Service Manual

Chassis & Mast MC/FC
2P3000 AT34-30121-up GP15NM AT34-T0100-up
2P3500 AT34-30121-up GP18NM AT34-W0100-up
2PC4000 AT34-30121-up GP20CNM AT34-P0100-up
2P4000 AT35-30121-up GP20NM AT17D-P0100-up
2P5000 AT35-30121-up GP25NM AT17D-T0100-up
2P5500 AT36-30121-up GP25NM-HP AT35-T0100-up
2P6000 AT13F-30121-up GP30NM AT13F-P0100-up
2P6500 AT13F-80121-up GP35NM AT13F-T0100-up
2P7000 AT13F-80121-up
2PD4000 AT18C-30121-up
2PD5000 AT18C-30121-up
2PD6000 AT14E-30121-up
2PD6500 AT14E-80121-up
2PD7000 AT14E-80121-up

For use with S4S and K21 / K25 Engine
Service Manuals. 99719-8M110

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K21. may result in minor or moderate injury. 1 Pub. The descriptions. FOREWORD This service manual is a guide for servicing Cat R Lift Trucks. For your convenience the instructions are grouped by systems as an easy reference. NOTE Indicates a condition that can cause damage to. it not WARNING avoided. 99719-8M110 . No. Servicing consistent with what you will learn by reading this service manual. For engine servicing. K25. the machine. could result in death or serious injury. K21E or K25E Gasoline engine S4S Diesel engine <Safety Related Signs> Indicates a potentially hazardous situation which. or damage to your machine. illustrations and specifications contained in this manual are for trucks with serial numbers in effect at the time of printing. please refer to the applicable engine service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test. repair or rebuild job. K21E or K25E gasoline engines or S4S diesel engines. Indicates a potentially hazardous situation which. Cat Lift Trucks reserves the right to change specifications or designs without notice and without incurring obliga- tions. or shorten service life of. The long productive life of your lift truck(s) depends on regular and proper servicing. K25. The trucks listed in this manual are powered by K21. if not CAUTION avoided.

make all repairs with the truck parked disassembly. Use proper lifting procedures when idle or off. slings. (7) To avoid burns. Read and understand the OPERATION & MAINTE- NANCE MANUAL before performing any lubrica. are outlined in the OPERATION & MAINTE. on a level. recommended by Cat Lift and understood the instructions in the OPERA- Trucks. before removing the last two bolts or nuts com- pletely. SAFETY The proper and safe lubrication and maintenance Do not operate these trucks unless you have read for these lift trucks. tubes and compartments. If this cannot be done. 2 . provide ladders. or work platforms to perform safe repair The serviceman or mechanic may be unfamiliar with operations. Make sure all is important before the removal or disassembly of any chains. when removing any components. TION & MAINTENANCE MANUAL. A knowledge of the system and/or components ponents which weigh 23 kg or more. in injury or death. (1) Read and understand all warning plates and decals on the truck before operating. Block truck so it does not (4) Lower the forks or other implements to the ground roll while working on or under truck. In particular. and are of the correct capacity. (11)Reinstall all fasteners with same part number. Be sure hooks are positioned correctly. many of the systems on this truck. Be aware that the danger of shoes when working around trucks. walkways or work platforms nance procedures is dangerous and could result before using. (8) Be careful when removing cover plates. Use welders gloves. are in good condition component. hood/goggles. and plugs on the truck. Do (3) Do not work on any truck that is supported only by not use a lesser quality fastener if replacements lift jacks or a hoist. lubricating or (9) Be careful when removing filler caps. loose to relieve any springs or other pressures. before performing any work on the truck. hooks. breathers repairing the product. Always face truck when using steps. stands to support the truck before performing any (12)If possible. all rings from fingers when working on machinery. or debris from steps. When it is not possible to use the designed access system. make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly. being sprayed or splashed is even greater if the wear protective glasses when using a hammer or truck has just been stopped because fluids can be sledge on any part of the truck or its attachments hot. (5) Use steps and grab handles (if applicable) when tion or maintenance on these trucks. Because of the size of some of the truck components.. Remove performing any service work. operation is dangerous and could result in injury or death. Lifting eyes are not to be side loaded during a lifting operation. Improper truck NANCE MANUAL. scaffolds. even noted in this Manual. mounting or dismounting a truck. hard surface. use a hoist when lifting com- work. Always use blocks or jack are necessary. Clean any mud Improper performance of lubrication or mainte. be sure you understand how to use them before Do not wear loose fitting or torn clothing. Hold a rag over the cap or plug to prevent being sprayed or splashed by liq- (2) Always wear protective glasses and protective uids under pressure. This makes it important to use caution when performing service (6) To avoid back injury. be alert of the hot sections and the serviceman or mechanic should check the weights hot fluids in lines. apron and other protective clothing (10)Always use tools that are in good condition and appropriate to the welding job being performed. with a hammer or sledge. ladders and walkways. Gradually remove the last two bolts or nuts located at oppo- Following is a list of basic precautions that should site ends of the cover or device and pry cover always be observed. etc.

Do not bend or strike high pressure lines or install ones which have been bent or damaged. tubes and hoses carefully. raised components are blocked correctly and be alert for possible pressure when disconnecting (14)Repairs. 3 . (17)Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed. Pin hole (very small) leaks could result in a high velocity oil stream that will be invis- ible close to the hose. use extra caution. (15)Do not damage wiring during the removal pro- cess. or by rubbing against an object or hot surface. (19)Tighten connections to the correct torque. which require welding. Reinstall the wiring so it is not damaged and ensure it will not be damaged in operation by con- tacting sharp corners. the type of metal being welded and select the cor. should be per- any device from a system that utilizes pressure. (16)Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. must be installed correctly. least to that of parent metal. which requires the mast in the raised position. Always make sure all partment. oil or water systems (electric trucks) before starting to work on truck. (18)Loose or damaged fuel. Shields that protect against oil spray onto hot exhaust components in event of a line. Do not check for leaks with your hands. Any high speed rotating component that has been rect welding procedure and electrodes. vibra- tion or rubbing against other parts during opera- tion. If a guard or shield must be removed to perform the repair work. Place wiring away from oil pipe. clamps and guards are installed correctly to avoid excessive heat. tubes and hoses could cause fires. Use cardboard or paper to locate pin hole leaks. connected or removed. formed only with the appropriate reference infor- mation and by personnel adequately trained and (21)Do not operate a truck if any rotating part is dam- knowledgeable in welding procedures. Make sure that all heat shields. tube or seal failure. This oil could penetrate the skin and cause personal injury. Determine aged or contacts any other part during operation. fittings or related items are dis- Hang "Do not Operate" tag in the Operator's Com. before any lines. lubricant and hydraulic lines. rods or damaged or altered should be checked for bal- wire to provide a weld metal strength equivalent at ance before reusing. Inspect lines.(13)Disconnect battery and discharge any capacitors (20)Relieve all pressure in air.

........... Trucks Equipped with K21.......... Trucks Equipped with Powershift Transmission 4 ........... K21E or K25E Gasoline Engine ŒDiesel-Engine Trucks(PD) . K25. Trucks Equipped with S4S Diesel Engine ŒPowershift Trucks.................GP) .......... HOW TO USE THIS MANUAL Lift truck models covered in this manual ŒMC Truck (Mechanical Control System) Mechanically controlled hydraulic system (conventional lever system) ŒFC Truck (Finger-tip Control System) Electronically controlled hydraulic system MC Truck Lever Control valve FC lever box Output unit Input unit VCM Controller Electric wiring FC Truck Electromagnetic control valve Flow regulator valve 213443 ŒGasoline-Engine Trucks(P...........

213446 Service Data Unit: mm (in.0043 to 0. Washer (part name) 2 Snap ring (part name) Suggestions for Disassembly Output shaft.11 to 0.) 0.5 (0. Assembly and Disassembly) Disassembly diagram (example) 2 1 213445 Sequence 1 Cover. Bolt.0110) Gear Backlash B 0. Installation.020) A: Standard value B: Repair or Service Limit 5 .28 A (0. HOW TO USE THIS MANUAL (continued) (Removal. Removing Remove output shaft using a special tool.

1383 kgf·m 6 .0703 kgf/cm2 1 N·m 0.102 kgf·m Torque 1 lbf·ft 0.4536 kgf 1 kPa 0.0102 kgf/cm2 Pressure 1 psi 0.102 kgf Force 1 lbf 0. Item SI unit Customary unit 1N 0. Symbols and abbreviations OP Option R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4) RC1/8 Taper pipe thread (external) 1/4 inch (formerly PT1/8) G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A) Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8) Units (1) SI Units are used in this manual. (2) The following table shows the conversion of SI unit and customary unit.