then lower

the forks to the ground. Make sure that the lift

cylinders are fully retracted.

(2) Raise the forks approx.

100

(4.0 in.) from the

ground.

(3) Turn the key to the (OFF) position.

nut

(4) Place blocks approx.

90 mm (3.5 in.) high below the

nut

forks.

(5) Push the chains at the middle point between the chain

Tightening torque

Unit :

wheel and chains fixed end on the lift bracket. Check

the right and left chains for even tightness.

class

Adjustment of right and left chain balance

Nuts

98 (3.86)

147

Remove the blocks below the forks. Start the engine.

(2) Lower the forks to the ground and tilt forward until the

tips come in contact with the ground. The chains are

After the adjustment, raise and lower the lift

now slack to facilitate the adjustment.

bracket several times. Then check the

(3) Stop the engine.

position of lift bracket when lift cylinder is

fully retracted. Make sure the protrusion of

(4) Loosen double nut (lower)

, then upper nut

each lift bracket main roller does not exceed

(5) Turn double nut (upper)

to adjust the chain tension.

of the roller diameter. If it exceeds,

(6) Start the engine, and place the mast vertical again.

elongation of chains is suspected.

(7) Repeat (2) through ( 5 ) of procedure 1, to check the

chain tension and adjust it as needed.

Tightening of nuts after adjustment

mast

bracket

lower roller

(1) Hold the anchor bolt at two flats with a wrench so as

not to twist the chain, the tighten the upper nut

the specified torque.

(2)

the double nut (upper)

with a wrench and

tighten double nut (lower)

to the specified torque.

40% of the roller

diameter or less

MAST AND FORKS

Duplex and Triplex Models

Note: The inspection and adjustment procedures are

completely the same as those for simplex mast

models. Follow the procedures in the previous page

to perform inspection or adjustment as necessary.

Checking Chain Elongation

(all mast models)

Apply maximum load evenly on both forks and expand

chain.

(2) Measure the length of 20 links of chain. When the

length exceeds the service limit specified in the table

below, replace the chain with new one.

Chain elongation

A: Standard value (New)

Service limit

Unit : mm

links

20 links

FORKS

4. Adjusting Clearance between Lift Bracket

Roller and Inner Mast (all mast models)

(1) Back-to-front clearance check on lift bracket main

rollers

(a) Raise the forks a little from the ground.

(b) Insert a bar between the upper part of lift bracket

and the inner mast, and push the inner mast to one

side. Using feeler gauges, measure the clearance F

between the main roller and inner mast on the

opposite side.

Clearance F

1.0 mm (0.04 in or less

is out of specification, use oversize

rollers. Remove lift bracket from mast and replace

rollers with proper sized rollers. For roller

replacement procedure, refer to "Choosing rollers

of correct diameters" on pages 12-20.

(2) Right-to-left clearance check on lift bracket main

rollers and side rollers

(a) Raise the mast to the top.

(b) Set a dial indicator on the inner mast with its

contact point rested on the side of the lift bracket.

the lift bracket to one side with a bar. Set the

indicator to zero.

(d) Insert a bar between the inner mast and lift bracket

on the indicator side, and push the lift bracket to

the opposite side.

(e) Read the indicator. This reading is the clearance

between middle roller and thrust plate. If

clearance

is out of specification, it is necessary

to add shims to the seat of the roller to adjust to

correct clearance.

Note: Upper rollers are free

checking and adjusting.

Clearance

0. to 0.5 mm (0.004 to 0.020 in.)

For adjustment, refer to "Adjusting clearance

between

the middle roller and thrust plate" on page 12-20.

MAST AND FORKS

Lower the lift bracket slightly from the top, so that

the side roller comes in contact with the inner

mast, then check clearance GI between the side

roller. If clearance GI is out of specification, it is

necessary to add shims to the seat of the roller

bracket to adjust to correct clearance. Remove lift

bracket from mast and adjust the shim thickness.

For adjustment and installation procedures, refer to

"Adjusting clearance GI between the side roller

and inner mast" on page 12-21.

(g) With the

bracket at the top, check clearance G

between lower roller and mast. If clearance G is

out of specification, it is necessary to add shims to

the seat of the roller to adjust to correct clearance.

Remove lift bracket

mast and adjust the

thickness for the rollers. For adjustment and

installation procedures, refer to "Adjusting

clearance

between lower rollers and inner mast⁹'

on page 12-20.

5. Mast Roller Clearance Adjustment

(all mast models)

(1) Back-to-front clearance inspection on mast main rollers

(a) Tilt the mast fully backward.

(b) Using feeler gauges, measure the clearance F

between the inner mast lower roller and outer mast.

Clearance

1 mm (0.04 in.) or less

is out of the specification, use

oversize rollers. For mast roller replacement and

installation procedures, refer to

mast

rollers" on page 12-22.

(2) Right-to-left clearance inspection on inner mast main

rollers

(a) Raise the mast to the top.

(b) Set a dial indicator on the inside of the outer mast

with its contact point rested on the inner mast.

the inner mast against the outer mast. Set the

indicator to zero.

MAST AND FORKS

(d) Insert a bar between the outer and inner masts on

the indicator side, and push the inner mast to the

opposite side.

(e) Read the indicator. This reading is the clearance G

between inner mast roller and outer mast.

Clearance

0.1 to 0.5 mm (0.004 to 0.020 in .)

If the clearance G is out of specification, it is

necessary to add shims to the seat of the roller to

2071

adjust to correct clearance. For adjustment and

installation procedures, refer to "Installing rnast

rollers" on page 12-22

(3) Right-to-left clearance check on outer mast main

rollers

(a) Raise the

to the top.

(b) Set a dial indicator on the outer mast with its

contact point rested on the inner mast.

the outer mast against the inner mast with a bar.

Set the indicator to zero.

(d) Insert a bar between the outer and inner mast, and

push the inner mast to the opposite side.

(e) Read the indicator. This reading is the clearance

between outer mast roller and inner mast.

Clearance

0.1 to 0.5 rnm (0.004 to 0.020 in.)

If the clearance

is out of specification, adjust

by shims.

It is necessary to add or remove shims at the seat

of the roller to adjust to correct clearance. For

adjustment

installation procedures, refer to

"Installing mast rollers" on page 12-22.

MAST AND FORKS

6. Mast Strip Clearance,

and

Adjustment (all mast models)

(1) Check the clearance

with the clearance between the

outer mast rollers and inner mast rolling contact

setting to zero (0) in maximum lift position.

Clearance G2

0.1 to 0.5 mm (0.004 to 0.020 in.)

(2) If clearance

is out of specification, adjust it by

adding or removing shims. For adjustment procedure,

refer to "Measuring and adjusting clearance G2

between mast strip and inner mast" on page 12-23.

(3) After adjusting the all clearance, move the mast and lift

bracket slowly to ensure that they

smoothly

through their full stroke.

7. Tilt Angle Adjustment (all mast models)

Adjust the tire pressure correctly and park the truck on

a level ground.

(2) Tilt the mast fully backward and stop the engine.

(3) Measure the backward tilt angle of the mast at both

sides.

(4) To adjust the tilt angle, loosen the bolt of tilt cylinder

socket, and adjust the rod length by turning the rod.

Adjust cylinder so that there is no difference in stroke

tilt angle between the cylinders, right and left.

Note: It is not necessary to adjust the forward tilt angle if

the backward tilt angle is properly adjusted.

Standard tilt angle

Mast model

Forward

Backward

Simplex Mast

12"

Duplex Mast

12"

Triplex Mast

(5) After adjusting the tilt angle, tighten the socket bolts to

the specified torque.

153 to 182

Tightening torque for tilt

(15.6 to 18.6

cylinder socket bolt

12.8 to 134.5

MAST AND FORKS

8. Right and Left Lift Cylinder Stroke Inspection

and Adjustment (all mast models)

(1) Slowly raise the inner mast, and observe how the

piston rods, left and right, stop at the moment the inner

mast reaches its maximum height.

(2) If the top of the inner mast jolts at that moment, make a

shim adjustment. Abnormal condition can be detected

by a little time lag in stopping between the piston rods,

left and right, and shaking of the rod with a longer

cylinder stroke.

(3) Adjusting method

(a) Raise the inner mast, place blocks under the right

and left sides of the inner mast, and lower the mast

until its rests on the blocks.

(b) Remove the set bolt at the top of lift cylinder

which showed earlier stroke end, retract the piston

rod, and insert shims at the top of piston rod end.

Note: When retracting piston rod, push the lift lever to

lowering direction for releasing the oil in the

cylinders.

bolt. Remove the blocks from under the inner

mast.

(d) Slowly lower the inner mast to the bottom to

ensure the piston rods move

and that the

left and right lift cylinders come to the end of

stroke simultaneously at the maximum lift position

of inner mast.

Cylinder

bracket

MAST AND FORMS

Troubleshooting

Clearance between lift rollers and side rollers incorrect

Readjust clearance.

inner mast will not

Rollers binding on their shafts

Relubricate of replace.

Mast strip clearance incorrect

Shim adjust.

0.1 to 0.5 mm

(0.004 to 0.020 in .)

TOO much clearance on side rollers

Readjust by adding shims.

Lift bracket or

Lift chains unequally tensioned

Readjust.

inner mast binds

Shim adjustments unequally made on between left

Readjust.

and right lift cylinders (at maximum height)

Mast makes noise

Rollers not rotating smoothly on their shafts

Relubricate or replace.

Lift cylinder packing damaged

Replace.

(drift)

Sliding (inside) surface of lift cylinder tube damaged

Replace.

Whole mast shakes

Mast-support bushing or metal worn

Retighten or replace.

Mast is distorted

Off-center loading or overload

Replace mast assembly

Finger bar bent

Fork tips differ in

Forks bent

Repair or replace.

height

Un-even loading

MAST AND FORKS

A: Standard value B: Repair or service limit

Unit: mm (in.)

Truck Model

2 ton

class

Item

^I A

381 (15)

508 (20)

Chain extension

Chains

links

(Duplex)

Main roller external diameter

Rollers

external diameter

Width of outer mast B

610 (24)

670 (26.4)

Duplex mast

Width of inner

516 (20.3)

568 (22.4)

Width of lift bracket

408 (16.1)

458

458 (18)

Dimensions

of outer mast

610 (24)

670 (26.4)

(Reference)

Width of middle mast

A 516 (20.3)

568 (22.4)

Triplex mast

Width of inner mast B2

426 (16.8)

468 (18.4)

Width of lift bracket C

A 318 (12.5)

358 (14.1)

Clearance between main roller circumference

1.0 (0.04) or less

and mast thrust surface F

Masts

Clearance between main roller side surface and

mast thrust surface

Clearance between inside mast and mast strip G2 A

0. to 0.5 (0.004 to 0.020)

Clearance between upper and lower roller

Clearances

(0.04) or less

circumference and inner mast thrust surface F

Clearance between middle roller side

surface and inner mast thrust plate

Lift brackets

Clearance between lower roller side

0.1 to 0.5 (0.004 to 0.020)

surface and inner mast thrust surface

Clearance between side roller circumference and

inner mast surface

Finger bar bend

(0.2) or less

Fork thickness

CE DATA

Maintenance Schedule

Tightening Torques for Standard Bolts and Nuts

Periodic Replacement Parts

Location of Periodic Replacement Parts

Lubrication nstructions

...........................................13.

Lubrication Chart

Fuel and Lubricant Specifications

. 11

Refill

Capacities

Weight of Major Components (Approximate

Special

Tools

13- 14

Special Service Tools

13- 14

SERVICE DATA

Maintenance Schedule

Abbreviation-

X: Check, C: Clean, D: Drain, Lubricate, R: Replace

Inspection point

Service data

ton: 0.5 to

(0.0197 to 0.0394 in.)

Brake drum shoe clearance

Feeler gauge

2, 3 ton: 0.1 to 0.35 mm

(0.004 to 0.014 in.)

Brake hose, pipes & joints

Visual

Powershift

1.5 to 6.5

Brake pedal clearance between pedal

Scale

(0.0591 to 0.2559 in.)

and floor

depressed

Manual

(0.2756 in.)

245 to 295 N (24.98 to 30.08 kgf)

Parking brake lever operating effort

Spring scale

to 66.32 lbf]

Service brake fluid level

Visual

Brake

pedal rod

(see Note 2)

Brake master cylinder hoses

rubber parts

Service brake fluid

135 cc (8.238 cu in.)

Brake wheel cylinder rubber parts

Radiator

(see Note 2)

Visual

belt (fan alternator) tension

asoline engine: 11 to 13 mm

Battery electrolyte specific gravity

Hydrometer

1.28 or higher

(see Note 4)

Driving interlock system

Operationlvisual

Electrical wires

Horn

Meter panel (instrument) lamps

(incl. parking brake and seat belt)

13-1

DATA

Abbreviation

X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Inspection point

How to check

Service data

Mast interlock system

Parking brake buzzer

Starter

Stop

Working & head lamps

Cylinder head bolt manifold nut

Wrench

Engine (exhaust, noise, vibration)

Engine oil level

Dip stick

Gasoline

rpm

Idling speed (for Carburetor and

diesel engine)

700

Gasoline engine (hot):

0.38

(0.0150 in.)

Intake exhaust valve clearance

Feeler gauge

Diesel-engine models (cold):

0.25

(0.0098 in.)

Positive crankcase ventilation valves

Air

& hoses

Engine oil

Engine oil filter

Frame assist grip

Loosen bolts nuts

Wrench

Overhead guard

Seat adjustment

belt

Tar in vaporizer (see Note 3)

Check drain

Fuel level

Meter panel

ection nozzle (for G, LP

SERVICE

Abbreviation

X: Check, C: Clean, D: Drain, Lubricate, R: Replace

Inspection point

How to check

Service data

Fuel hose

Change gasoline fuel filter (for G

dual engine

(see Note 3)

LPG fuel filter (see Note 3)

Vaporizer rubber parts

Oil pressure

Control valve

Hydraulic hose, pipes joints

Visual

Hydraulic oil

Visual

Hydraulic

Hydraulic tank strainer

Visual

Hydraulic hose (high-pressure hose)

1 ton: 28 liter (7.398

gal.)

Hydraulic oil

2, 3 ton: 39 liter (10.30 U.S. gal.)

Hydraulic tank return oil filter

Check distributor point, cap rotor

(for G

dual engine

elec.

con .)

Check ignition

(for G

dual engine

Spark plug gap

Plug gauge

Clean distributor inside (for G

dual engine

elec

Air cleaner element (see Note 2)

Visual

Air cleaner element (see Note 2)

Lift

Lift cylinder mounting bolts

Load backrest

Mast forks

Mast strip sliding surfaces

Visual

Tilt cylinder socket bolts

Lift chains (see Note 2)

Mast support (see Note 2)

DATA

Abbreviation

X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Inspection point

Service data

Tilt socket pins (see Note 2)

Lift chains

Front axle

Dye

Power steer cylinder

Operationlvisual

Rear axle

Steer gear box

Operationlvisual

Play 15 to 30

(0.5906 to

Steer wheel

Operationlscale

King pins (see Note 2)

rod pins (see Note 2)

Power steer cylinder

rubber parts

Accelerator pedal

Operation

Check clutch

play &

fluids for manual

Check clutch pedal (for manual TIM)

Differential oil

Visual

Operation

Visual

Last chance filter (TIM control valve) Visual

TIM strainer

Visual

Lubricate clutch pedal shifter shaft

Lubricate TIM change levers

(for manual TIM)

Adjust inching pedal for powershift

Cable play: 0.5 to 1 5

Scale

TIM

(0.0197 to 0.059 1 in.:

rubber parts

1 ton: 4.2 liters

U.S. gal.)

Differential oil

2,3 ton: 5 liters (1.3 U.S. gal.)

DATA

Abbreviation

X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Inspection point

Service data

Note 1: *:

Change in 1 to 2 years

**: Change in 2 years

Change in 2 to 4 years

Note 2: In corrosive or abrasive environments, clean, lubricate and change more frequently.

Note 3: When fuel with poor quality is used, check, drain, clean and change more frequently.

Note 4: Not required if battery is full maintenance free battery.

Note 5: Apply soap suds to the piping joints to check for any gas leakage after replacing the LPG tank.

DATA

Tightening Torques for Standard Bolts and Nuts

With spring washer

656

Pitch

With spring washer

101656

Metric

fine

Nominal

thread

in.

0.24

0.04

8.6

0.88

6.4

10.8

1.1

8.0

14.7

1.5

10.8

0.32

1.25

0.05

19.6

2.0

14.5

26.5

2.7

19.5

36.6

3.7

26.8

0.39

1.25

0.05

41.2

4.2

30.4

53.0

5.4

29.1

81.4

8.3

60.0

1.25

0.05

74.5

7.6

55.0

97.1

9.9

71.6

144.2

14.7

106.3

0.55

1.5

0.06

119.6

12.2

88.2

155.9

15.9

115.0

226.5

23.1

167.1

0.63

1.5

0.06

182.4

18.6

134.5

237.3

24.2

175.0

338.3

34.5

249.5

0.71

1.5

0.06

263.8

26.9

194.6

343.2

35.0

253.2

487.4

49.7

359.5

0.79

1.5

0.06

365.8

37.3

269.8

475.6

48.5

350.8

674.7

68.8

497.6

0.87

1.5

0.06

486.4

49.6

358.8

632.5

64.5

466.5

897.3

91.5

661.8

0.95

1.5

0.06

643.3

65.6

474.5

836.5

85.3

617.0

1183.7

120.7

873.0

1.06

1.5

0.06

934.6

95.3

689.3

1216.0

123.9

894.2

1707.3

174.1

1259.3

1.18

1.5

0.06

1294.5

132.0

954.8

1682.8

171.6

1241.2

2367.3

241.4

1746.0

1.30

1.5

0.06

1726.0

176.0

1273.0

2243.8

228.8

1654.9

3153.8

321.6

2326.1

Remarks: 1. The tolerance on the torque is

10%

2. The torques are for "dry" condition.

SERVICE DATA

With spring washer

656

Nominal

Pitch

size

in.

kgfm

0.39

1.5

0.06

33.3

3.4

24.6

43.1

4.4

31.8

67.7

6.9

49.9

0.47

1.75

0.07

58.8

6.0

43.4

76.5

7.8

56.4

115.7

11.8

85.3

0.55

0.08

96.4

9.8

70.9

124.5

12.7

91.9

182.4

18.6

134.5

0.63

0.08

147.1

15.0

108.5

191.2

19.5

141.0

274.6

28.0

202.5

0.71

2.5

0.10

203.0

20.7

149.7

264.8

27.0

195.3

383.4

39.1

282.8

0.79

2.5

0.10

286.4

29.2

211.2

371.7

37.9

274.1

536.4

54.7

395.6

0.87

2.5

0.10

383.4

39.1

282.8

499.2

50.9

368.2

725.9

74.0

535.2

0.95

0.12

492.3

50.2

363.1

640.4

65.3

472.3

924.8

94.3

682.1

1.06

0.12

724.7

73.9

534.5

942.2

96.1

695.1

1350.4

137.7

996.0

1.18

3.5

0.14

969.9

98.9

715.3

1259.2

128.4

928.7

1843.7

188.0

1359.8

With spring washer

101656

Metric

Nominal

Pitch

coarse

size

thread

in.

0.39

1.5

0.06

39.2

4.0

28.9

51.0

5.2

37.6

79.4

8.1

58.6

Remarks: 1. The tolerance on the torque is

10%

2. The torques are for "dry" condition.

SERVICE DATA

Periodic Replacement Parts

The parts listed below are important for the safe operation of the truck, and are specially designated as the parts to be

replaced at specified periods. Each service shop is requested to adhere to the replacement schedule given here on all

trucks brought into its care:

Period

1 month

Every

Periodic replacement parts

Service

after

3 months

6 months

1 year

2 years

delivery

(500 hrs) (1000 hrs) (2000 hrs) (4000 hrs)

1 *Rubber parts for brake master cylinder

Replace

2 *Rubber parts for brake wheel cylinder

Replace

9 Engine oil filter element

Replace

every 3 months (500 hrs)

Clean

10 LPG fuel filter

Replace

Hydraulic tank return filter

Replace

Clean

12 Air clearance element

Replace

Note:

indicates important safety-related parts.

DATA

Fuel and Lubricant Specifications

Recommendation for ambient temperature

Fuel or lubricant

Specification

1-30

-20

-10

Consult your local Cat lift truck dealer

Gasoline-engine API service classification SJ

Engine

model

or above

SAE

oils

Diesel-engine

API service classification CF

model

or above

Transfer and differential oil GL-4 or GL-5

SAE 90

Powershift transmission oil Dexron

Consult your local Cat lift truck dealer

Hydraulic oil

FMVSS - DOT 3 or DOT 4

Brake fluid

(SAE

NLGI No.2 grade multi-purpose type

Wheel bearings

(lithium base),

Consistency:

NLGI No. grade multi-purpose type

Grease

(calcium base),

Consistency:

320

Chassis

NLGI No. grade multi-purpose type

(lithium base),

Consistency:

315

Ambient temperature,

- 39

- 30

- 25

- 20

Antifreeze solution

(- 38.2)

(- 22)

(- 13)

(-4)

(Long Lift Coolant)

5 5

Avoid mixing lubricants. In some cases, different brands of lubricants are not

with each

other and deteriorate when mixed. It is best to stick with one and the same brand

successive

service intervals.

SERVICE DATA

Refill Capacities

Unit: liter

. gal

Truck Models

ton class

2 ton class

3 ton class

Items

Fuel tank

53 (14.0)

76 (20.1)

Engine lubrication system

6.8

(1.8)

8.7

(2.3)

0.65 liter (0.17

U . gal.) for reserve tank]

7.4

(2.0)

Engine lubrication system

8.5

(2.2)

10 (2.6)

(including oil filter capacity)

3.8 (1.O)

Transmission oil

(2.6)

Differential gear oil

(1.3)

8.5

(2.2)

Hydraulic tank

28 (7.4)

39 (10.3)

Brake fluid reservoir

135 cc (8.2 cu in.)

SERVICE DATA

Weight of Major Components (Approximate)

Unit: kg (lb)

Truck Models

Gasoline-engine model

140 (300)

Engine service weight

Diesel-engine model

180 (400)

260 (570)

Power train

Gasoline-engine

280 (620)

290 (640)

Engine, transmission (excl.

reduction gear

differential)

350 (770)

395 (870)

Overhead guard

60 (130)

Outer mast

160 (350)

220 (485)

245 (540)

Inner mast

130 (290)

150 (330)

165 (360)

Lift bracket

Duplex mast m (118 in.)]

(incl. backrest)

Forks (two)

80 (180)

130 (290)

165 (360)

Lift cylinder and related

105 (230)

parts

Special

Tools

Special Service Tools

2 ton

3 ton

Part number

Part name

No.

class

91268 - 00100

Wrench

Removal

installation of pulley

(To be used

91 268 - 00200)

91268 - 00200

Wrench

Removal and installation of pulley

91868 - 00100

Wrench

91 268 - 00701

Socket wrench

Removal and installation of rear wheel nut and weight bolt

91268

05100

Bolt

Removal of pump body

Installer

Installation of pump body oil seal

Installer

Installation and tightening of transmission output shaft oil

seal

Puller

Removal of bearing

Plate

(To be used with plate, bolt and puller)

Bolt

(Commercially available, BANZAI)

Puller

Installer

Installation of ball bearing

Piston tool

Removal and installation of

return spring

91268

00500

Ring puller

Removal and installation of snap ring

Gauge kit

Measurement of transmission hydraulic pressure

Connector

Measurement of hydraulic pressure

(To be used with 64309 - 17701 Gauge kit)

Socket

Removal and installation of front wheel hub nut

Socket wrench

Removal and installation of front wheel hub nut

Bevel pinion puller

Removal of front wheel

Puller seat

Removal of front wheel hub

Wheel hub puller

Removal of front wheel hub

91468 - 00300

Installer

Installation of front axle wheel bearing inner race

64309 - 12300

Installer

91268 - 05400

Installer

Installation of oil seal into carrier cover input flange

differential carrier

91268 - 05600

Installer

Installation of bevel pinion taper roller bearing into

91268 - 05700

Installer

Installation of bevel pinion taper roller bearing into carrier

cover

91268 - 05800

Installer

Installation of bevel pinion taper roller bearing

91268 - 05900

Installer

Installation of drive gear ball bearing into carrier cover

SERVICE DATA

ton

2 ton

3 ton

Part number

Part name

class

31268 - 01500

[nstaller

Installation of rear axle inner bearing inner race

54309 - 40400

Installer

Installation of rear axle inner bearing inner race

31268 - 01400

Installer

Installation of rear axle outer bearing inner race

1468 - 00400

[nstaller

Installation of rear axle outer bearing outer race

1468 - 00500

[nstaller

Press-fitting of rear axle pivot bushing

31468 - 00100

[nstaller

Installation of bell crank bearing and king pin bearing

1468 - 00200

Installer

Removal of bell crank bearing and king pin bearing

91268 - 01200

Installer

Removal and installation of king pin bearing

(To be used

91468 - 00100 and 91468 - 00200

Installers)

64309 - 15411

Spring remover

Removal of return spring

64309 -

Spring retainer

Removal and installation of brake

64309 - 15413

Spring hook

Installation of return spring (Tools No.

and 37 are

included in 64309 - 15400 Tool Set)

91268 - 10600

Steering wheel

Removal of steering wheel

puller

91268 - 01800

arm puller

Removal of

arm

91268 - 13400

Socket

Removal and installation of power cylinder guide

91268 - 13600

Rod cap

Insertion of power cylinder guide

91268 - 03300

Plate

Assembly of steering gear control valve

91268 - 06200

Connector

Measurement of power steering relief pressure

(To be used with 64309 - 17701 Gauge kit)

91268 - 01600

Installer

Installation of tilt Cylinder tube busing

09305 - 00680

Hook wrench

Removal and installation of tilt cylinder guide bushing

09305 - 00750

Hook wrench

Removal and installation of tilt cylinder guide bushing

09305 - 00880

Hook wrench

Removal and installation of tilt cylinder guide bushing

64309 - 16300

Pipe

Measurement of control valve main relief pressure and

- 06300

Connector

overload relief pressure

(To be used with 64309 - 17701 Gauge kit)

TECHNICAL

Date:

Print)

Dealer

Submitted By:

Address:

P.O. Box:

City:

State:

Zip Code:

Country:

The following discrepancy or omission has been discovered in:

Operation Maintenance Manual

Option Bulletin

Part

Special Instructions

Service Manual

Service Data Manual

Electronic Manual

Other

Publication

Engine Model

Truck model

Issue date

Truck serial

Page

(Please Print)

of discrepancy or omission:

(Please fax or mail completed form to):

Mitsubishi Caterpillar Forklift America Inc.

Mitsubishi Caterpillar Forklift Europe B.V.

Attn: Technical Publications

Attn: Service Engineering

21 21 W. Sam Houston Parkway N.

Box 30171

Houston, Texas 77043-2305

1303 AC, Almere, The Netherlands

Fax: 713-365-1616

Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

RCB No. 199203169H

Attn: Service Engineering

No. 2 Tuas Avenue 20

Singapore 638818

Republic of Singapore

Fax: 65-6861-9277

Cat Lift Trucks. For use with K21/K25 and S4S Engine Service Manuals (2007) - page 4