|||||||||||||||||||||||||||||||||||||||||||||||||||||||||| MAINTENANCE |||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ General
Taking proper care of your lift truck is a vital
part of the overall planned maintenance pro-
gram.
Your participation in this program will provide
an early warning to help identify potential
maintenance problems.
Do-it-yourself maintenance does not include
repairs. If your truck requires any repairs, con-
sult your Cat lift truck dealer. The dealer’s lift
truck mechanics are well trained and know how
to safely make repairs. Service Manuals are
also available from your Cat lift truck dealer.
Follow these rules to help save you from injury
and to service your truck properly.
close
open
101712A
The fuel shut off valve is located near the bat-
tery inside the engine hood. To avoid an acci-
dent, close this valve when performing mainte-
nance.
84
! WARNING
– Make sure the service area is safe.
– Park the truck on a level ground with
the forks lowered, parking brake
applied, transmission in NEUTRAL,
engine stopped and the wheels
blocked.
– Follow the recommended safety pro-
cedures.
– Use only the right tools for the job.
! WARNING
Lines, Tubes and Hoses
DO NOT bend or strike high pressure
lines. DO NOT install bent or damaged
lines, tubes or hoses.
Repair loose or damaged fuel and oil
lines, tubes or hoses. Leaks can cause
fires. Contact your dealer for repair or
replacement.
Check lines, tubes and hoses carefully.
DO NOT use your bare hands to check
for leaks, use a board or cardboard.
Tighten connections to the recommend-
ed torque. If any of the following is found
on a part, replace the part.
– End fittings damaged or leaking.
– Outer covering chafed or cut and
wire reinforcing exposed.
– Outer covering ballooning locally.
– Evidence of kinked or crushed hose.
– Metal embedded in the outer cover.
– End fittings displaced.
Make sure all clamps, guards and heat
shields are installed correctly to reduce
the risk of vibration, rubbing against
other parts, and excessive heat during
operation.
84
MAINTENANCE 85

◆ Inspection Precautions

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

– Avoid mixing lubricants. In some safety. At the beginning of each shift, check
If it is necessary to make an inspection
cases different brands of lubricants are your lift truck to make sure it is in safe operat-
while the engine is running, ALWAYS
not compatible with each other and ing condition.
USE TWO WORKERS –– one, the oper-
ator, at the controls and the other check- deteriorate when mixed. It is best to Always inspect your truck under the following
ing within visual contact of the operator. stick with the same brand at successive conditions.
service intervals.
– Before refilling, clean filler holes. – Lift truck level
After filling, clean up spills.
– Mast in vertical position
– Fork tips on ground
– Engine stopped
! WARNING
– Wheels blocked

100879

If your truck requires any repair, attach a DO

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

85 85
MAINTENANCE 86

◆ Maintenance Schedule
• Every 10 Service Hours or Daily (Pre-Start), Whichever Comes
As the operator, you are responsible for the performance of daily pre-start First, continued
inspection. You are also responsible for those items listed under Every 50
Service Hours or Weekly, whichever Comes First to keep your lift truck in Item Service Page
proper working condition. Brake pedal (B) Check 90
For periodic inspection and periodic change of rubber parts, however, rely on
Inching pedal (C) Check 90
the expert knowledge of the factory-trained servicemen, and the service facil-
ities at your Cat lift truck dealer’s workshop. Parking brake lever Check 90
Seat belt Check 90

• One month after delivery of a new truck Seat adjustment Check 90

• Every 200 service hours or monthly, Horn Check 91
whichever comes first
Periodic inspection Steering wheel Check 91
• Every 1200 service hours or 6 months,
time intervals movement
whichever comes first
• Every 2400 service hours or 1 year, Amount of fuel (truck level) Check 91
whichever comes first
Stop lights Check 91
OK monitor Check 91
• Every 10 Service Hours or Daily (Pre-Start), Whichever Comes Lift chains Check– 92
First adjust

Item Service Page Engine Check 93

Damage or faulty operation found Check 89 Inching Check 93

the day before Service brakes Check 93
Oil, fuel or coolant leaks Check 89 Backup lights Check 93
Lights Check 89 Battery Check 94
Tilt cylinder lock nuts Check 89 electrolyte
level
Overhead guard Check 89
Engine crankcase Check 95
Assist grip Check 89 oil level
Accelerator pedal (A) Check 90 Engine coolant Check 97
coolant level

86 86
MAINTENANCE 87

• Every 10 Service Hours or Daily (Pre-Start), Whichever Comes • Every 50 service Hours or Weekly, Whichever Comes First
First, continued
Item Service Page
Item Service Page Air cleaner Clean– 105
Hydraulic oil Check 99 inspect
oil level Alternator drive belt Check– 106
Service brakes Check 100 adjust
fluid level Mast supports Lubricate 107
Tire inflation pressure Inspect– 101 Fan belt Check– 107
check adjust
Tires and rims Inspect– 101
check
Wheel nuts Check– 102 • One Month After Delivery of a New Truck
tighten
Item Service Page
Mast and forks Check 103
Hydraulic tank return oil filter Change 107

Fuel filter Change 107

87 87
MAINTENANCE 88

• Every 200 service Hours or Monthly, Whichever Comes First • Every 1200 Service Hours or 6 Months, Whichever Comes First
Item Service Page Item Service Page
Wheel nuts Retighten 108 Powershift transmission Change oil, 113
filter and
Front axle Check 108
wash strainer
oil level
Hydraulic system Change 115
Powershift transmission Check 109
return oil
oil level
filter and
Engine crankcase Change oil 110 wash strainer
and filter
Front axle Change oil 116
Mast strip sliding surfaces Lubricate 111
Air cleaner Change 116
Lift bracket side rollers Lubricate 111 element
Lift chains Lubricate– 111 Fuel filter Change 117
inspect
Engine coolant Change 119
Tilt socket pins Lubricate 111
Tilt cylinder pins Lubricate 111
Water pump Lubricate 112 • Every 2400 service Hours or 1 Year, Whichever Comes First
Tie rod ends Lubricate 112
Item Service Page
Rear axle center pins Lubricate 112
Hydraulic oil Change 122
Service brake fluid Change 122

88 88
MAINTENANCE 89

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

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

• Damage or Faulty Operation Found • Oil, Fuel or Coolant Leaks • Overhead Guard
the Day Before Check on the floor for oil, fuel or coolant leaks.
– Have repairs been made properly?
Check the daily inspection sheet. • Lights
– Are all the lights in safe working condi-
WARNING tion?
! – Are their lenses clean and not defective?
– Do the tail, clearance and head lights come
ON properly when you switch them on.
101335C
• Tilt Cylinder Lock Nuts
1. Check the front and rear overhead guard
mounting bolts on each side.
2. Inspect overhead guard for bent or cracked
100678A
sections. Contact your Cat lift truck dealer
if repairs are needed.
Fill out a daily inspection sheet. Remember,
the complete performance of a daily inspection • Assist Grip
is the best protection against injury and proper-
ty damage.
Mark 101686

– Are the lock nuts tightened properly? Use a

wrench.
NOTICE: After retightening the lock nut, put
a mark across the nut and tilt cylin-
der socket. This permits you to eas-
ily notice loosening of the lock nut. 102553

Inspect, and if necessary, tighten the screws of

the assist grip.

89 89
MAINTENANCE 90

• Accelerator Pedal (A) • Inching Pedal (C) • Seat Belt

– Is the free play correct?
Free play: 30 to 49 mm
(A)
(C) (B) (1.2 to 1.9 in.)

• Parking Brake Lever

– Can you pull the lever all the way with rea-
sonable effort?
– Can you hold your truck on a grade by
103766 pulling the brake lever? 103761

– Can you depress the accelerator pedal
smoothly without any sign of rubbing?
• Brake Pedal (B)
Lever Operating Effort: – Is the seat belt in safe condition?
250 to 290 N (25 to 30 kgf) [55 to 66 lbf] Replace the belt assembly if the belt is torn,
cut, or if the plate and/or buckle is defec-
tive.
Adjustment

• Seat Adjustment
Release Apply

101437

Turn the knob to the right to increase the lever’s

100700
– Do you have sufficient pedal travel when
you depress the brake pedal?
– Does the pedal have a correct free play?
Free play: 22 to 41 mm
(0.9 to 1.6 in.)
tension; to the left to decrease it. Adjustment is
correct when the lever requires an effort of 250
to 290 N (25 to 30 kgf) [55 to 66 lbf] to snap it 101839A
over center.
– Can you depress the pedals all the way?
NOTICE: See Seat Adjustment in the
Operator’s Seats.

90 90
MAINTENANCE 91

• Horn • Amount of Fuel (truck level) • OK Monitor

102591A 102394 102444C

– Does the horn sound properly when you – Is the amount of fuel in the tank enough for – Do all the warning lamps glow when the
push the switch? the day’s work? key is in the I (ON) position?
NOTICE: When this lamp does not light with
• Steering Wheel • Stop Lights the key in the I (ON) position, the
bulb may be burned out. Get an
inspection at a specified service sta-
tion.

101726D 101306A

– Is the free play 70 mm (2.8 in.)? Check the – Do all stop lights come ON properly when
play at the rim of the wheel by rotating the you depress the brake pedal?
wheel in both directions.
– Is wheel installation loose? Check by shak-
ing the wheel up and down.

91 91
MAINTENANCE 92

• Lift Chains To Adjust

Check and Adjust

! WARNING ➁
– Check the lift chains periodically and
determine if they are still in usable
condition.
– Check the lift chains for wear, cracks,
missing links and worn or seized link
102009
➂
pins. ➀ 102709
2. Lift the forks high enough to put their full
– Improper maintenance of the lift
weight on the carriage and chains.
chains could cause accidents. If 1. Loosen the locknut ➀ and the nut ➁. Then
3. Check to be sure the lift chains have equal
something is wrong with the chains, turn the nut ➂ to adjust tension.
tension.
consult your Cat lift truck dealer for 2. Hold the nut ➂, and then tighten the nut ➁
4. If the chains are loose or the tension is not
repair or replacement. to the specified torque.
equal, have the chains adjusted.
– Do NOT put your foot under the fork. Hold the nut ➂ and tighten the locknut ➀ to
the specified torque.

1. Check the lift chains for wear. Use the fol- 385 N·m (39.3 kgf·m) [284 lbf·ft]
lowing chart to determine if it is still in
usable condition.

Lift Chain Elongation Limit: (/20 links)

654 mm (25.7 in.)
102708

92 92
MAINTENANCE 93

• Engine • Inching • Backup Lights

! WARNING
Exhaust fumes could kill you! If it is nec-
essary to start the engine in an enclosed
area, make sure there is adequate ventila-
tion.
Fire hazards! Clean up spillage of fuel,
oil, or other flammable materials in the
engine compartment. Know the location
of all emergency devices (such as fire
extinguisher, first aid kit, etc.) and how to
use them.
– Does the truck inch when you slowly
depress the inching pedal?
• Service Brakes
– Do the brakes apply and stop the truck
properly – without pulling, dragging, chat-
tering, squealing?
102360
When you move the direction lever into
REVERSE position:
– Do all backup lights come ON?
– Does the backup buzzer sound (if
equipped)?

103815B

– Is exhaust smoke normal?

– Listen for abnormal noise or excessive
vibration.

93 93
MAINTENANCE 94

• Battery
! WARNING Float Electrolyte
level
Check Electrolyte Level
If acid gets in your eyes, FLUSH THEM
WARNING IMMEDIATELY WITH LARGE
! AMOUNTS OF WATER AND SEE A
Batteries give off flammable fumes that DOCTOR AT ONCE. Glass tube
can explode. If you spill acid on yourself, FLUSH Electrolyte
Do not smoke when checking the battery SKIN IMMEDIATELY WITH LOTS OF
electrolyte levels. WATER. APPLY BAKING SODA TO 100801
Electrolyte is an acid and could cause HELP NEUTRALIZE THE ACID AND
Using a battery hydrometer, check the specific
injury if it contacts your skin or eyes. SEE A DOCTOR AT ONCE.
gravity of the battery cells. Take the reading at
Always wear protective glasses when eye level.
working with batteries.
! CAUTION
Specific gravity
1. Raise the hood. If distilled water has to be added frequently, corrected to Battery condition
2. Clean the top of the battery and terminals. have your Cat lift truck dealer check the 27°C (80°F)
3. Check terminals for corrosion. Coat termi-
battery. 1.265 to 1.280 Fully charged
nals with heavy grease.
4. Maintain electrolyte level between the 1.225 to 1.260 Three-fourths charged
UPPER LEVEL and LOWER LEVEL (to be recharged)
marked on the case. NOTE: If an addition Below 1.220 Completely discharged
of water is necessary, use distilled water. If (to be recharged and
not available, use clean water that is low in retested)
minerals. Do not use artificially softened vel
Upper le l
water. Lower leve

5. Close and secure the hood.

101688

94 94
MAINTENANCE 95

• Engine Crankcase 3. Maintain the correct level range on the dip- Adding Engine Oil
Check Oil Level stick.
! CAUTION
! WARNING
– Perform the work on level ground.
Hot oil and components could cause per- – Clean the filler hole to prevent dirt from
Correct level range
sonal injury. Do not allow hot oil or com- dropping into the engine.
ponents to contact your skin. – DO NOT overfill.
– Clean up spillage.
Park the lift truck with the forks lowered, park-
ing brake applied, transmission in NEUTRAL,
101304 1. Remove the oil filler cap.
the engine stopped and the wheels blocked.
1. Raise the hood.
2. Remove the dipstick and wipe it clean, then 4. Close and secure the hood.
insert it all the way.

103727

103729

95 95
MAINTENANCE 96

2. Add engine oil as required.

For engine oil, see the topic, Recommended
Fuels and Oils.

103728

3. After adding oil, make sure the level is in

the correct range on the dipstick.
4. Close the filler cap tight.

96 96
MAINTENANCE 97

• Engine Coolant
Check Coolant Level Adding Coolant

! WARNING ! WARNING ! CAUTION

At operating temperature, the engine
coolant is hot and under pressure.
Steam could cause injuries. DO NOT let
it contact your skin and eyes.
To avoid having scalding coolant or steam
blow out of the radiator, do not remove
the radiator cap unless the engine is cold.
Muffle the cap in a thick cloth and turn it
slowly to release all pressure before
removing the cap.
The lift truck must be level, the forks lowered,
the parking brake applied, the transmission in
NEUTRAL, the engine stopped and cooled,
and the wheels blocked.
1. Raise the hood.
2. Maintain the coolant level between the
FULL and LOW marks on the reserve
tank.
Keep fire away from undiluted antifreeze
as it is FLAMMABLE.
! CAUTION
DO NOT add water only. This dilutes the
antifreeze/summer coolant protection and
adversely affects the engine. Be sure to pre-
mix antifreeze/summer coolant with tap
water (soft water). See the topic, Engine
Cooling System Capacity under
Specifications.
If coolant has to be added frequently, have
your Cat lift truck dealer check the cooling
system.
– Antifreeze/summer coolant (ASC) con-
tains rust inhibitors. It is not necessary
to add other chemicals.
– Recommended concentration range of
ASC is 30% to 60% by volume. ASC
of less than 30% concentration does not
provide sufficient corrosion protection.
Concentrations over 60% adversely
affect freeze protection and heat trans-
fer rates.
– Avoid mixing different brands of
coolant.
– Select an ASC suitable for use in
engines using aluminum alloy parts.
– Select an ASC which contains silicate
of less than 0.2% by weight.

Correct
level
range

101465C

3. Close and secure the hood.

97 97
MAINTENANCE 98

1. Remove the reserve tank cap and add

coolant to the FULL mark. ! WARNING
2. When adding coolant, maintain the same
concentration of antifreeze solution.

100899

Antifreeze solution is TOXIC. In case of con-

tact with your skin, FLUSH IMMEDIATELY
101299A
WITH WATER. Have your Cat lift truck dealer
NOTICE: The engine cooling system is pro- discard antifreeze solution drained from the
tected to –30°C (22°F) with 50% engine.
concentration of antifreeze/summer
coolant (ASC) when shipped from
the factory.
3. Put the reserve tank cap back on.

98 98
MAINTENANCE 99

• Hydraulic Oil
Check Oil Level
4. Add oil needed to raise it to the correct
! WARNING
Hot oil and components could cause
serious injury. Do not allow hot oil or
components to contact your skin.
Remove the hydraulic tank filler cap
only after the engine has been stopped
and the cap is cool enough to remove
with your hands.
Remove the hydraulic tank filler cap
slowly to relieve pressure.
1. Operate the lift truck for a few minutes to
warm the oil.
2. Park the lift truck on a level surface, with
Adding Hydraulic Oil
level range on the dipstick. ! CAUTION
When adding hydraulic oil:
– Perform the work on level ground.
– Clean the filler hole to prevent dirt
from dropping into the tank.
– DO NOT overfill.
– Clean up spillage.
103790
1. Remove the hydraulic tank filler cap.
2. Add oil to the hydraulic tank.
For Hydraulic Oil, see the topic,
Recommended Fuel and Oils.
Correct level range

the forks lowered, mast tilted back, parking

brake applied, transmission in NEUTRAL,
the engine stopped and the wheels blocked.
3. Remove the hydraulic tank filler cap by
turning it counterclockwise.

100698

5. Put the hydraulic tank filler cap back on.

6. Check for oil leaks. 103792
7. Close and secure the hood.
3. After adding oil, make sure the level is in
the correct range on the dipstick.
4. Insert the dipstick into the filler port and
install the hydraulic tank filler cap secure-
ly.
101316B 5. Close and secure the hood.
99 99
MAINTENANCE 100

• Service Brakes
Check Fluid Level

1. Raise the hood. Adding Brake Fluid

! WARNING
If the brake fluid in the reservoir decreas-
es rapidly, the brake system is leaking.
Have your Cat lift truck dealer check the
system.
2. Check the brake fluid level at the reservoir. 1. Remove the reservoir cap.
2. Add brake fluid to the reservoir slowly.
3. Put the reservoir cap back on.

! CAUTION
Before refilling the reservoirs, clean the
ports to reduce the risk of dirt from getting
101303
inside the reservoirs.

Park the lift truck with the forks lowered, park-
ing brake applied, transmission in NEUTRAL,
the engine stopped and the wheels blocked.
101672
3. Maintain the brake fluid level between the
MAX and MIN marks on the reservoir.
4. Close the hood.

100 100
MAINTENANCE 101

• Tire Inflation Pressure • Tires and Rims

Inspect – Check Inspect – Check

! WARNING ! CAUTION
Carefully follow the specific information The lift truck tires are highly inflated. Even
provided by your tire servicing company slight damage to the tire or rim can cause a
or dealer. blowout of the tire.
Use a tire inflation gauge and stand 101589
behind the tread when inflating a tire and
checking tire pressure.
Limit: 5 mm
Proper inflation equipment, and training (0.2 in.)
in using the equipment, are necessary to
avoid overinflation. A tire blowout or
rim failure can result from improper or
misused equipment.

! CAUTION 101158A 101295A

– Underinflated tires flex excessively at
every turn of the wheel, resulting in pre-
mature failures. Overinflation subjects
the center of tread to excessive wear.
– Unevenly inflated tires can cause hard
steering or shimmy.
– The inner and outer tires of the dual
wheel should be equally inflated.
– After adding air, be sure to put the cap
back on the air valve.
Inflate all the tires properly. – Are all the tires free of cuts, gouges or for-
Use a tire inflation gauge. eign objects?
Recommended Tire Pressures – Are all the rims free of distortion or cracks?
– Use a tire depth gauge to measure the tire
Unit: kPa (kgf/cm2) [psi]
groove depth. If it is not more than 5 mm
Front/Rear 686 (7) [100] (0.2 in.), replace the tire.
NOTICE: For tire replacement, see in the
Changing a Tire.
Do not reinflate a tire mounted on a split type
rim that has been driven on while flat or under-
inflated without inspecting the rim for damage
and checking the lock ring for proper installa-
tion.

101 101
MAINTENANCE 102

• Wheel Nuts Tightening Torques for Wheel Nuts

Check – Tighten, when required Unit: N·m (kgf·m) [lbf·ft]
– Wheel nuts should be visually inspected
Front 382.5±38.2 (39.0±3.9) [282±28]
everyday. Any loose nuts should be tight-
ened and any missing or damaged nuts Rear 403 (41.1) [297]
should be replaced.

Retightening
– Always stand behind the tread of the tire,
NOT in front of the rim.
– Tighten the nuts evenly and in a diagonal
sequence to the specified torque.

101155

– Are the wheel nuts tightened properly?

Use a torque wrench.

102 102
MAINTENANCE 103

• Mast and Forks Heel Free Type of Fork: Heel Hold Type of Fork:
Check

B B
B B

A A

101840A
– Does the mast move up and down smooth-
ly when you operate the lift control lever?
– Does the mast tilt forward and back
smoothly when you operate the tilt control
lever?
– Are there any oil leaks from the cylinders
and hydraulic lines?
101628A 101628B
If the truck is being used to carry maximum
capacity loads, the forks should be checked
daily.
1. Carefully inspect the forks for cracks.
Special attention should be given to the
heel section A, and mounting brackets B,
all weld areas.
Forks with cracks should be removed from
service.
“Wet Test” magnetic particle inspection is gen-
erally preferred due to its sensitivity and the
ease of interpreting the results. Portable equip-
ment is usually recommended so it can be
moved to the lift truck.
Contact your Cat lift truck dealer for further
information.

101663A

– Are the stopper pins properly engaged?

– Are the forks free of distortion and cracks?

103 103
MAINTENANCE 104

C D

101629A 101630A

2. Check the difference in height of one fork 3. Check the fork blade D. The fork should
tip to the other when mounted on the fork be withdrawn from service if the thickness
carrier. A difference in fork tip height can is reduced to less than the tolerant thick-
result in uneven support of the load and ness.
cause problems when entering loads. Fork blade length may also be reduced by wear,
The maximum allowable difference in fork tip especially on tapered forks and platens.
elevation C is 5 mm (0.19 in.) for pallet forks. Remove the forks from service when the blade
Replace one or both forks when the difference length is no longer adequate for the intended
in fork tip height exceeds the maximum allow- loads.
able difference.
Tolerant Thickness (std.)
Unit: mm (in.)
Model Std. Limit
DP 60 60 (2.4) 50 (2.0)
DP 70 60 (2.4) 54 (2.1)

104 104
MAINTENANCE 105

◆ Every 50 Service Hours or Weekly, Whichever Comes First

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

• Air Cleaner
! CAUTION
Clean and Inspect
Install the dust pan with its arrow mark up.

! WARNING 1. Raise the hood.

Element

Wing nut
101197
Dust pan
6. Direct air inside the element along the
length of the pleats, and lightly tap it.
100901
When using compressed air for cleaning, 101318
wear an approved face shield and pro-
tective clothing. 2. Remove the dust pan by releasing the latch-
Use a maximum air pressure of 196 kPa es at three places.
(2 kgf/cm2) [30 psi] for cleaning purpos- 3. Unscrew the wing nut, and remove the ele-
es. ment by pulling it.

NOTICE:
Never service the air cleaner with the engine
running.
101199
Do not clean the elements by striking them
against another object. 7. Insert a light inside a clean, dry element
Always inspect the element before and after Cover and check. Discard the element if tears or
cleaning. Use a light inside the element. rips are found.
Do not use elements with damaged pleats, gas- 8. Put the element back in place.
101198
kets or seals. 9. Reinstall the dust cap.
Park the lift truck on a level surface, with the 4. Remove the cover from the dust pan, and 10. Close the hood.
forks lowered, the parking brake applied, the clean the inside of the pan by removing
transmission in NEUTRAL, the engine stopped dust.
and the wheels blocked. 5. Clean the inside of the air cleaner housing.
105 105
MAINTENANCE 106

• Alternator Drive Belt

Check and Adjust
1. Raise the hood.
2. Push the belt downward with about 98 N
! CAUTION (10 kgf) [22 lbf] pressure midway between
– After stopping the engine, check and the pulleys as shown.
adjust the rotating part.
– After adjusting the belt, tighten the 11 to 13 mm
Deflection (0.4 to 0.5 in.)
bracket bolt securely.
– If the belt is too tight, unnecessary
stresses are placed on the alternator Deflection 101417A
bearing and belt. Such stresses will
shorten the service life of both. 3. Loosen the alternator bracket bolts (indi-
– Keep the belt free of oil and grease to cated by the black arrows), and move the
reduce the risk of slipping. alternator out or in.
4. Close and secure the hood.

NOTICE: If it is difficult to adjust or replace

the belts, consult your Cat lift truck 100696B

dealer. NOTICE: If the deflection is out of the correct

range, readjust the belt.
Park the lift truck on a level surface, with the Also, check the belt to make sure
forks lowered, the parking brake applied, the that it is not worn, frayed, or has
transmission in NEUTRAL, the engine separated piles.
stopped and the wheels blocked.

106 106
MAINTENANCE 107

◆ One Month After Delivery of a New

• Mast Supports • Fan Belt Truck
Lubricate Check – Adjust
You must read and understand the warnings
and instructions contained in this manual
before performing any operation or mainte-
nance procedure.

• Hydraulic Tank Return Oil Filter

Change
Tension pulley – Filter should be changed.
bolt

101696 203767 See Hydraulic System, Change Return Oil

Lubricate 1 fitting on each side for a total of 2
fittings.
Filter in the Every 1200 Service Hours.
To inspect
1. Make sure the belt is free from oil, grease • Fuel Filter
or other foreign materials. Replace the belt Change
if necessary. A slightly dirty belt can be
reused by cleaning with cloth or paper. Do – Filter should be changed.
not clean the belt with gasoline or the like.
2. At the time of overhauling the engine or See Fuel Filter, Change in the Every 1200
adjusting the belt tension, check the belt Service Hours.
and replace it if defective.
To adjust
1. Loosen the tension pulley bolt 3 to 4 turns
by ratchet wrench through the access hole.
2. The belt will be properly tightened by the
tension spring. Tighten the tension pulley
bolt.

107 107
MAINTENANCE 108

◆ Every 200 Service Hours or Monthly, Whichever Comes First

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

• Wheel Nuts • Front Axle 5. Remove the level/fill plug (2). Maintain oil
Retighten Check Oil Level level to the bottom of the plug opening (1)
– Wheel nuts should be retightend. Park the lift truck on a level surface, parking and (2).
brake applied, transmission in NEUTRAL, the 6. Clean the level/fill plug (2) and level plug
See Wheel Nuts, Check – Tighten, when
engine stopped and the wheels blocked. (1). Put them back in place.
required.
7. Remove the blocking. Lower the lift
1. Align the planetary hub level mark to the
bracket.
horizontal position.
2. Remove the planetary hub level plug (1).
3. Raise the lift bracket high enough to gain
access to the front axle housing level/fill
plug (2).
4. Use blocking under the inner mast to
secure the lift bracket in this position.

(2) 103794

Adding Oil
See Front Axle, Change the Oil in the Every
(1)
1200 Service Hours or 6 Months Whichever
Mark
103787
Comes First.

108 108
MAINTENANCE 109

• Powershift Transmission
Check Oil Level
! WARNING
Hot oil and components can cause
injury. Do not allow hot oil or compo-
nents to contact your skin.
6. Remove the dipstick. Observe the oil level.
Adding Oil
See Powershift Transmission, Change Oil,
Filter and Wash Strainer in the Every 1200
Service Hours or 6 Months, Whichever
Comes First.

1. Operate the lift truck a few minutes to

warm the oil. 102886
2. Park the lift truck on a level surface with
the forks lowered, parking brake applied,
transmission in NEUTRAL, the engine 7. Maintain the correct level range indicated
stopped and the wheels blocked. on the dipstick.
3. Open the engine hood.
4. Remove the accelerator pedal rod.
5. Remove the floor plate.
Correct level range

101631

103788

109 109
MAINTENANCE 110

• Engine Crankcase
Change Oil and Filter
Whenever the engine oil is changed, the filter must be replaced at the same time with a genuine MCF oil
filter.
! WARNING

Hot oil and components could cause 7. Apply a small amount of clean engine oil to 10. Check for oil leaks.
serious injury. Do not allow hot oil or the oil filter element gasket. Install the new 11. Stop the engine and measure the oil level.
components to contact skin. filter element. Maintain the correct level range on the dip-
stick.

1. Operate the lift truck a few minutes to

warm the oil.
2. Park the lift truck on a level surface with
the forks lowered, parking brake applied,
transmission in NEUTRAL, the engine
stopped and the wheels blocked.
3. Raise the hood.
4. Remove the drain plug at the side of the 101675
engine oil pan. Allow the oil to drain. Clean 103729
8. Fill the crankcase. See Refill Capacities
and put the drain plug back in place.
and Lubrication Specifications charts.

Correct level range

103727 101304

101674 9. Start the engine and allow the oil to fill the 12. Close and secure the hood.
5. Remove and discard the oil filter element. filter and passages.
6. Wipe the sealing surface of the oil filter
element mounting base.

110 110
MAINTENANCE 111

• Mast Strip Sliding Surfaces • Lift Chains 2. Raise and lower the lift bracket a few times
Lubricate Lubricate – Inspect to work lubricant into the chain links.
NOTICE: Lubricate chains more frequently
than normal where the atmosphere
can cause corrosion of components
or when the truck must work in
rapid lift cycles.
3. Inspect the chain anchors and individual
links for wear, loose pins or cracked leaves.

102887 102889

Lubricate 1 fitting on each side of the inner 1. Apply engine oil onto the chain links with
mast for a total of 2 fittings. a brush.

• Lift Bracket Side Rollers • Tilt Socket Pins • Tilt Cylinder Pins
Lubricate Lubricate Lubricate

103789 101686A 102890

Lubricate 2 fittings on each side roller for a Lubricate 1 fitting on each pin for a total of 2 Lubricate 1 fitting on each pin for a total of 2
total of 4 fittings. fittings. fittings.

111 111
MAINTENANCE 112

• Water Pump • Tie Rod Ends • Rear Axle Center Pins

Lubricate Lubricate Lubricate

101714 102891 205558

Lubricate 1 fitting. Lubricate 2 fittings on each end for a total of 4 Lubricate 1 fitting on each pin for a total of 2
fittings. fittings.

112 112
MAINTENANCE 113

◆ Every 1200 Service Hours or 6 Months, Whichever Comes First

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

• Powershift Transmission 1. Open the engine hood. 4. Use filter wrench to remove filter element.
Change Oil, Filter and Wash Strainer 2. Remove the drain plug ➀. Allow the oil to 5. Clean sealing surface of filter base.
drain. Remove the cover ➁, the O-ring seal 6. Apply a light coat of engine oil to the gas-
WARNING and the strainer. ket of the new filter element.
!
Hot oil and components could cause per-
sonal injury. Do not allow hot oil or
components to contact your skin.

Park the lift truck on a level surface with the

forks lowered, parking brake applied, transmis- ➀
sion in NEUTRAL, the engine stopped and the ➁
wheels blocked. 101667 102892

3. Wash the strainer and the plug in clean, and 7. Install the new filter element by hand.
non-flammable solvent. Dry the strainer 8. Prime the system.
and the plug. Wipe off the O-ring seal, 9. Close and secure the hood.
check and replace if necessary. Install the
strainer, the O-ring seal, and the cover. Put
the drain plug back in place.

101635

113 113
MAINTENANCE 114

10. Remove the floor plate. 16. Maintain the oil level to the correct level
11. Remove the filter plug. Fill the transmis- range on the dipstick.
sion with oil. See Capacity in the
Specifications. Put the filter plug back in
place.
Correct level range

101631

17. Check for oil leaks at the strainer, filter and

102893 drain plug.
18. Put the floor plate back in place.
12. Start the engine.
13. Run the engine at low idle.
14. Stop the engine.
15. Let the oil level stabilize, then remove the
dipstick. Observe the oil level.

114 114
MAINTENANCE
• Hydraulic System
Change Return Oil Filter and Wash
Strainer
WARNING
! place. And then install the hoses.
Hot oil and components could cause per-
sonal injury. Do not allow hot oil or com-
ponents to contact your skin.
At operating temperature, the hydraulic
tank is hot and can be under pressure.
Park the lift truck with the forks lowered, park-
ing brake applied, transmission in NEUTRAL,
the engine stopped and the wheels blocked.
1. Raise the engine hood.
2. Remove the tank cover.
103791
115
3. Remove the hoses.
103793
4. Remove the gasket and strainer ➀.
5. Remove the gasket and return oil filter ➁.
Discard the filter element.
➀
➁ Correct level range
101679
6. Clean the filter parts and replace the seal
and gasket, if necessary. Install a new fil-
ter element.
7. Put the filter body assembly back in place
and tighten the retaining bolt.
115
8. Wash the strainer in clean, and nonflamma-
ble solvent.
9. Inspect the gasket and replace it, if neces-
sary.
10. Put the strainer, gasket and cover back in
11. Remove the dipstick. Check the oil level.
12. Add oil, if need, to reach the correct level
range on the dipstick.
103790
100698
13. Put the dipstick and filler cap back on.
14. Check for oil leaks.
15. Close and secure the hood.
115
MAINTENANCE 116

• Front Axle
Change Oil
Park the lift truck on a level surface, parking
brake applied, transmission in NEUTRAL,
forks lowered, lubricant warm, the engine
stopped and the wheels blocked.
1. Align the planetary hub level/mark to the
horizontal position.
Mark
4. Raise the lift bracket high enough to gain
access to the front axle housing level/fill
plug ➁.
5. Use blocking under inner mast to secure
the lift bracket in this position.
6. Remove the level/fill plug ➁.
9. Fill with oil to the bottom of the level/fill
hole. See Capacity in the Specifications.
Install the level/fill plug ➁.
10. Install the planetary hub level plug ➀.
11. Remove blocking. Lower the lift bracket.
• Air Cleaner
Change Element
Mitsubishi Caterpillar Forklift Asia Pte. Ltd.
(MCFS) strongly recommends that the air
cleaner element be changed if it is dirty. If you
attempt to clean the element, handle it carefully.

Recommended Change Intervals

➀ ➁ 103794
NOTICE: Have spare elements on hand to use
while cleaning used elements.
103787 Normal Every 1200 hours
7. Remove the drain plug ➂ and allow the conditions or 6 months
2. Remove the planetary hub level plug ➀. lubricant drain.
Severe dust or Every 200 hours
3. Allow the oil to drain. Clean and reinstall lint conditions or monthly
the level plug ➀.
Care in severe dust or lint conditions
Check the radiator core frequently for clogging
or dirt accumulation. Clean or wash the truck
as needed.
See Air Cleaner, Clean and Inspect in the
Every 50 Hours or Weekly, Whichever
➂ 101701 Comes First.

8. Clean and reinstall the drain plug ➂.

116 116
MAINTENANCE 117

• Fuel Filter
Change

! WARNING
Fuel leaked or spilled onto hot surfaces
or electrical components can cause a fire.
Clean up any spillage of fuel. Know the
location of all emergency devices (such as
fire extinguishers, first aid kits, etc.) and
how to use them.
Disconnect the battery when changing 101682A
fuel filters. 3. Use filter wrench to remove filter element.
4. Clean sealing surface of filter base.
NOTICE: Engine must be stopped and cool. 5. Apply a light coat of engine oil to the gas-
Park the lift truck in an authorized ket of the new filter element.
refueling area, with the forks low-
ered, parking brake applied, trans-
mission in NEUTRAL, the engine
stopped and cooled, and the wheels
blocked.
1. Raise the hood.
2. The fuel filter is located on the right side of
the truck. Remove the filter.

101681A

6. Install the new filter element by hand until

the gasket contacts the filter base.
7. Start the engine and check for fuel leaks.
8. Stop the engine.
9. Close and secure the hood.

101743

117 117
MAINTENANCE 118

How to Prime the Fuel System Fuel Filter Fuel Injection Pump

NOTICE: If the engine runs out of fuel, it can- ➂

➁
not be started even if the fuel tank is
filled. In such a case, prime the fuel
system as follows:

➀
! CAUTION
– Make sure no fuel leaks from the air
vent plug. 103733
– Clean up spillage.
1. Loosen the air vent plug ➀ on the fuel fil-
ter about 1.5 turns with a wrench.
2. Unlock priming pump plunger ➁ by turn-
ing it counterclockwise. Operate the prim-
ing pump until the fuel flows free of bub-
bles from the vent.
3. Tighten air vent plug ➀.
➁
103734
1. Loosen the air vent plug ➂ on the fuel
injection pump about 1.5 turns with a
wrench.
2. Unlock priming pump plunger ➁ by turn-
ing it counterclockwise. Operate the prim-
ing pump until the fuel flows free of bub-
bles from the vent.
3. Tighten air vent plug ➂.

118 118
MAINTENANCE 119
• Engine Coolant
Change
See the topic, Engine Coolant, Check Level 2. Turn the radiator filler cap slowly to
under Every 10 Service Hours or Daily, ! WARNING
relieve the pressure, then remove the cap.
whichever comes first.

! WARNING
At operating temperature, the engine
coolant is hot and under pressure.
Steam could cause severe burns.
Park the lift truck in an authorized refu-
eling area, with the forks lowered, park- 100899
ing brake applied, transmission in NEU- 101738
TRAL, the engine stopped and cooled, Antifreeze solution is TOXIC. In case of con-
and the wheels blocked. tact with your skin, FLUSH IMMEDIATELY
Check the coolant level only after the WITH WATER. Have your Cat lift truck dealer 3. Remove the engine block drain plug.
engine has been stopped and the filler cap discard antifreeze solution drained from the
is cool enough to touch with your bare engine.
hand. 1. Loosen the radiator cover retaining knob.
Remove the filler cap slowly to relieve Lift and remove the radiator cover.
pressure.
Cooling system conditioner contains
alkali. Avoid contact with your skin and
eyes to reduce the risk of burns and other
injuries. Allow cooling system compo-
407181
nents to cool before draining.
Use all cleaning solutions with care.
Antifreeze is TOXIC. In case of contact
with your skin, FLUSH IMMEDIATELY
WITH WATER. For disposal of the 102678
antifreeze coolant drained from the
engine, consult your Cat lift truck dealer.

119 119
MAINTENANCE
4. Open radiator drain valve.
coolant to drain.
5. Drain the reserve tank.
6. Close the radiator drain valve.
120
120
Allow the 7. Fill the cooling system with 1 kg (2 lb) 15. Close the drain valve.
sodium bisulfate per 40 liters (10 gallons) 16. Mix a coolant solution of water and
of water. Most commercial cooling system antifreeze.
cleaners can be used. 17. Fill the cooling system. See Refill
8. Start and run the engine for 30 minutes. Capacities. To avoid air locks, add the
9. Stop the engine and drain the cleaning coolant slowly.
solution.
10. Flush the system with clean water until the
draining water is clear.
11. Close the drain valve. Fill the system with
neutralizing solution, 250 g (1/2 lb) sodi-
100504A um carbonate per 40 liters (10 gallons) of
water.
12. Start and run the engine for 10 minutes.
13. Stop the engine and drain the neutralizing
solution.
103719
14. Flush the system with clean water until
draining water is clear. 18. Start and run the engine until the coolant
level is stabilized.
19. Stop the engine.
20. Add coolant, if necessary, to maintain the
level to below the bottom of the filler tube.
101465D
101641
21. Put the radiator filler cap back on.
120
MAINTENANCE 121

22. Remove the reserve tank filler cap.

23. Keep the coolant level at the FULL line on
the reserve tank.

101299

101465E

24. Put the reserve tank filler cap back on.

121 121
MAINTENANCE 122

◆ Every 2400 Service Hours or 1 Year, Whichever Comes First

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

• Hydraulic Oil 3. Remove the hydraulic tank drain plug.

Change Allow the oil to drain. Clean and put the
plug back in place.
! WARNING

Hot oil and components could cause

serious injury. Do not allow hot oil or
components to contact your skin.
The engine has been stopped and the
filler cap is cool enough to remove with
your hand.
Remove the filler cap slowly to relieve
pressure.
Park the lift truck with the forks lowered on a
level surface parking brake applied, transmis-
sion in NEUTRAL, the engine stopped and the
wheels blocked.
1. Operate the lift truck to warm the oil.
2. Remove the filler cap.
Correct level range
102760 100698
4. Fill the hydraulic tank. See Refill 8. Put the dipstick and the filler cap back in
Capacities. Put the filler cap back on. place.
5. Start the engine and operate the hydraulic
controls and the steering system through a
few cycles to fill the filters and lines. • Service Brake Fluid
6. Retract all hydraulic cylinders and stop the Change
engine.
7. Remove the filler cap and the dipstick. NOTICE: When changing fluid consult with
Keep the oil level at the HIGH mark on the your Cat lift truck dealer.
dipstick.

101316B

101303
103790

122 122
MAINTENANCE 123

◆ Parts to be Changed Periodically

The following parts should be periodically

7
changed as noted below.
These parts are made of materials which will
deteriorate overtime. Further, it is difficult to
determine visually whether or not they are still
in good condition. Changing at proper intervals
will reduce the risk of injury to the operator
and damage to the truck. 8

1
Ref.
No. Parts to be changed Interval
6
1 Cups and dust seals of the 2
wheel cylinders 2400 service hours or 1 year
5
2 Cup and dust seal of the 3
master cylinder 2400 service hours or 1 year 4
3 Brake booster 2400 service hours or 1 year 1
When changing, consult your Cat lift 8
truck dealer. 8
4 Power steering hoses 4800 service hours or 2 years
5 Fuel hoses 4800 to 9600 service hours
101658
or 2 to 4 years
6 Inner rubber parts of the 4800 service hours or 2 years
power steering cylinders
7 Lift chains 4800 to 9600 service hours
or 2 to 4 years
8 Hydraulic hoses on and 2400 to 4800 service hours
around mast or 1 to 2 years

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

123 123