||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| SERVICE DATA ||||||||||||||||||||||||||||||||||||||||||||||||||||||||

Fuel Information Diesel Fuel Specifications

Use only fuel recommended in this section.
Types of Fuel
The preferred fuels provide maximum engine
service life and performance. They are
distillate fuels. They are commonly called
diesel fuel, furnace oil, gas oil or kerosene (for
cold weather operation).
Mitsubishi Caterpillar Forklift America Inc.
(MCFA) strongly encourages the use of fuels
that meet the Preferred Fuels specification.
Fuel Sulfur Content
The percentage of sulfur in the fuel will affect
the engine oil recommendations. Fuel sulfur is
chemically changed during combustion to
form both sulfurous and sulfuric acid. These
acids chemically attack metal surfaces and
cause corrosive wear.
Any API classification performance of oil
should have sufficient TBN for fuels with less
than 0.5% sulfur. For fuels with 0.5% to 1.5%
sulfur by weight, engine oil must have a TBN
of 20 times the percentage of fuel sulfur as
measured by the ASTM (American Society of
Testing Materials) D-2896 method. (ASTM
D-2896 can normally be found at your local
technological society, library or college.)

127 127
SERVICE DATA 128

Coolant Information
NOTICE:
Mitsubishi Caterpillar Forklift America Inc.
(MCFA) recommends that the coolant mix
contain 50% commercially available
automotive antifreeze, and 50% water.
To prevent damage to your engine, never add
coolant to an overheated engine. Allow the
engine to cool first.
Dowtherm 209 full-fill coolant will lower the
water pump cavitation temperature and cooling
boiling point. These lowered temperatures will
cause overheating at a lower ambient
temperature than an ethylene glycol and water
mix. If Dowtherm is used, follow the
instructions provided and use only the inhibitor
package recommended by the supplier.
If the lift truck is to be stored in, or shipped to,
an area with freezing temperatures, the cooling
system must be protected to the lowest
expected outside (ambient) temperature.
The engine cooling system is protected with a
commercially available automotive antifreeze
when shipped from the factory.
In cold weather, check the specific gravity of
the coolant frequently to ensure adequate
protection.
Clean the cooling system if it is contaminated,
if the engine overheats or if foaming is
observed in the radiator.
Old coolant should be drained, the system
cleaned and new coolant added as
recommended using a commercially
available automotive antifreeze.
Filling at over 20 liters (5 U.S. gallons) per
minute can cause air pockets in the cooling
system.
After draining and refilling the cooling system,
run the engine with the radiator cap off. Run it
until the coolant reaches its normal operating
temperature and the coolant level stabilizes.
Add coolant as necessary to fill the system to
the proper level.
Operate with a thermostat in the cooling
system all year-round. Cooling system
problems can arise without a thermostat.
Coolant Water
Hard water, or water with high levels of
calcium and magnesium ions, encourages the
formation of insoluble chemical compounds by
combining with cooling system additives such
as silicates and phosphates.
The tendency of silicates and phosphates to
precipitate out-of-solution increases with
increasing water hardness. Hard water, or
water with high levels of calcium and
magnesium ions, encourages the formation of
insoluble chemicals, especially after a number
of heating and cooling cycles.
Mitsubishi Caterpillar Forklift America Inc.
(MCFA) prefers the use of distilled water or
deionized water to reduce the potential and
severity of chemical insolubility.
ACCEPTABLE WATER
Water Content Limits ppm
Chlorides (Cl) 50 maximum
Sulfates (SO4) 50 maximum
Total Hardness 80 mg/l
Total Solids 250 maximum
pH 6.0 to 8.0
ppm = parts per million
Using water that meets the minimum
acceptable water requirement may not prevent
dropout of these chemical compounds
completely but should control the dropout rate
at acceptable levels.

128 128
SERVICE DATA 129

Antifreeze
NOTICE: Make Proper Antifreeze Additions.
Mitsubishi Caterpillar Forklift America Inc, Do not add pure (100%) antifreeze to the
(MCFA) recommends the coolant mix contain cooling system. Add antifreeze mixed with
50% commercially available automotive water using the same freeze protection ratio
antifreeze, or equivalent, and acceptable water that is in your cooling system.
to maintain an adequate water pump cavitation
temperature for efficient water pump
performance.
Premix the coolant solution to provide
protection to the lowest expected outside
(ambient) temperature. Pure undiluted
antifreeze will freeze at 23C (10F).
Use a greater concentration (above 50%) of
commercially available automotive antifreeze
only as needed for anticipated outside
(ambient) temperatures. Do not exceed the
coolant-to-water mix ratio recommendations
provided with the commercially available
automotive antifreezes.

Most commercial antifreezes are formulated

for gasoline engine applications and will,
therefore, have high silicate content.

129 129
SERVICE DATA 130

Recommended Fuel and Oils

Recommendation for ambient temperatures C (F)

Fuel or oil Recommendation 30 20 10 0 10 20 30

(22) (4) (14) (32) (50) (68) (86)

Fuel Consult your local Cat lift truck dealer

Engine oil API service classification CD min. SAE10W SAE30
Gear oil API service classification multipurpose type
SAE80W SAE90
(Front axle oil) GL-4 or GL-5
Transmission oil Dexron II Consult your local Cat lift truck dealer
Hydraulic oil ISO VG32
Brake fluid F.M.V.S.S. No. 116 DOT3 or DOT4 (SAE J1703)
Grease Wheel bearings NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295
Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340

Ambient temperature, C (F) 45 (49) 39 (38) 30 (22) 25 (13) 20 (4) 15 (5) 10 (14)
Antifreeze solution
Concentration (%) 60 55 50 45 40 35 30

NOTICE:
Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick
with the same brand at successive service intervals.
For refill capacities and measurements, see Specifications in this section.

130 130
SERVICE DATA 131

Below oils are reference only.

Engine Oils Brake Fluids
Spec
ificat
Vis
ions API service classification CD or MIL-L-2104E equivalents
cos
ity
Manufacturer SAE10W SAE30 SAEJ1703
Mobil Mobil Delvac 1210 Mobil Delvac 1230 Mobil Universal Brake Fluid
Shell Shell Rotella T 10W Shell Rotella T 30 Shell Advance Brake Fluid
Exxon XD-3 10W XD-3 30 Brake Fluid DOT-3
Castrol Castrol Syntec 10W-30 Castrol GT LMA Brake Fluid

Antifreeze/Summer
Gear Oils Greases Coolant
Spec
ificat API service classification GL-4 or GL-5 NLGI No. 1 NLGI No. 2
ions
Vis
cos
ity Full Force
Manufacturer SAE80W SAE90 Consistency 310 - 340 Consistency 265 - 295
Mobil Mobilube HD 80W-90 Mobilux EP 1 Mobilux EP 2 USI Chemical

Shell Shell Spirax HD 80W-90 Retinax HD NLGI 1 Retinax HD NLGI 2 Marcus

Exxon Gear Oil GX80W-90 Ronex Extra Duty 1 Ronex Extra Duty 2 Peak
Castrol Castrol Hypoy 80W-90 Castrol EPL1 Castrol EPL2

Hydraulic Oils Transmission Oils

Specif
ication ISO VG32 Dexron
s
Vis
cos
ity
Manufacturer
Mobil Mobiltrans HD 10W Mobil ATF
Shell Tellus T32 Shell Donax TC
Exxon Nuto H32 Exxtrans
Castrol Castrol Hyspin AWH-M32 Castrol Dexron III/Mercon
NOTICE: Brands of oil are subject to change without notice. When you buy oil, check specification. (For example: API service classification CD, SAE10W)
131 131
SERVICE DATA 132

Specifications (Standard Models)

DP80 DP90 DP80 DP90

Alternator belt deflection Fuel tank capacity 225 liters (59 U.S. gal.)
(when pushed with 10 to 15 mm (0.4 to 0.6 in.)
Cooling system capacity
98 N (10 kgf) [22 lbf])
[incl. 0.65 liter (0.2 U.S. gal.) 23 liters (6.1 U.S. gal.)
Engine idle speed 690 to 720 rpm in reserve tank]
Steering wheel free play Engine 9.5 liters (2.5 U.S. gal.)
70 mm (2.8 in.)
(at rim, with engine idling)
Engine oil Oil filter 4 liters (1.1 U.S. gal.)
Inching pedal free play 16 mm (0.63 in.)
Total 13.5 liters (3.6 U.S. gal.)
Brake pedal free play 15 mm (0.59 in.)
2 speed 22 liters (5.8 U.S. gal.)
Transmission oil
Parking brake lever operating 3 speed 23 liters (6.1 U.S. gal.)
250 to 290 N (25 to 30 kgf) [55 to 66 lbf]
effort
Gear oil (Front axle oil) 20 liters (5.3 U.S. gal.)
Front tire
Tire size 9.00-20-12NHS 9.00-20-14NHS Hydraulic oil N level: 130 liters (34.3 U.S. gal.)
Rear tire
Brake fluid 200 cc (12.2 cu in.)
Front tire 637 kPa 686 kPa
Tire inflation Specific gravity of battery
(6.5 kgf/cm2) (7.0 kgf/cm2) 1.28
pressure electrolyte
Rear tire [92 psi] [100 psi]
Wheel nut 382.538.2 Nm (393.9 kgfm)
Front wheel
tightening [28228 lbfft]
torque Rear wheel 403 Nm (41.1 kgfm) [297 lbfft]
Lift chain elongation limit
785 mm (30.9 in.) 915 mm (36.0 in.)
(20 links)

132 132
SERVICE DATA 133

Rated Capacity and Truck Weight

With 3.7 m (146 in.) Simplex Mast
Unit: kg (lb)
Model DP80 DP90
Mast Simplex Triplex Simplex
8000 7500 9000
Rated capacity
(17500) (16500) (20000)
11430 11960 13170
Truck weight
(25140) (26310) (28970)

133 133
|||||||||||||||||||||||||||||||||||||||||||||||||||||||||| MAINTENANCE |||||||||||||||||||||||||||||||||||||||||||||||||||||||
General
Taking proper care of your lift truck is a vital
part of the overall planned maintenance
program.
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,
consult your Cat lift truck dealer. The dealers
lift truck mechanics are well trained and know
how to safely make repairs. Service manuals
are also available from your Cat lift truck
Follow these rules to help save you from injury
dealer.
and to service your truck properly.
Close
Open
101712A
The fuel shut off valve is located near the air
cleaner inside the engine hood. To avoid an
accident, close this valve when performing
maintenance.
86
! 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, and engine stopped.
Follow the recommended safety
procedures.
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
line, 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
recommended 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 that all clamps, guards and
heat shields are installed correctly to
reduce the risk of vibration, rubbing
against other parts, and excessive heat
during operation.
86
MAINTENANCE
Inspection Precautions
! WARNING
If it is necessary to make an inspection
while the engine is running, ALWAYS
USE TWO WORKERS one, the
operator, at the controls and the other
checking within visual contact of the
operator.
! WARNING
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.
87
87
A daily (Pre-Start) inspection is the key to
! CAUTION safety. At the beginning of each shift, check
Avoid mixing lubricants. In some your lift truck to make sure it is in safe
cases different brands of lubricants are operating condition.
not compatible with each other and Always inspect your truck under the following
deteriorate when mixed. It is best to conditions.
stick with the same brand at successive
service intervals. Lift truck level
Before refilling, clean filler holes. Mast in vertical position
After filling, clean up spills. Fork tips on ground
Engine stopped
87
MAINTENANCE 88

Maintenance Schedule
As the operator, you are responsible for the performance of daily pre-start Every 10 Service Hours or Daily (Pre-Start), Whichever Comes
inspection. You are also responsible for those items listed under Every 50 First, continued
Service Hours or Weekly to keep your lift truck in proper working condition.
For periodic inspection and periodic change of rubber parts, however, rely on Item Service Page
the expert knowledge of the factory-trained servicemen, and the service Horn Check 92
facilities at your Cat lift truck dealers workshop.
Steering Wheel Check movement 92
Amount of Fuel (truck level) Check 92
One month after delivery of a new truck Stop Lights Check 92
Every 200 service hours or monthly,
whichever comes first OK Monitor Check 92
Periodic inspection time
Every 1200 service hours or 6 months, Lift Chains Check adjust 93
intervals
whichever comes first
Every 2400 service hours or 1 year, Engine Check 94
whichever comes first Inching Pedal Check 94
Service Brakes Check 94
Every 10 Service Hours or Daily (Pre-Start), Whichever Comes Backup Lights Check 94
First
Conventional Battery Requiring Check 92
Item Service Page Maintenance electrolyte level

Damage or Faulty Operation Found Check 90 Engine Crankcase Check oil level 96
the Day Before Engine Coolant Check 98
Oil, Fuel or Coolant Leaks Check 90 coolant level

Lights Check 90 Hydraulic System Check oil level 100

Tilt Cylinder Lock Nuts Check 90 Service Brakes Check fluid level 101

Overhead Guard Check 90 Tire Inflation Pressure Inspect check 102

Assist Grip Check 90 Tires and Rims Inspect check 102

Accelerator Pedal Check 91 Wheel Nuts Check tighten 103

Brake Pedal Check 91 Mast and Forks Check 104

Parking Brake Lever Check 91 Air Tank Drain water 105

Seat Belt Check 91

Seat Adjustment Check 91
88 88
MAINTENANCE 89

Every 50 service Hours or Weekly, Whichever Comes First Every 200 service Hours or Monthly, Whichever Comes First,
continued
Item Service Page
Item Service Page
Air Cleaner Clean inspect 106
Universal Joints Lubricate 114
Alternator Drive Belts Check adjust 108
Tie Rod Ends Lubricate 114
Mast Supports Lubricate 109
Rear Axle Center Pins Lubricate 114
Fan Belt Check adjust 109
Every 1200 Service Hours or 6 Months, Whichever Comes First
One Month After Delivery of a New Truck
Item Service Page Item Service Page
Powershift Transmission Change oil, filter 115
Hydraulic tank return oil filter Change 109
and wash strainer
Fuel filter Change 109
Hydraulic System Change 117
return oil filter and
Every 200 service Hours or Monthly, Whichever Comes First wash strainer
Item Service Page Front Axle Change lubricant 118
Wheel Nuts Retighten 110 Air Cleaner Change element 118
Front axle Check 110 Fuel Filter Change 119
lubricant level Engine Coolant Change 121
Powershift Transmission Check oil level 111
Every 2400 service Hours or 1 Year, Whichever Comes First
Engine Crankcase Change 112
oil and filter
Item Service Page
Mast Strip Sliding Surfaces Lubricate 113
Hydraulic Oil Change 124
Lift Bracket Side Rollers Lubricate 113
Service Brake Fluid Change 125
Lift Chains Lubricate inspect 113
Tilt Socket Pins Lubricate 113
Tilt Cylinder Pins Lubricate 113
Water Pump Lubricate 114

89 89
MAINTENANCE 90

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 operarion or maintenance procedures.
Damage or Faulty Operation Found Oil, Fuel or Coolant Leaks Overhead Guard
the Day Before Check Check
Check Check on the floor for oil, fuel or coolant
Have repairs been made properly? leaks.
Check the daily inspection sheet.
Lights
! WARNING
Check
Are all the lights in safe working
condition?
Are their lenses clean and not defective?
101335A
Do the tail, clearance and head lights come
ON properly when you switch them on. 1. Check the front and rear overhead guard
mounting bolts on each side.
Tilt Cylinder Lock Nuts 2. Inspect overhead guard for bent or cracked
Check sections. Contact your Cat lift truck dealer
100678A
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
Check
property damage.

Mark 101686

Are the lock nuts tightened properly? Use a

wrench.
NOTICE: After retightening the lock nut, put
102553
a mark across the nut and tilt
cylinder socket. This permits you Inspect, and if necessary, tighten the screws of
to easily notice loosening of the the assist grip.
lock nut.

90 90
MAINTENANCE 91

Accelerator Pedal (A) Parking Brake Lever Seat Belt

Check Check Check
Can you pull the lever all the way with
(B) (A) reasonable effort?
Can you hold your truck on a grade by
pulling the brake lever?
Lever Operating Effort:
250 to 290 N (25 to 30 kgf) [55 to 66 lbf]

Adjustment
101362D 100977

Can you depress the accelerator pedal Is the seat belt in safe condition?
Release Apply
smoothly without any sign of rubbing? Replace the belt assembly if the belt is
torn, cut, or if the plate and/or buckle is
Brake Pedal (B) defective.
Check
101437 Seat Adjustment
Free play: Turn the knob to the right to increase the Check
15 mm (0.6 in.)
levers 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 over center.

100129A

Do you have sufficient pedal travel when

101839
you depress the brake pedal?
Does the pedal have a correct free play? Can you depress the pedals all the way?
Free play: 15 mm (0.6 in.) NOTICE: See Seat Adjustment in the
Operators Seats.

91 91
MAINTENANCE 92

Horn Amount of Fuel (truck level) OK Monitor

Check Check Check

102591 102394 102444B

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 days work? key is in the (ON) position?
NOTICE: When this lamp does not light
Steering Wheel Stop Lights with the key in the (ON)
Check Movement Check position, the bulb may be burned
out. Get an inspection at a
specified service station.

101726A 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
shaking the wheel up and down.

92 92
MAINTENANCE 93

Lift Chains To Adjust

Check Adjust
8 ton model
! WARNING
Check the lift chains periodically Nut (1)
and determine if they are still in
usable condition.
Check the lift chains for wear, 102009 Nut (2)
cracks, missing links and worn or
seized link pins. 2. Lift the forks high enough to put their full 102709 Locknut

Improper maintenance of the lift weight on the carriage and chains.

chains can cause accidents. If 3. Check to be sure the lift chains have equal 9 ton model
something is wrong with the chains, tension.
Nut (1)
consult your Cat lift truck dealer for 4. If the chains are loose or the tension is not
repair or replacement. equal, have the chains adjusted. Nut (2)
Do NOT put your foot under the
fork.
Locknut

1. Check the lift chains for wear. Use the 101687

following chart to determine if it is still in
usable condition. 1. Loosen the locknut and the nut (1). Then
turn the nut (2) to adjust tension.
Lift Chain Elongation Limit: (/20 links) 2. Hold the nut (2), and then tighten the nut
(1) to the specified torque.
8 ton model 785 mm (30.9 in.) 102708
Hold the nut (2) and tighten the locknut to
9 ton model 915 mm (36.0 in.) the specified torque.

93 93
MAINTENANCE 94

Engine Inching Pedal Backup Lights

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

101707

Is exhaust smoke normal?

Listen for abnormal noise or excessive
vibration.

94 94
MAINTENANCE 95

Conventional Battery Requiring Electrolyte

Maintenance ! WARNING Float
level

Check Electrolyte Level If acid gets in your eyes, FLUSH THEM

IMMEDIATELY WITH LARGE
! WARNING AMOUNTS OF WATER AND SEE A
DOCTOR AT ONCE. Glass tube
Batteries give off flammable fumes that If you spill acid on yourself, FLUSH
can explode. SKIN IMMEDIATELY WITH LOTS
Electrolyte

Do not smoke when checking the OF WATER. APPLY BAKING SODA 100801
battery electrolyte levels. TO HELP NEUTRALIZE THE ACID
Using a battery hydrometer, check the specific
Electrolyte is an acid and can cause AND SEE A DOCTOR AT ONCE.
gravity of the battery cells. Take the reading at
injury if it contacts your skin or eyes.
eye level.
Always wear protective glasses when
working with batteries.
! CAUTION Specific gravity
corrected to Battery condition
1. Raise the hood. If distilled water has to be added 27C (80F)
2. Clean the top of the battery and terminals. frequently, have your Cat lift truck dealer
1.265 to 1.280 Fully charged
check the battery.
3. Check terminals for corrosion. Coat 1.225 to 1.260 Three-fourths charged
terminals with heavy grease. (to be recharged)
4. Maintain electrolyte level between the Below 1.220 Completely discharged
UPPER LEVEL and LOWER LEVEL (to be recharged and
marked on the case. NOTE: If an addition retested)
of water is necessary, use distilled water. If
not available, use clean water that is low in
minerals. Do not use artificially softened
water.
5. Close and secure the hood.

101688

95 95
MAINTENANCE 96

Engine Crankcase 3. Maintain the correct level range on the Adding Engine Oil
Check Oil Level dipstick.
! CAUTION
! WARNING
Perform the work on level ground.
Hot oil and components can cause Correct level range Clean the filler hole to prevent dirt
personal injury. Do not allow hot oil or from dropping into the engine.
components to contact your skin. DO NOT overfill.
Clean up spillage.
Park the lift truck with the forks lowered,
parking brake applied, transmission in 1. Remove the oil filler cap.
NEUTRAL, and the engine stopped. 101304

1. Raise the hood. 4. Close and secure the hood.

2. Remove the dipstick and wipe it clean,
then insert it all the way.

101690

101689

96 96
MAINTENANCE 97

2. Add engine oil as required.

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

101691

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

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

97 97
MAINTENANCE
Engine Coolant
Check Coolant Level
! WARNING
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 any
pressure before removing the cap.
The lift truck must be level, the forks lowered,
the parking brake applied, the transmission in
NEUTRAL, and the engine stopped and cold.
1. Raise the hood.
101692
98
98
2. Maintain the coolant level between the
FULL and LOW marks on the reserve tank.
IMPORTANT
Antifreeze/summer coolant (ASC)
contains 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
Full Correct
level range not provide sufficient corrosion
Low protection. Concentrations over 60%
adversely affect freeze protection and
101465 heat transfer rates.
3. Close and secure the hood. Avoid mixing different brands of
coolant.
Adding Coolant Select an ASC suitable for use in
engines using aluminum alloy parts.
Select an ASC which contains silicate
! WARNING
of less than 0.2% by weight.
Keep fire away from undiluted anti-
freeze 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
premix antifreeze/summer coolant with tap
water (soft water). See Engine cooling
system capacity in the Specifications.
If coolant has to be added frequently, have
your Cat lift truck dealer check the cooling
system.
98
MAINTENANCE 99

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

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

99 99
MAINTENANCE 100

Hydraulic System
Check Oil Level
! WARNING
Hot oil and components could cause
personal 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 fill cap is cool enough to remove
with your bare hand.
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
the forks lowered, mast tilted back, parking
brake applied, transmission in NEUTRAL,
and the engine stopped.
3. Raise the hood.
4. Remove the hydraulic tank filler cap by
turning it counterclockwise.
5. Add oil if needed to raise it to the correct
level range on the dipstick.
101268B
Correct level range
101342
6. Put the hydraulic tank filler cap back on.
7. Check for oil leaks.
8. Close and secure the hood.
Adding Hydraulic Oil
! CAUTION
When adding hydraulic oil:
clean the filler hole to prevent dirt from
dropping into the tank.
DO NOT overfill.
clean up spillage.
1. Remove the hydraulic tank filler cap.
2. Add oil to the hydraulic tank.
For Hydraulic Oil, see the topic,
Recommended Fuel and Oils.
101317B

101316A

100 100
MAINTENANCE 101

Service Brakes 1. Raise the hood. Adding Brake Fluid

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

! CAUTION 102484

Before refilling the reservoir, clean the 3. Maintain the brake fluid level between the
MAX and MIN marks on the reservoir. 102485
ports to prevent dirt from getting inside the
reservoir. 4. Close the hood.

Park the lift truck with the forks lowered,

parking brake applied, transmission in
NEUTRAL, and the engine stopped.

101 101
MAINTENANCE 102

Tire Inflation Pressure Tires and Rims

Inspect Check Inspect Check

! WARNING ! CAUTION
Carefully follow the specific information The lift truck tires are highly inflated.
provided by your tire servicing Even slight damage to the tire or rim can
company or dealer. OK OK OK cause a 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 (0.2 in.)
training in using the equipment, are
necessary to avoid overinflation. A tire
blowout or rim failure can result from
improper or misused equipment.

! CAUTION
Underinflated tires flex excessively at
every turn of the wheel, resulting in
premature 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.
101158 101295A
Inflate all the tires properly. Are all the tires free of cuts, gouges or
Use a tire inflation gauge. foreign objects?
Are all the rims free of distortion or
Recommended Tire Pressures cracks?
Unit: kPa (kgf/cm2) [psi] Use a tire depth gauge to measure the tire
groove depth. If it is not more than 5 mm
8 ton model 637 (6.5) [92]
Front/Rear (0.2 in.), replace the tire.
9 ton model 686 (7) [100] NOTICE: For tire replacement, see in the If
Do not reinflate a tire mounted on a split type Tire Blows Has to be Changed.
rim that has been driven on while flat or
underinflated without inspecting the rim for
damage and checking the lock ring for proper
installation.

102 102
MAINTENANCE 103

Wheel Nuts Tightening Torques for Wheel Nuts

Check Tighten, when required Unit: Nm (kgfm) [lbfft]
Wheel nuts should be visually inspected Front 382.538.2 (39.03.9) [28228]
everyday. Any loose nuts should be Rear 403 (41.1) [297]
tightened and any missing or damaged nuts
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.

103 103
MAINTENANCE 104

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

(B) (B) (B)

(B)

(A) (A)

101840
Does the mast move up and down
smoothly 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), all weld areas and
mounting brackets (B).
Forks with cracks should be removed from
service.
Wet Test magnetic particle inspection is
generally preferred due to its sensitivity and
the ease of interpreting the results. Portable
equipment 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?

104 104
MAINTENANCE 105

Air Tank
Drain Water

(C) (D)

101629A 101630A

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 entering loads.
The maximum allowable difference in fork tip
elevation (C) is 5 mm (0.19 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 (D). The fork should
be withdrawn from service if the thickness 102894
is reduced to less than the tolerant
thickness. At the end of each shift or when operators
change, pull down the handle at the bottom of
Fork blade length may also be reduced by
the brake air tank to allow water to drain.
wear, especially on tapered forks and platens.
Remove the forks from service when the blade
length is no longer adequate for the intended
loads.
Tolerant Thickness (std.)
Unit: mm (in.)
8 ton model 60 (2.4)
9 ton model 70 (2.8)

105 105
MAINTENANCE 106

Every 50 Service Hours or Weekly, Whichever Comes First

You must read and understand the warnings and instructions contained in this manual before preforming any operation or maintenance procedures.
Air Cleaner
Clean Inspect ! WARNING ! CAUTION
Install the dust pan with its arrow mark up.
Air cleaner indicator

RED signal Element

Clamp

Reset button Dust cup

100901

100142 When using compressed air for cleaning,

Clean the air cleaner element if the indicator wear a safety face shield and protective
clothing. Wing bolt
shows RED. After installing clean element,
Use a maximum air pressure of 196 kPa (2 100188A
reset the indicator.
kgf/cm2) [30 psi] for cleaning purposes. 1. Loosen clamp and remove dust cup.
2. Remove wing bolt and take out element.
NOTICE: Never service the air cleaner with
the engine running.
Do not clean the elements by
striking them against another
object.
Always inspect the element before
and after cleaning. Use a light
inside the element.
Do not use elements with Baffle

damaged pleats, gaskets or seals. 101543

3. Remove the baffle from the dust cup and

Park the lift truck on a level surface, with the clean the inside of the air cleaner housing.
forks lowered, the parking brake applied, the
transmission in NEUTRAL, and the engine
stopped.

106 106
MAINTENANCE 107

101197

4. Direct air inside the element along the

length of the pleats, and lightly tap it.

101199

5. Insert a light inside a clean and dry element

and check. Discard the element if tears or
rips are found.
6. Put the element back in place.
7. Reinstall the dust cap.

107 107
MAINTENANCE
Alternator Drive Belt
Check Adjust
! CAUTION
After adjusting the belt, tighten the
bracket bolts, securely.
If the belt is too tight, unnecessary
stresses are placed on the alternator
bearing and belt. Such stresses will
shorten the service life of both.
Keep the belt free from oil and grease
to prevent slipping.
NOTICE: If it is difficult to adjust or replace
the belts, consult your Cat lift
truck dealer.
Park the lift truck on a level surface, with the
forks lowered, the parking brake applied, the
transmission in NEUTRAL, and the engine
stopped.
108
108
1. Raise the hood.
2. Push the belt downward with
approximately 98 N (10 kgf) [22 lbf]
pressure midway between the pulleys as
shown.
Deflection
10 to 15 mm
Alternator drive belt 101417A
(0.4 to 0.6 in.)
3. Loosen the alternator bracket bolts
(indicated by the black arrows), and move
Deflection the alternator out or in.
4. Tighten the bolts after the adjustment of
the belt deflection.
5. Close and secure the hood.
100696A
NOTICE: If the deflection is out of the
correct range, re-adjust the belt.
Also, check the belt to make sure that it is not
worn, frayed, or has separated piles.
108
MAINTENANCE 109

One Month After Delivery of a New

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

Hydraulic Tank Return Oil Filter

Change
Filter should be changed.
See Hydraulic System, Change Return Oil
Filter in the Every 1200 Service Hours.
Tension pulley bolt
101696 203767
Fuel Filter
Lubricate 1 fitting on each side for a total of 2 To inspect
Change
fittings. 1. Make sure the belt is free from oil, grease
Filter should be changed.
or other foreign materials. Replace the belt
if necessary. A slightly dirty belt can be See Fuel Filter, Change in the Every 1200
reused by cleaning with cloth or paper. Do Service Hours.
not clean the belt with gasoline or the like.
2. At the time of overhauling the engine or
adjusting the belt tension, check the belt
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.

109 109
MAINTENANCE 110

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
Retighten Check Lubricant Level lubricant level to the bottom of the plug
opening (1) and (2).
Wheel nuts should be retightened. Park the lift truck on a level surface, parking
brake applied, transmission in NEUTRAL, and 6. Clean the level/fill plug (2) and level plug
See Wheel Nuts, Check Tighten, when
the engine stopped. (1). Put them back in place.
required.
1. Align the planetary hub level mark to the 7. Remove the blocking. Lower the lift
horizontal position. bracket.
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)
101697

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

101209B

110 110
MAINTENANCE 111

Powershift Transmission
Check Oil Level
! WARNING
Hot oil and components can cause
injury. Do not allow hot oil or
components 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, 7. Maintain the correct level range indicated
transmission in NEUTRAL, and the engine on the dipstick.
stopped.
3. Open the engine hood.
4. Remove the accelerator pedal rod.
5. Remove the floor plate. Correct level range

101631

102759

111 111
MAINTENANCE 112

Engine Crankcase 5. Remove and discard the oil filter elements.

Change Oil and Filter
! WARNING
Hot oil and components can cause
serious injury. Do not allow hot oil or
components to contact skin.
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, and the engine
stopped.
3. Raise the hood.
4. Remove the drain plug of the engine oil
pan. Allow the oil to drain. Clean and put
the drain plug back in place.
6. Wipe the sealing surface of the oil filter
element mounting base.
7. Apply a small amount of clean engine oil
to each filter element gasket. Install the
new filter element.
101699
101690
8. Fill the crankcase. See Capacity in the
Specifications.
9. Start the engine and allow the oil to fill the
filter and passages.
10. Check for oil leaks.
11. Stop the engine and measure the oil level.
Maintain the oil level between the MAX.
and MIN. notches on the dipstick.

Correct level range

101689 101304

101699 12. Close and secure the hood.

112 112
MAINTENANCE 113

Mast Strip Sliding Surfaces Lift Chains Tilt Socket Pins

Lubricate Lubricate Inspect Lubricate

102887 102889 101686A

Lubricate 1 fitting on each side of the inner
mast for a total of 2 fittings.
Lift Bracket Side Rollers
Lubricate
1. Apply engine oil onto the chain links with Lubricate 1 fitting on each pin for a total of 2
a brush. fittings.
2. Raise and lower the lift bracket a few times
to work lubricant into the chain links.
NOTICE: Lubricate chains more frequently Tilt Cylinder Pins
than normal where the atmosphere Lubricate
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.

102888 102890

Lubricate 4 fittings on each side roller for a Lubricate 1 fitting on each pin for a total of 2
total of 8 fittings. fittings.

113 113
MAINTENANCE 114

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.

Universal Joints
Lubricate

101715

Lubricate 1 fitting.

114 114
MAINTENANCE 115

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. Allow the oil to 5. Clean sealing surface of filter base.
drain. Remove the cover, the O-ring seal 6. Apply a light coat of engine oil to the
! WARNING and the strainer. gasket of the new filter element.
Hot oil and components can cause
personal 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, Drain plug
Cover
transmission in NEUTRAL, and the engine
stopped.
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

115 115
MAINTENANCE 116

10. Remove the floor plate. 16. Maintain the oil level to the correct level
11. Remove the filter plug. Fill the range on the dipstick.
transmission 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

drain plug.
102893
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.

116 116
MAINTENANCE
Hydraulic System
Change Return Oil Filter and Wash
Strainer
! WARNING
Hot oil and components can cause
personal injury. Do not allow hot oil or
components 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,
parking brake applied, transmission in
NEUTRAL, and the engine stopped.
1. Raise the engine hood.
2. Remove the tank cover.
101678A
117
117
3. Remove the hoses. 8. Wash the strainer in clean, and
nonflammable solvent.
9. Inspect the gasket and replace it, if
necessary.
10. Put the strainer, gasket and cover back in
place. And then install the hoses.
11. Remove the dipstick. Check the oil level.
12. Add oil, if need, to reach the correct level
range on the dipstick.
101680A
4. Remove the gasket and strainer.
5. Remove the gasket and return oil filter.
Discard the filter element.
Strainer 101268B
Oil filter
Correct level range
101679
6. Clean the filter parts and replace the seal
and gasket, if necessary. Install a new filter
element.
7. Put the filter body assembly back in place 101342
and tighten the retaining bolt.
13. Put the dipstick and filler cap back on.
14. Check for oil leaks.
15. Close and secure the hood.
117
MAINTENANCE 118

Front Axle 4. Raise the lift bracket high enough to gain 9. Fill the front axle housing and planetary
Change Lubricant access to the front axle housing level/fill hub through the level/fill opening until the
plug. lubricant starts to flow out. See Capacity
Park the lift truck on a level surface, parking
5. Use blocking under inner mast to secure in the Specifications. Install the level/fill
brake applied, transmission in NEUTRAL,
the lift bracket in this position. plug.
forks lowered, lubricant warm and the engine
stopped. 6. Remove the level/fill plug. 10. Install the planetary hub level plug.
1. Align the planetary hub level/mark to the 11. Remove blocking. Lower the lift bracket.
horizontal position.
Air Cleaner
Mark Change Element
Cat strongly recommends that the air cleaner
element be changed if it is dirty. If you
attempt to clean the element, handle it
carefully.
Level/fill plug
101697
Level plug

7. Remove the drain plug and allow the Recommended Change Intervals
Drain plug
101209B lubricant drain. Normal Every 1200 hours
2. Remove the planetary hub drain plug and conditions or 6 months
level plug. Severe dust or
Every 200 hours or monthly
3. Allow the lubricant to drain. Clean and lint conditions
reinstall the drain plug.
NOTICE: Have spare elements on hand to
use while cleaning used elements.
Care in severe dust or lint conditions
Check the radiator core frequently for clogging
Drain plug
or dirt accumulation. Clean or wash the truck
101701
as needed.
8. Clean and reinstall the drain plug. See Air Cleaner, Clean and Inspect in the
Every 50 Hours or Weekly, Whichever
Comes First.

118 118
MAINTENANCE 119

Fuel Filter
Change

! WARNING
Fuel leaked or spilled onto hot surfaces
or electrical components could cause a
fire.
Clean up any spillage of fuel. Know the 101682A
location of all emergency devices (such
as fire extinguishers, first aid kits, etc.) 3. Use filter wrench to remove filter element.
and how to use them. 4. Clean sealing surface of filter base.
Disconnect the battery when changing 5. Apply a light coat of engine oil to the
fuel. gasket of the new filter element.

NOTICE: Engine must be stopped and cool.

Park the lift truck in an authorized refueling

area, with the forks lowered, parking brake
applied, transmission in NEUTRAL, and the
engine stopped and cool.
1. Raise the hood.
2. The fuel filter is located on the right side of 101681A
the truck. Remove the filter.
6. Install the new filter element by hand until
the gasket contacts the filter base.
7. Prime the system.
8. Close and secure the hood.

101698

119 119
MAINTENANCE 120

How to Prime the Diesel Fuel System Priming pump Air vent plug (1)
plunger
Air vent
NOTICE: If the engine runs out of fuel, it plug (2)
cannot be started even if the fuel
tank is filled. In such a case,
prime the fuel system as follows:

! CAUTION
101702
Make sure no fuel leaks from the air
1. Loosen the air vent plug (1) on the fuel
vent plug.
filter about 1.5 turns with a wrench.
Clean up spillage.
2. Unlock priming pump plunger by turning it
counterclockwise. Operate the priming
pump until the fuel flows free of bubbles
from the vent.
3. Tighten air vent plug (1).
4. Loosen air vent plug (2) on the injection
pump about 1.5 turns with a wrench.
5. Operate the priming pump until the fuel
flows free of bubbles from the vent plug
(2). Lock the priming pump plunger by
turning it clockwise while pressing
downward.
6. Tighten air vent plug (2).

120 120
MAINTENANCE 121

Engine Coolant 2. Turn the radiator filler cap slowly to relieve

Change ! WARNING the pressure, then remove the cap.
See Engine Coolant, Check Level in the
Every 10 Service Hours or Daily.

! WARNING
At operating temperature, the engine
coolant is hot and under pressure.
Steam could cause severe burns.
100899
Park the lift truck in an authorized 101738
refueling area, with the forks lowered, Antifreeze solution is TOXIC. In case of
3. Remove the engine block drain plug.
parking brake applied, transmission in contact with your skin, FLUSH
NEUTRAL, and the engine stopped and IMMEDIATELY WITH WATER. Have your
cool. Cat lift truck dealer discard antifreeze solution
Check the coolant level only after the drained from the engine.
engine has been stopped and the filler
cap is cool enough to touch with your 1. Loosen the radiator cover retaining knob.
bare hand. Open the radiator cover.
Remove the filler cap slowly to relieve
pressure.
Cooling system conditioner contains 101704
alkali. Avoid contact with your skin and
eyes to prevent burns and other injuries.
Allow cooling system components to
cool before draining.
Use all cleaning solutions with care.
Knobs
Antifreeze is TOXIC. In case of contact 101711
with your skin, FLUSH IMMEDIATE-
LY WITH WATER. For disposal of the
antifreeze coolant drained from the
engine, consult your Cat lift truck
dealer.

121 121
MAINTENANCE 122

4. Open radiator drain valve. Allow the 7. Fill the cooling system with 1 kg (2 lb) 15. Close the drain valve and put the engine
coolant to drain. sodium bisulfate per 40 liters (10 gallons) block drain plug back in place.
of water. Most commercial cooling system 16. Mix a coolant solution of water and
cleaners can be used. antifreeze.
8. Start and run the engine for 30 minutes. 17. Fill the cooling system. See Capacity in
9. Stop the engine and drain the cleaning the Specifications. To avoid air locks, add
solution. the coolant slowly.
10. Flush the system with clean water until the
draining water is clear.
11. Close the drain valve and put the engine
100504A block drain plug back in place. Fill the
system with neutralizing solution, 250 g
5. Drain the reserve tank. (1/2 lb) sodium 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 101740
solution.
18. Start and run the engine until the coolant
14. Flush the system with clean water until
Full level is stabilized.
draining water is clear.
19. Stop the engine.
Low
20. Add coolant, if necessary, to maintain the
101465B level to below the bottom of the filler tube.
6. Close the radiator drain valve and put the
engine block drain plug back in place.

101641

122 122
MAINTENANCE 123

22. Remove the reserve tank filler cap.

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

101299A

Correct
level range
Full

Low

101465A

24. Put the reserve tank filler cap back on.

123 123
MAINTENANCE 124

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
Change

! 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 101316A 101268B
only after the engine has been stopped
and the filler cap is cool enough to 4. Remove the hydraulic tank drain plug.
remove with your bare hand. Allow the oil to drain. Clean and put the
Correct level range
Remove the hydraulic tank filler cap plug back in place.
slowly to relieve pressure.

1. Operate the lift truck to warm the oil.

2. Park the lift truck with forks lowered,
parking brake applied, transmission in
NEUTRAL, and engine stopped. 101342

3. Remove filler cap. 8. Remove the filler cap and the dipstick.
Keep the oil level at the HIGH mark on the
102760 dipstick.
5. Fill the hydraulic tank. See Capacity in 9. Put the dipstick and the filler cap back in
the Specifications. Put the filler cap back place.
on.
6. Start the engine and operate the hydraulic
controls and the steering system through a
few cycles to fill the filters and lines.
7. Retract all hydraulic cylinders and stop the
engine.Remove the hydraulic tank drain
plug. Allow the oil to drain. Clean and put
the plug back in place.

124 124
MAINTENANCE 125

Service Brake Fluid

Change
NOTICE: When changing fluid, consult your
Cat lift truck dealer.

102483

125 125
MAINTENANCE 126

Parts to be Changed Periodically

The following parts should be periodically
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 chance of injury to the
operator and damage to the truck.
11

Ref.
Parts to be changed Interval
No.
1 Repair kit of air master 2400 service hours or 1 year, whichever 5 9
8
cylinder comes first 4 11

2 Rubber parts of brake 2400 service hours or 1 year, whichever 1

wheel cylinders comes first 10

3 Repair kit of brake 2400 service hours or 1 year, whichever 8

11
valve comes first 3

4 Tube of brake fluid 2400 service hours or 1 year, whichever 7

cup comes first
5 High-pressure hoses of 2400 to 4800 service hours or 1 to 2 years, 2
hydraulic system whichever comes first 6

6 Hydraulic hoses of 4800 service hours or 2 years, whichever

power steering cylinder comes first 5
7 Inner rubber parts of 4800 service hours or 2 years, whichever
power steering cylinder comes first
8 Fuel hoses 4800 to 9600 service hours or 2 to 4 years,
whichever comes first 5 2
5
9 Lift chains 4800 to 9600 service hours or 2 to 4 years,
whichever comes first
10 Stop light switch 4800 service hours or 2 years, whichever
102761
(air type) comes first
11 Brake hoses 2400 service hours or 1 year, which comes
first

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

126 126
|||||||||||||||||||||||||||||||||||||||||||||||||||||| TROUBLESHOOTING |||||||||||||||||||||||||||||||||||||||||||||||||||
If a Tire Has to be Changed
Tire Information
! WARNING
Servicing and changing tires and rims
can be dangerous and should be done
only by trained personnel using proper
tools and procedures. If correct
procedures are not followed while
servicing tires and rims, the assemblies
could burst with explosive force and
cause serious injury or death. Follow
carefully the specific information
provided by your tire servicing
company or dealer.
Use a tire inflation gauge and stand
behind the tread when inflating a tire
and checking tire pressure.
Proper inflation equipment, and
training in using the equipment, are
necessary to avoid overinflation. A tire
blowout or rim failure can result from
improper or misused equipment.
77
NOTICE: When changing tires, change them
in sets, even if only one of the tires
is damaged. If new and used tires
are used on the same axle, tilting
of the mast and rapid tire wear
will result.
The mounting faces of the hub,
wheel nuts and wheels must be
free of any foreign material and Block Stand Jack 101202A
lubricants of any kind. Tighten
wheel nuts again after 24 hours of (Start by)
operation. 1. Park the truck on level ground with the
Do not reinflate a tire mounted on parking brake applied, transmission in
a split type rim that has been neutral, forks lowered and engine stopped.
driven on while flat or 2. Prepare tools, jack, stands, and wheel
underinflated without inspecting block.
the rim for damage and checking
the lock ring for proper Jack capacities
installation.
Front Have available two jacks, each having
tire a capacity of 3 tons (6600 lbf).
! CAUTION Rear Have available two jacks, each having
tire a capacity of 7 tons (16000 lbf).
Always deflate tires fully before
removing them from their rims to
prevent a tire explosion. Weight of wheel 100 kg (221 lb), approx.
Make sure the replacement tires are of
the same size, type and load range. 3. Block the wheels. When removing a front
Make sure the replacement tires are wheel, block the right and left rear wheels.
properly inflated. When removing a rear wheel, block the
right and left front wheels.
4. Slightly deflate tires before removing the
wheels from the truck.
77
TROUBLESHOOTING 78

! WARNING ! WARNING Removing wheels

Outer wheel nut

Extension valve

101837
DO NOT attempt to change the tire with the
truck loaded. Injury and/or damage could
result.
101838
101203A
Stop raising the truck when the tire clears the
(Front outer wheels)
ground. DO NOT raise the truck more than
necessary. 1. Remove the inner tire extension valve by
turning it counterclockwise.

! CAUTION
! WARNING ! WARNING When removing the outer wheel nuts, hold
a socket wrench against each nut properly
to prevent the wrench from slipping off the
nut.

2. Loosen the outer wheel nuts about two

turns.
NOTICE: Only loosen the wheel nuts. DO
NOT remove them.
100832 100833

BE SURE no one is in the truck when raising DO NOT place any part of your body under
the front or rear tires. the truck. SECURELY SUPPORT the truck
with blocks after jacking it up.

78 78
TROUBLESHOOTING 79

! WARNING
DONT put any portion of your body
under the truck being raised. Inner wheel nut
After raising the truck, place the
stands under the right and left frame
members to support the truck.

101322A 3. Raise the truck until the tire just clears the 101205A
ground.
Jacking (Front inner wheels)
Position the jack under the frame and raise the 1. Lower the truck to the ground once.
front wheel. 2. Loosen the inner wheel nuts about two
! CAUTION
turns.
Be careful NOT to strip the threads of 3. Raise the truck until the tire just clears the
inner wheel nuts or wheel bolts by the ground.
edges of wheel disk holes. 4. Unscrew the inner wheel nuts and remove
the inner wheel. It is recommended to use
Tilt Tilt 4. Unscrew the outer wheel nuts and remove the special tool TIRE HANDLER when
forward the outer wheel. It is recommended to use
backward removing the wheel.
the special tool TIRE HANDLER when
removing the wheel.

Block

101325A

Hydraulic-jacking
Tilt the mast all the way backward, put blocks
under the mast, then tilt the mast forward.

79 79
TROUBLESHOOTING 80

Installing wheels

101206 101323

(Rear wheels) 101333

1. Loosen the wheel nuts about two turns. ! CAUTION
Clean the threads of wheel bolts and nuts and
NOTICE: Only loosen the wheel nuts. DO Be careful NOT to strip the bolt threads by the counterbores of the wheel disc.
NOT remove them. the edges of rim holes.

3. Remove the wheel nuts.

4. Firmly grip the wheel with both hands and
remove it from the truck.

101346

2. Raise the truck until the tire just clears the

ground.
Raising rear wheels:
Position the jack under the counterweight, and
raise the truck.

80 80
TROUBLESHOOTING 81

Tightening sequence Dual wheel nut retighten

Loosen outer wheel nut.

Tighten outer
wheel nut.


101209B 101210A

(Front outer wheels) Tighten inner wheel nut.

! CAUTION 1. Raise the truck until the tire just clears the 101213

ground.
Use the same size and brand tire.
Make sure the clamping surfaces of the
2. Install the outer wheel. Tighten the wheel ! CAUTION
nuts just enough to hold the wheel without
wheel nuts and counterbores are free of After wheel replacement, drive the
rattling.
dirt. truck for a while, and retighten the
3. Lower the truck until the tire just touches
wheel nuts.
the ground.
(Front inner wheels) In case of the dual wheel, BE SURE to
4. Tighten the outer wheel nuts in the same
1. Install the inner wheel. Tighten the wheel retighten the inner wheel nuts after the
manner as tightening the inner wheel nuts.
nuts just enough to hold the wheel without outer wheel nuts are tightened.
5. Install the extension valve.
rattling.
2. Lower the truck until the tire just touches NOTICE: Retighten the wheel nuts at
the ground. periodic intervals.
3. Tighten the wheel nuts, in two or three
steps, to the specified torque. Each of the
steps must follow the tightening sequence
shown.
NOTICE: Even when replacing an outer
wheel tire, make sure the inner
wheel nuts are tightened properly.
Tightening torque 382.538.2 Nm
for inner and outer (39.03.9 kgfm)
wheel nuts [28228 lbfft]

81 81
TROUBLESHOOTING 82

How to determine tightening torque If your weight is 60 kg (132 lb), for instance,
rest the weight on the wrench handle at a
point of 68.5 cm (27 in.) from the wheel nut
t
weigh to tighten the wheel nuts.
32 lb)
60 kg (1

101211A

(Rear wheels) 68.5 cm

1. Install the rear wheel. Tighten the wheel (27 in.) 101736

nuts just enough to hold the wheel without

rattling. ! CAUTION

Tightening sequence DO NOT bounce the weight when

A torque wrench is recommended for
101212A
2. Lower the truck until the tire just touches
the ground. Tighten the wheel nuts, in two
or three steps, to the specified torque.
Each of the steps must follow the
tightening sequence.
resting it on the wrench handle.
DO NOT overtighten the wheel nuts.
Overtightening will strain the bolts or
deform the clamping surface of wheel
disc.
tightening the wheel nuts. If a torque wrench
is not available, tighten the nuts with a socket
wrench for wheel nuts by resting the weight on
the handle of the wrench.
Torque is a turning effort. It is expressed as a
product of length and force.

403 Nm
Tightening torque
(41.1 kgfm)
for wheel nuts
[297 lbfft]

82 82
TROUBLESHOOTING
Checking tire pressure
101214B
1. Lower the truck fully and inflate the tires.
2. Check to make sure the tire pressure is
correct. For tire pressure, see SERVICE
DATA.
NOTICE: The tire pressure is indicated
on the nameplate attached on
the left side of the engine hood.
3. After wheel replacement, drive the truck
for a while and check the wheel nuts for
tightness.
83
83
If Powershift Transmission Oil
Temperature Warning Light Glows
! WARNING
101440F
100904
1. Stop the truck in a non-traffic area.
2. Apply the parking brake. Place and lock
Your lift truck uses high pressure tires. the direction lever in the NEUTRAL (N)
Whenever it is time to add air, check the rim position. Allow the engine to run at low
for damage that could cause an air leak.
idle for a while.
NEVER overinflate the tire.
3. After the warning light has gone out,
When adding air to the tire, or when checking operate the truck again.
tire pressure, BE SURE to keep your body
away from the side. Use an inflation cage or
other safety device to prevent injuries.
! CAUTION
When adding air to the tire using an air
compressor, make sure the compressor valve is If the warning light does not go out, or if it
correctly set. Failure to follow this precaution glows often, consult your Cat lift truck
may cause personal injury or may damage the dealer.
tire. Always maintain the correct tire pressure.
83
TROUBLESHOOTING
If Engine Stalled
101222A
If the engine stalls, hydraulic pressure is lost in
the power steering system and the air brake
system. If this happens, greater steering effort
and greater brake pedal effort will be required.
Stop your truck in a safe area and check the
cause before restarting the engine.
84
84
If Engine Coolant Temperature Gauge
Needle Moves into the Red Zone
! WARNING
101434B
1. Stop the truck in a safe area. 100813
2. Open the engine hood to ventilate the
engine compartment. DO NOT attempt to remove the radiator
filler cap if the engine is overheated. This
3. Allow the engine to idle for a while. DO
could cause injury from scalding hot
NOT attempt to stop the engine.
coolant or steam blowing out of the
4. Stop the engine when the coolant radiator.
temperature gauge needle moves into the
DO NOT add cold water to an overheated
WHITE zone.
engine. This could cause damage to the
5. Check for: engine. Wait for the engine to cool.
lack of coolant Immediately stop the engine if the fan belt
loose or broken fan belt is broken.
low engine oil level
foreign material buildup in radiator air
passages
84
TROUBLESHOOTING 85

Driving Interlock Indicator Light Flickers or Flashes, and the Truck Stops Moving

The driving interlock indicator Are you seated? Place the direction lever to the neutral position and sit securely.
light starts flickering and the
truck stops moving.

NO

104577 104579 104144

YES
The driving interlock indicator Stop working and move the truck to a safe area. Shut down the engine and
light is OFF but the truck fails to consult your Cat lift truck dealer.
move.

TROUBLE

104578 101463

85 85