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 identification of potential maintenance
problems. Do-it-yourself maintenance does not
include repairs. If your lift truck requires any
repairs, consult your Cat lift truck dealer. The
dealer's lift truck mechanics are well trained and
know how to safely make repairs. The fuel shut
off valve is located near the fuel pump assembly
inside the engine compartment. To avoid an
accident, close this valve when performing
maintenance.
– Make sure the service area is safe.
– Park the lift truck on a level ground with
the forks lowered until the fork tips touch
the floor, parking brake applied, direction
lever in the neutral position, engine
stopped and the wheels blocked.
– All repairs must be made by authorized
personnel.
– Follow the recommended safety proce-
dures.
– Use only the right tools for the job.
Follow these rules to help save you from injury
and to service your lift truck properly.
118
DO NOT bypass any electrical switches on
this lift truck.
If during operation the lift truck becomes
unsafe in any way, the matter must be
reported immediately to the user's desig-
nated authority, and the lift truck must not
be operated until it has been restored to a
safe operating condition.
– BE SURE to perform inspections.
– If you fail to perform required inspec-
tions, it could lead to accidents.
– Operate at reduced speed when
inspecting with the lift truck operated.
– If operated at higher speed, it could
cause accidents in case that the lift truck
is faulty.
– Dress properly for the job. DO NOT wear
loose clothing or accessories—flapping
cuffs, dangling chains, neck ties,
scarves, or rings—that could catch in
moving parts.
– Wear personal protective equipment
appropriate for the conditions of your
work places.
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
could cause fires. Contact your authorized
Cat lift truck dealer for repair or change.
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,
change 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.
118
MAINTENANCE 119

◆ Inspection Precautions

CAUTION
– Avoid mixing lubricants. In some cases,
If it is necessary to make an inspection
different brands of lubricants are not
while the engine is running, ALWAYS USE
compatible with each other and deteri-
TWO WORKERS—one, the operator, at the
orate when mixes. It is best to stick with
controls and the other checking within
the same brand at successive service
visual contact of the operator.
intervals.
– Before refilling, clean filler holes. After
filling, clean up spills.

CAUTION
A daily (Pre-Start) inspection is the key to
safety. At the beginning of each shift, check
your lift truck to make sure it is in a safe
Q00001
operating condition. Always inspect your lift
truck under the following conditions.
If the lift truck requires any repair, attach a "DO
NOT OPERATE" or similar warning tag to the
steering wheel or other controls, remove the key
from the key switch, and contact your authorized
Cat lift truck dealer.

119 119
MAINTENANCE 120

◆ Maintenance Schedule

As the operator, you are responsible for the performance of the daily Pre-Start • Every 10 Service Hours or Daily (Pre-Start), Whichever Comes
inspection. First, Continued
You are also responsible for those items listed under Every 50 Service Hours or
Weekly, Whichever Comes First to keep your lift truck in a proper working Item Service Page
condition.
Brake Pedal Check 125
For periodic inspection and periodic change of rubber parts, however, rely on the
expert knowledge of the dealer's well-trained mechanics, and consult your autho- Inching Pedal (Powershift) Check 126
rized Cat lift truck dealer's workshop. Clutch Pedal (Manual) Check 126

– One month (30 days) or 200 service hours after delivery of a Parking Brake Lever Check 126
new truck, whichever comes first Seat Belt Check 126
Periodic – Every 200 service hours or monthly, whichever comes first
Operator's Seat Check 126
Inspection – Every 500 service hours or 3 months,
Time whichever comes first Horn Check 127
Intervals – Every 1000 service hours or 6 months, Steering Wheel Check movement 127
whichever comes first
– Every 2000 service hours or 1 year, whichever comes first Amount of Fuel (Truck Level) Check 127
Stop Lights (if equipped) Check 127
• Every 10 Service Hours or Daily (Pre-Start), Whichever Comes Lamps of Instrument Panel Check 127
First
Lift Chains Check 128
Item Service Page Engine Check 129
Faulty Operation Found the Day Clutch Check 129
Check 124
Before
Mast Strip Sliding Surfaces and Roller Check 129
Oil, Fuel or Coolant Leaks Check 124
Lights (if equipped) Check 124
Load Backrest Extension Check 124
Tilt Cylinder Socket Bolts Check 125
Overhead Guard Check 125
Assist Grip Check 125
Accelerator Pedal Check 125

120 120
MAINTENANCE 121

• 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 Alternator Drive Belt Check / Adjust 141
Backup Lights Check 129 Air Cleaner Element Clean /Inspect 142
Engine Crankcase Check oil level 130 Brake Hoses, Pipes and Joints Check 143
Engine Coolant Check coolant level 131 Fuel Hoses, Pipes and Joints Check 143
Hydraulic Oil Check oil level 133 Hydraulic Hoses, Pipes and Joints Check 143
Powershift Transmission Check oil level 134
• One Month (30 days) or 200 Service Hours After Delivery of a New
Service Brakes (MANUAL ONLY) Check fluid level 135
Truck, Whichever Comes First
Wheel Nuts Check 136
Item Service Page
Tires and Rims Inspect / Check 136
Hydraulic Tank Return Oil Filter Change 144
Mast and Forks Check 137
Engine Crankcase Change oil / filter 144
Lift Cylinder Mounting Bolts Check 138
Fuel Filter
Cooling Fan Check 138 Standard Change 144
– Gasoline
Check
Battery 138 Fuel Filter – Diesel Change 144
electrolyte level
Check specific
Mast Interlock System Check 139 Battery 144
gravity of electrolyte
Driving Interlock System Check 139
Parking Brake Warning Buzzer and
Check 140
Lamp
Seat Belt Warning Lamp Check 140

121 121
MAINTENANCE 122

• One Month (30 Days) or 200 Service Hours After Delivery of a New • Every 200 Service Hours or Monthly, Whichever Comes First
Truck, Whichever Comes First, Continued
Item Service Page
Item Service Page
Mast Strip Sliding Surfaces Lubricate 146
Bolts and Nuts Check 144
Lift Chains Lubricate 146
Differential Check oil level 145
Tilt Socket Pins Lubricate 145
Tie Rod Pins Lubricate 145
Mast Support Lubricate 145
King Pins Lubricate 145
Mounting Bush of Rear Axle Lubricate 145
Gearshift Lever (Manual) Lubricate 145
Clutch Pedal Shifter Shaft (Manual) Lubricate 145

122 122
MAINTENANCE 123

• Every 500 Service Hours or 3 Months, Whichever Comes First • Every 1000 Service Hours or 6 Months, Whichever Comes First
Item Service Page Item Service Page
Bolts and Nuts Retighten 147 Change oil /
Powershift Transmission 152
Differential Check oil level 147 wash strainer

Tilt Socket Pins Lubricate 147 Change return oil filter /

Hydraulic System 153
Wash strainer
Tie Rod Pins Lubricate 147
Differential Change oil 154
Mast Support Lubricate 148
Air Cleaner Element Change 154
King Pins Lubricate 148
Fuel Filter – Diesel Change 155
Mounting Bush of Rear Axle Lubricate 148
Fuel Filter – Gasoline (Standard Engine) Change 155
Gearshift Lever (Manual) Lubricate 148
Clutch Pedal Shifter Shaft (Manual) Lubricate 148
Fuel Filter – LP-Gas Clean 149 • Every 2000 Service Hours or 1 Year, Whichever Comes First

Check specific Item Service Page

Battery 150
gravity of electrolyte Hydraulic Oil Change 156
Engine Crankcase Change oil and filter 151 Service Brake Fluid (MANUAL ONLY) Change 157
Engine Coolant Change 157
For Diesel
Fuel Filter – LP-Gas Change 159
The change intervals for engine oil and filter depend on the percentage of sulfur
in the diesel fuel. Check the following:
Sulfur Percentage Oil Grade Spec. Change Interval
0 to 0.2% CF or higher 500 hrs. or 3 months*
0.2 to 0.5% CF or higher 300 hrs. or 3 months*
Over 0.5% CF or higher 200 hrs. or 3 months*
*Whichever comes first
Whenever the engine oil is changed, MNA recommends the filter be changed
at the same time with a genuine MNA oil filter.

123 123
MAINTENANCE 124

◆ 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 procedure.

• Faulty Operation Found the Day • Oil, Fuel or Coolant Leaks • Load Backrest Extension
Before
Have repairs been made properly?
Check the daily inspection sheet.

Q00004 Q00005

Check on the floor for oil, fuel or coolant leaks. Is the load backrest extension free of distortion,
cracks and other defects? Shake the load
• Lights (If Equipped) backrest extension to check for excessive rattle.

Q00002 – Are all the lights in a safe working condition?

Fill out a daily inspection sheet. Remember, the
complete performance of a daily inspection is
the best protection against injury and property
damage.
– Are their lenses clean and not defective?
– Do the tail and head lights come ON properly
when you switch them on?

124 124
MAINTENANCE 125

• Tilt Cylinder Socket Bolts • Overhead Guard • Accelerator Pedal

Q00007 Q00008 Q00011

Are the bolts tightened properly? Use a wrench.
NOTICE:
After retightening the bolt, put a mark across the
bolt and tilt cylinder socket. This permits you to
easily notice loosening of the bolt.
Tightening Torque for the Bolt
153 to 182 N•m (16 to19 kgf•m)
1. Check the front and rear overhead guard Can you press the accelerator pedal smoothly
mounting bolts on each side. Tighten bolts without any sign of rubbing?
to 49 to 69 N•m (5. 0 to 7. 0 kgf•m).
2. Inspect overhead guard for bent or cracked
sections. Contact your authorized Cat lift • Brake Pedal
truck dealer if repairs are needed. – Do you have sufficient pedal travel?
– Does the pedal have a free play of 7 mm?
• Assist Grip Free Play
Unit:mm
Powershift Manual
1 to 3.5 ton models 7 7

Q00010

Inspect the assist grip for damage or cracks and

also check that it is secure. Tighten the screws
of the assist grip if necessary.

125 125
MAINTENANCE 126

• Inching Pedal (Powershift) • Parking Brake Lever • Seat Belt

Release

Rod

Q00012 Q00013

Is the free play correct? Can you pull the parking brake lever all the way E00051
back with reasonable effort?
Can you hold your lift truck on a grade by pulling If the seat belt is torn, the pulling motion is inter-
Correct free play
the parking brake lever? rupted during extension of the belt, or the belt
Unit:mm
cannot be inserted into the buckle properly,
1 to 3.5 ton models 2.5 to 7.5
To Adjust: replace the seat belt assembly. The seat belt
Put the lever to the release position. must be checked at regular service intervals.
Turn the rod clockwise to increase the lever's
• Clutch Pedal (Manual)
tension; counterclockwise to decrease it.
Is the free play correct to feel some resistance • Operator's Seat
when you push down the pedal a little? Lever operating effort
Unit:N (kgf)
NOTICE: 1 ton model 150 to 200 (15 to 20)
The play of wet clutch (Power clutch) lift truck
should be checked while the engine is running. 2 ton model 200 to 250 (20 to25)
3 ton model 230 to 250 (23 to 25)
Correct free play
Unit:mm
Dry Clutch Models 0 to 6
Slide
Wet Clutch Models 0 to 6
lever Q00149

– Check the operator's seat for secure lock with

adjusting the operator's seat by the slide lever.
– Make sure that there is no looseness on the
operator's seat.

126 126
MAINTENANCE 127

• Horn • Amount of Fuel for Gasoline and • Lamps of Instrument Panel

Diesel Models (Lift Truck Level)

G D G，
D

D for Diesel Models

G for Gasoline Models

Q00015 E00138S
Q00017

Does the horn sound properly when you push Is the amount of fuel in the tank enough for the Do all the warning lamps and indicator lamps
the switch? day's work? glow when the key switch is in the (ON)
position? (Except warning lamps with G and D.)

• Steering Wheel • Stop Lights (If Equipped) NOTICE:

When these lamps do not glow with the key
switch in the (ON) position, LED (Light-
Emitting Diode) may have a defect.
Contact your authorized Cat lift truck dealer for
repairs.

Q00016 Q00018

Is the free play 15 to 30 mm? Do all stop lights come ON properly when you
Check the play at the rim of the wheel by rotating press the brake pedal?
the wheel in both directions. Is wheel installation
loose? Check by shaking the wheel up and
down.

127 127
MAINTENANCE 128

• Lift Chains
Check/Adjust To Adjust

– Check the lift chains periodically and

determine if they are still in usable Clamp
condition.
– Check the lift chains for wear, cracks and
worn or seized link pins. Improper
Nut
maintenance of the lift chains could
cause accidents. Locknut
– If something is wrong with the chains, Q00021 Q00022
consult your authorized Cat lift truck 1. Loosen the locknut and the clamp. Then turn
dealer for repair or change. 2. Lift the forks high enough to put their full the nut to adjust tension.
– DO NOT put your foot under the forks. weight on the carriage and chains. 2. Hold the nut and tighten the clamp. Hold the
– Stop the engine before working. 3. Make sure the lift chains have equal tension. nut and tighten the locknut to torque A.
– DO NOT lean over from the lift truck to 4. If the chains are loose or the tension is not
perform inspections. equal, adjust the chain tension. Tightening Torque
– It could cause accidents. Unit:N•m (kgf•m)
1 to 2.5 ton models A 98 (10.0)
Lift chain elongation limit (/20 links)
3 to 3.5 ton models A 147 (15.0)
1 to 1.8 ton models 327 mm
2 to 2.5 ton models 392 mm
3 to 3.5 ton models 523 mm

Q00020
1. Check the lift chains for wear. Use the
following chart to determine if it is still in
usable condition.

128 128
MAINTENANCE
• Engine
Exhaust fumes could kill you! If it is
necessary to start the engine in an
enclosed area, make sure there is
adequate ventilation. 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.
Q00023
– Is exhaust smoke normal?
– Listen for abnormal noise or excessive
vibration.
129
129
• Clutch • Back-up Lights (Optional)
Does flywheel clutch (manual truck) or trans-
mission cluch (powershift truck) move smoothly,
or show slip? The clutch is sticking when the
cluch pedal (manual truck) or inching pedal
(powershift truck) is pressed down but the lift
truck speed does not decrease. The clutch is
slipping when the accelerator pedal is pressed
but the lift truck speed does not increase.
Q00025
• Mast Strip Sliding Surfaces and Roller
When you place the direction lever into reverse
position:
– Do the back-up lights come ON?
– Does the back-up buzzer sound (if equipped)?
Q00024
Inspect the mast strip sliding surfaces and
rollers for wear and cracks.
– Does the mast and rollers move smoothly? If
not, lubricate on each side of the inner mast.
129
MAINTENANCE 130

• Engine Crankcase
Check Electrolyte Level Adding Engine Oil

Hot oil and components could cause When adding engine oil:
injury. DO NOT allow hot oil or components
– Perform the work on a level ground.
to contact your skin.
– Clean the filler hole to prevent dirt from
dropping into the engine.
NOTICE: – DO NOT overfill.
Park the lift truck on a level ground with the forks – Clean up spillage.
lowered until the fork tips touch the floor, parking
Q00029
brake applied, direction lever in the neutral
(GASOLINE)
position, engine stopped and the wheels
2. Add engine oil as required.
blocked.
For engine oil, see the topic, "Recom-
The engine must be cooled down. Correct level range
mended Fuels and Oils."
3. After adding oil, make sure the level is in the
correct range on the dip stick.
4. Close and tighten the filler cap.

Correct level range

Q00027

(DIESEL)

Q00026

1. Raise the engine hood.

2. Remove the dip stick and wipe it clean, then
re-insert it.
3. Maintain the correct level range on the dip
stick. Q00028
4. Close and secure the hood.

1. Remove the oil filler cap.

130 130
MAINTENANCE 131

• Engine Coolant
.Check Coolant Level Adding Coolant

Park the lift truck on a level ground with forks

lowered until fork tips touch the floor, parking
brake applied, direction lever in neutral position
and engine stopped. Block the wheels securely.
FULL F
LOW L
Q00030
1. Raise the engine hood.
2. Maintain the coolant level between the FULL
and LOW marks on the reserve tank.
3. Close and secure the hood.
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
premix antifreeze/summer coolant with tap
water (soft water).
If coolant has to be added frequently, have
your authorized Cat lift truck dealer check the
cooling system.
CAUTION
– 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 transfer rates.
– Avoid mixing different brands of coolant.
– 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.

131 131
MAINTENANCE 132

Q00031

Q00140
1. Remove the reserve tank cap and add
coolant to the FULL mark. Antifreeze solution is TOXIC. In case of contact
2. When adding coolant, maintain the same with your skin, FLUSH IMMEDIATELY WITH
concentration of antifreeze solution. WATER. Have your authorized Cat lift truck
dealer discard antifreeze solution drained from
NOTICE: the engine.
The engine cooling system is protected to -30°C
with 50% concentration of antifreeze/summer
coolant (ASC) when shipped from the manufac-
turer.

132 132
MAINTENANCE 133

• Hydraulic Oil
Check Electrolyte Level Adding Hydraulic Oil

CAUTION

– Hot oil and components could cause When adding hydraulic oil:
personal injury. DO NOT allow hot oil or – Perform the work on a level ground.
components to contact your skin. – Clean the filler hole to reduce the risk of dirt
– Remove the hydraulic tank filler cap only from dropping into the tank.
after the engine has been stopped and – DO NOT overfill.
the cap is cool enough to remove with – Clean up spillage.
your bare hand.
– Remove the hydraulic tank filler cap E00078
slowly to relieve pressure. 1. Remove the hydraulic tank filler cap.
4. Add oil needed to raise it to the correct level 2. Add oil to the hydraulic tank.
range on the dip stick.
For hydraulic oil, see the topic, "Recommended
1. Operate the lift truck for a few minutes to
Fuel and Oils."
warm the oil.
2. Park the lift truck on a level ground with the Cor
rec
t le
forks lowered until the fork tips touch the vel
ran
floor, mast tilted back, parking brake ge

applied, direction lever in the neutral

position, engine stopped and the wheels
blocked.
3. Remove the hydraulic tank filler cap by
turning it counterclockwise.
Q00035 Q00036

5. Put the hydraulic tank filler cap back on.

6. Check for oil leaks.
7. Close and secure the engine hood.

133 133
MAINTENANCE 134

• Powershift Transmission
Check Electrolyte Level Adding Oil

See the topic, "Powershift Transmission,

Change Oil and Wash Strainer" under "Every
– Hot oil and components could cause 1000 Service Hours or 6 Months, Whichever
injury. Comes First."
– DO NOT allow hot oil or components to
contact your skin.

1. Operate the lift truck for a few minutes to

warm the oil. Q00037
2. Park the lift truck on a level ground with the
forks lowered until the fork tips touch the 4. Remove the dip stick. Check the oil level.
floor, parking brake applied, direction lever
in the neutral position, engine stopped and
the wheels blocked.
3. Remove the floor plate.
Correct level range

Q00038

5. Maintain the correct level range indicated on

the dip stick.

134 134
MAINTENANCE 135

• Service Brakes (Manual Only)

Check Electrolyte Level (Clutch Oil Level) Adding Brake Fluid

1. Remove the reserve tank cap.

2. Add brake fluid to the reserve tank.
If the brake fluid in the reserve tank 3. Put the reserve tank cap back on.
decreases rapidly, the brake system is
leaking. Have your authorized Cat lift truck
dealer check the system.

CAUTION Q00037

Before refilling the reserve tanks, clean the 4. Maintain the brake fluid level between the
ports to reduce the risk of dirt from getting (MAX) and (MIN) marks on the reserve tank.
inside the reserve tanks. 5. Close the cover.

1. Park the lift truck on a level ground with the

forks lowered until the fork tips touch the
floor, parking brake applied, direction lever
in the neutral position, engine stopped and
the wheels blocked.
2. Open the cover.
3. Check the brake fluid level at the reserve
tank.

135 135
MAINTENANCE 136

• Wheel Nuts • Tires and Rims

Check–Tighten, when required Tightening Torques for Wheel Nuts Check
Unit :N•m (kgf•m)
Wheel nuts should be visually inspected Front
everyday. Any loose nuts should be tightened 1 to 1.8 ton models 157 (16) Limit:
Rear 5 mm
and any missing or damaged nuts should be
changed. Front 378 (38.5)
2 to 3 ton models
Rear 157 (16)
Retightening
Front 378 (38.5)
1. Always stand behind the tread of the tire, 3.5 ton models
NOT in front of the rim. Rear 233 (23.8)
2. Tighten the nuts evenly and in a diagonal
sequence to the specified torque. Q00041

Are all the tires free of cuts, gouges or foreign

objects?
Are all the rims free of distortion or cracks?
Is the tread groove depth more than 5 mm when
checked with a tire depth gauge? If not, change
the tire.

Q00040
Make sure the replacement tire is of the
same size, type and load range. See
3. Are the wheel nuts tightened properly? Use manufacturer name plate on front of the lift
a torque wrench. truck for correct tire size.

CAUTION
The lift truck tires are highly inflated. Even
slight damage to the tire or rim could cause a
blowout of the tire.

136 136
MAINTENANCE 137

• Mast and Forks

If the lift truck is used to carry maximum capacity 2. Check the difference in height of one fork tip
Check loads, the forks should be checked daily. to the other when mounted on the lift
bracket.
A difference in fork tip height could result in
B uneven support of the load and cause problems
when entering loads. The maximum allowable
difference in fork tip elevation C is 5 mm for
pallet forks. Replace one or both forks when the
difference in fork tip height exceeds the
A maximum allowable difference.

Q00042
– Does the mast move up and down smoothly
when you operate the lift lever?
– Does the mast tilt forward and back smoothly
when you operate the tilt lever?
– Are there any oil leaks from the cylinders and
hydraulic lines?
OK OK
OK OK
D00218
– Is the fork locking pin properly engaged?
– Are the forks free of distortion and cracks?
– Are the welds of the hangers free of cracks?
Q00045
1. Carefully inspect the forks for cracks.
Special attention should be given to the heel
section A, all weld areas and mounting
brackets B. D
DO NOT use the forks with cracks. "Wet Test"
magnetic particle inspection is generally recom-
mended due to its sensitivity and the ease of
Q00047
interpreting the results. Portable equipment is
usually recommended so it can be moved to the
lift truck. Contact your authorized Cat lift truck 3. Check the fork blade D. DO NOT use the
dealer for further information. forks if the thickness is reduced to less than
the tolerant thickness. Fork blade length
may also be reduced by wear, especially on
tapered forks and platens. DO NOT use the
forks when the blade length is no longer
adequate for the intended loads.
Unit:mm
Tolerant Thickness Standard Limit
C
1 to 1.8 ton models 35 32
2 to 2.5 ton models 40 36
Q00046 3 to 3.5 ton models 45 40

137 137
MAINTENANCE 138

• Lift Cylinder Mounting Bolts • Battery

Check Check Electrolyte Level
– Check for looseness.
– If acid contacts your skin or clothes
• Cooling Fan which could cause burns, FLUSH THEM
IMMEDIATELY WITH LARGE AMOUNTS
Check
OF WATER.
– Check for damage and rotation. – If acid gets in your eyes by accident,
FLUSH THEM IMMEDIATELY WITH
Correct LARGE AMOUNTS OF WATER AND SEE
level A DOCTOR.
range – If you drink acid by accident, DRINK
LARGE AMOUNTS OF WATER AND SEE
A DOCTOR AT ONCE. To disconnect
Q00048 battery terminals, negative terminal (-)
must be removed first.
1. If the electrolyte level is low, remove the filler – To connect battery terminals, negative
caps and add distilled water to the cells. terminal (-) must be installed last in
Before removing the caps, clean the top of reverse sequence from the discon-
the battery. nection.
2. After adding the distilled water, tighten the
caps securely.

138 138
MAINTENANCE
• Mast Interlock System
Check
Q00049
Raise the forks high enough to see them from
the operator's seat.
Pull the parking brake lever all the way back and
place the direction lever to the neutral position.
Then, with the engine idling (not pressing the
accelerator pedal), half rise from the operator's
seat and after approximately 3 seconds:
– Check that the mast interlock indicator light is
flickering in approximately 3 seconds.
– Operate the lift lever and check that the forks
do not move up and down.
– Operate the tilt lever and check that the mast
does not tilt forward or backward.
The mast interlock will work only for the lift and
tilt levers. Attachments can be moved
regardless of whether the mast interlock
function is operating or not. Therefore, when the
attachment lever is operated, some of the
attachments will move, even though the engine
is not running or the key switch is in the
(OFF) position, as a result of the handling load
or of its own weight.
139
139
• Driving Interlock System
Check
Raise the forks a little from the floor.
CAUTION
Make sure that the area is clear of pedestrians
when checking the mast and driving interlock
systems.
CAUTION
Q00051
– Check this system on a level and hard
ground.
With the engine idling (not pressing on the – DO NOT park the lift truck on a grade to
accelerator pedal), place the direction lever to prevent it from traveling by itself.
the forward or reverse position, and then half – Make sure that the sufficient space is
rise from the operator's seat and after approxi- available for the lift truck to move around and
mately 3 seconds. that no one or obstacle is around the lift
truck.
– The transmission should electrically shift into
neutral with the driving interlock indicator light
flickering. If you are on a grade, the lift truck
will continue to roll because the transmission
is in neutral.
To restore the lift truck to its normal driving
condition, sit properly in the operator's seat and
press the brake pedal to hold the lift truck.
Return the direction lever to the neutral position,
then place the lever to the forward or reverse
position.
139
MAINTENANCE 140

• Parking Brake Warning Buzzer and • Seat Belt Warning Lamp

Lamp
Check Check
Park the lift truck on a level ground with the forks
lowered until the fork tips touch the floor, parking
brake applied, direction lever in the neutral
position, engine stopped and the wheels
blocked. And remove the starter key.

Release

Q00054

Turn the key switch to the (ON) position and

buckle the seat belt.
– Unbuckle the seat belt. The warning lamp will
glow and a buzzer will sound for 30 seconds.

Q00053

Push the parking brake lever forward and leave

the operator's seat and after approximately 2
seconds.
– The warning buzzer will sound with the
warning lamp flickering.
– Pull the parking brake lever all the way back.
– Pull the parking brake lever all the way back.

CAUTION
Check this system on a level and hard ground.

140 140
MAINTENANCE 141

◆ 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 operation or maintenance procedure.

• Alternator Drive Belt

Check and Adjust

CAUTION
Deflection
– 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 of oil and grease to
prevent slipping.
Q00055 Q00056

NOTICE:
1. Raise the engine hood. 3. Loosen the alternator bracket bolts
If it is difficult to adjust or change the belts,
2. Push the belt downward with about 98 N (10 (indicated by the black arrows), and move
consult your authorized Cat lift truck dealer.
kgf) pressure midway between the pulleys the alternator out or in.
as shown. 4. Close and secure the engine hood.
NOTICE:
Park the lift truck on a level ground with the
forks lowered until the fork tips touch the floor, Gasoline 11 to 13 mm
parking brake applied, direction lever in the Deflection
Diesel 10 to 12 mm
neutral position, engine stopped and the wheels
blocked.
NOTICE:
If the deflection is out of range, readjust the belt.
Also, check the belt to make sure that it is not
worn, frayed, or has separated piles.

141 141
MAINTENANCE
• Air Cleaner Element
Clean and Inspect
Q00057
When using compressed air for cleaning, wear
an approved face shield and protective clothing.
Use a maximum air pressure of 196 kpa (2 kgf/
cm2) [30 BAR] for cleaning purposes.
NOTICE:
– DO NOT service the air cleaner with the
engine running.
– DO NOT clean the elements by pounding
them against another object.
– Always inspect the element before and after
cleaning.
– Use a light inside the element.
– DO NOT use elements with damaged pleats,
gaskets or seals.
– Clean and change more frequently in
corrosive or abrasive environments.
142
142
NOTICE: 4. Direct air inside the element along the
Park the lift truck on a level ground with the forks pleats, and lightly tap it.
lowered until the fork tips touch the floor, parking 5. Insert a light inside a clean element and
brake applied, direction lever in the neutral check.
position, engine stopped and the wheels 6. Replace the element if tears or rips area
blocked. found.
7. Install the air cleaner element.
8. Close the engine hood.
Q00058
Q00060
1. Raise the engine hood.
2. Unclamp the dust cup (at 3 places) and take
out the element.
3. Clean the inside of the air cleaner housing.
CAUTION
– DO NOT wash the air cleaner element.
– DO NOT use damaged air cleaner element.
– DO NOT operate the lift truck without the air
cleaner element installed.
– If not followed, dust, water droplets or foreign
objects will get in the engine, which could
result in engine damage.
Q00059
142
MAINTENANCE 143

• Brake Hoses, Pipes and Joints

Check
– Hoses, pipes and joints should be checked for
damage, cracks and brake fluid leaks.

• Fuel Hoses, Pipes and Joints

Check
– Hoses, pipes and joints should be checked for
damage, cracks and fuel leaks.

• Hydraulic Hoses, Pipes and Joints

Check
– Hoses, pipes and joints should be checked for
damage, cracks and hydraulic oil leaks.

143 143
MAINTENANCE 144

◆ One month (30 days) or 200 Service Hours After Delivery of a New Truck, Whichever Comes First
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.

• Hydraulic Tank Return Oil Filter • Fuel Filter–Gasoline • Battery

Change
– Replace return filter.
See the topic, "Hydraulic System, Change
Return Oil Filter and Wash Strainer" under
"Every 1000 Service Hours or 6 Months,
Whichever Comes First. "
• Engine Crankcase
Change Oil and Filter
– Replace oil and filter.
See the topic, "Engine Crankcase, Change Oil
and Filter" under "Every 500 Service Hours or 3
Months, Whichever Comes First. "
Change Check specific gravity of electrolyte
– Replace filter. (Standard engine) – The specific gravity of the battery cells should
be checked.
See the topic, "Fuel Filter (Gasoline), Change" – Not required if battery type is maintenance
under "Every 1000 Service Hours or 6 Months, free.
Whichever Comes First."
See the topic, "Battery, Check Specific Gravity
of Electrolyte" under "Every 500 Service Hours
• Fuel Filter–Diesel or 3 Months, Whichever Comes First. "
Change
– Replace filter.
• Bolts, Nuts
See the topic, "Fuel Filter–Diesel, Change" Retightening
under "Every 1000 Service Hours or 6 Months, – Bolts and nuts of overhead guard should be
Whichever Comes First." retightened.

144 144
MAINTENANCE
• Differential
Check Oil Level
Park the lift truck on a level ground with the forks
lowered until the fork tips touch the floor, parking
brake applied, direction lever in the neutral
position, engine stopped and the wheels
blocked.
1. Raise the lift bracket high enough to gain
access to the level/fill plug.
2. Use blocking under the inner mast to secure
the lift bracket in this position.
Q00061
3. Remove the level/fill plug. Maintain lubricant
level to the bottom of the level/fill hole.
4. Clean and install the level/fill plug.
5. Remove the blocking. Lower the lift bracket.
Adding Oil
See the topic, "Differential, Change Oil" under
"Every 1000 Service Hours or 6 Months,
Whichever Comes First."
145
• Tilt Socket Pins
Lubricate
– Lubricate tilt socket pins.
See the topic, "Tilt Socket Pins, Lubricate"
under the "Every 500 Service Hours or 3
Months, Whichever Comes First."
• Tie Rod Pins
Lubricate
– Lubricate tie rod pins.
See the topic, "Tie Rod Pins, Lubricate" under
"Every 500 Service Hours or 3 Months,
Whichever Comes First."
• Mast Support
Lubricate
– Lubricate mast support bushings.
See the topic, "Mast Support, Lubricate" under
"Every 500 Service Hours or 3 Months,
Whichever Comes First."
145
• King Pins
Lubricate
– Lubricate king pins.
See the topic, "King Pins, Lubricate" under
"Every 500 Service Hours or 3 Months,
Whichever Comes First."
• Mounting Bush of Rear Axle
Lubricate
– Lubricate mounting bush of rear axle.
See the topic, "Mounting Bush of Rear Axle,
Lubricate" under "Every 500 Service Hours or 3
Months, Whichever Comes First."
• Gearshift Lever (Manual)
Lubricate
– Lubricate shift lever.
See the topic, "Shift lever (Manual Truck),
Lubricate" under "Every 500 Service Hours or 3
Months, Whichever Comes First."
• Clutch Pedal Shifter Shaft (Manual)
Lubricate
– Lubricate Clutch Pedal Shaft.
See the topic, "Clutch Pedal Shifter Shaft,
Lubricate" under "Every 500 Service Hours or 3
Months, Whichever Comes First."
145
MAINTENANCE
◆ Every 200 Service Hours or Monthly, Whichever Comes First
• Mast Strip Sliding Surfaces and Roller
Lubricate
Q00024
Inspect the mast strip surfaces and rollers for
wear and cracks.
– Does the mast and rollers move smoothly? If
not, lubricate on each side of the inner mast.
For lubrication of mast strip sliding surfaces,
have it done by your authorized Cat lift truck
dealer.
146
146
• Lift Chains
Lubricate
Q00062
Inspect the chain anchors and individual links
for wear, loose pins or cracked leaves.
– Does the chains move smoothly? If not
lubricate each chain on the left and right of the
mast.
For lubrication of the lift chains, have it done by
the authorized Cat lift truck dealer.
NOTICE:
Lubricate chains more frequently than normal
where the atmosphere could cause corrosion of
components or when the lift truck must work in
rapid lift cycles.
146
MAINTENANCE 147

◆ Every 500 Service Hours or 3 Months, Whichever Comes First

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

• Bolts, Nuts • Differential • Tilt Socket Pins

Retightening Check Oil Level Lubricate
– Lubricate tilt socket pins.
– Bolts and nuts of overhead guard should be Park the lift truck on a level ground with the forks
retightened. lowered until the fork tips touch the floor, parking See the topic, "Tilt Socket Pins, Lubricate"
brake applied, direction lever in the neutral under the "Every 500 Service Hours or 3
position, engine stopped and the wheels Months, Whichever Comes First."
blocked.
1. Raise the lift bracket high enough to gain
access to the level/fill plug.
2. Use blocking under the inner mast to secure
the lift bracket in this position.

Q00061

3. Remove the level/fill plug. Maintain lubricant

level to the bottom of the level/fill hole.
4. Clean and install the level/fill plug.
5. Remove the blocking. Lower the lift bracket.

Adding Oil
See the topic, "Differential, Change Oil" under
"Every 1000 Service Hours or 6 Months,
Whichever Comes First."

147 147
MAINTENANCE 148

• Tie Rod Pins • King Pins • Gearshift Lever (Manual)

Lubricate Lubricate Lubricate

Q00143 Q00066 Q00067

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

• Mast Support • Mounting Bush of Rear Axle • Clutch Pedal Shifter Shaft (Manual)
Lubricate Lubricate Lubricate

Q00065 Q00144 Q00068

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

148 148
MAINTENANCE 149

• Fuel Filter–LP-Gas
Clean

NOTICE:
Park the lift truck in an authorized refueling area
with the forks lowered until the fork tips touch
the floor, parking brake applied, direction lever
in the neutral position, engine stopped and the
wheels blocked. The engine must be cooled
down. Open

Fuel lock filter Q00070 Q00072

3. Disconnect the fuel line. 10. Open the fuel valve.

4. Remove the fuel lock filter. 11. Check the filter for fuel leaks with a soap
solution.
Close
O-ring O-ring
Filter
Q00069

1. Close the fuel valve on the LP-Gas tank.

The fuel shutoff valve turns clockwise to
close. Run the engine until fuel in the fuel O-ring
line runs out and the engine stops. Turn the
key switch to OFF. Q00098
2. Raise the engine hood.
5. Disassemble the fuel lock filter as above.
6. Remove the filter and O-rings.
7. Wash the filter in cleaner. And direct air
inside the filter to clean.
8. Re-assemble and re-install the fuel lock
filter.
9. Connect the fuel line.

149 149
MAINTENANCE 150

• Battery
Check Specific Gravity of Electrolyte

Electrolyte level
Float
If acid gets in your eyes, FLUSH THEM
IMMEDIATELY WITH LARGE AMOUNTS OF
WATER AND SEE A DOCTOR AT ONCE.

Glass tube
Electrolyte

N00002

Using a battery hydrometer, check the specific

gravity of the battery cells. Take the reading at
eye level.

Battery
Electrolyte
Specific Gravity, Battery Condition
corrected to
20°C (68°F)
1.260 to 1.280 Fully charged
1.220 to 1.260 Three-fourths charged (to
be recharged)
Below 1.220 Completely discharged
(to be recharged and
retested)

150 150
MAINTENANCE 151

• Engine Crankcase
Change Oil and Filter

(DIESEL)

Hot oil and components could cause

injury. DO NOT allow hot oil or components
to contact your skin.

Q00075 Q00028

5. Remove and discard the oil filter elements. 9. See Refill Capacities and Lubrication Speci-
6. Wipe the sealing surface of the oil filter fications charts. Start the engine and allow
element mounting base. the oil to fill the filter and passages.
7. Apply a small amount of clean engine oil to 10. Check for oil leaks.
each filter element gasket. Install a new 11. Stop the engine and measure the oil level.
Q00074 filter element. Maintain the correct level range on the dip
1. Operate the lift truck a few minutes to warm stick.
the oil. (GASOLINE)
2. Park the lift truck on a level ground with forks
lowered until fork tips touch the floor,
parking brake applied, direction lever in
neutral position and engine stopped. Block
Correct level range
the wheels securely.
3. Raise the engine hood.
4. Remove the drain plug at the side of the
engine oil pan. Allow the oil to drain. Clean
and re-install the drain plug. Q00076
Q00026
8. Fill the crankcase.
12. Close and secure the engine hood.

151 151
MAINTENANCE 152

◆ Every 1000 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
Change Oil and Wash Strainer

Hot oil and components could cause

injury. Do not allow hot oil or components Correct level range
to contact your skin.

NOTICE:
Park the lift truck on a level ground with the forks
Drain plug
lowered until the fork tips touch the floor, parking Cover
Q00077 Q00038
brake applied, direction lever in the neutral
position, engine stopped and the wheels
1. Remove the drain plug. Allow the oil to drain. 3. Remove the floor plate.
blocked.
Remove the cover, the O-ring seal and the 4. Remove the dip stick. Fill the transmission
strainer. with oil, See the topic, "Refill Capacities."
2. Wash the strainer and the plug in clean, Install the dip stick.
nonflammable solvent. Dry the strainer and 5. Start the engine.
the plug. Wipe off the O-ring seal, check and 6. Run the engine at low idle.
change if necessary. Install the strainer, the 7. Stop the engine.
O-ring seal, and the cover. Put the drain 8. Remove the dip stick. Check the oil level.
plug back in place. 9. Add oil, if needed, to reach the correct level
range on the dip stick.
10. Check for oil leaks at the strainer and drain
plug.
11. Install the floor plate.

152 152
MAINTENANCE 153

• Hydraulic System
Change Return Oil Filter and Wash Strainer

Tank cover
Hose
Hot oil and components could cause
injury. Do not allow hot oil or components
to contact your skin. Return oil filter
At operating temperature, the hydraulic
tank is hot and could be under pressure. Strainer

NOTICE:
Q00079 E00078
Park the lift truck on a level ground with the forks
lowered until the fork tips touch the floor, parking
3. Remove the hose and tank cover. 8. Wash the strainer in clean, nonflammable
brake applied, direction lever in the neutral
solvent.
position, engine stopped and the wheels
9. Inspect the gasket and change it, if
blocked.
necessary.
Return oil filter Strainer 10. Install the strainer, gasket and cover.
Air cleaner

Cor
rec
t le
vel
ran
ge

Q00080

4. Remove the gasket and strainer.

Q00078
5. Remove the gasket and return oil filter.
1. Raise the engine hood. Discard the filter element.
2. Remove the air cleaner. 6. Clean the filter parts and change the seal
and gasket, if necessary. Install a new filter
element.
7. Re-install the filter body assembly and
tighten the retaining bolt.
Q00035
11. Remove the filler cap. Check the oil level.
12. Add oil, if needed, to reach the correct level
range on the dip stick.
13. Install the dip stick.
14. Check for oil leaks.
15. Close and secure the engine hood.

153 153
MAINTENANCE 154

• Differential • Air Cleaner Element

Change Oil Change

NOTICE:
Park the lift truck on a level ground with the forks
lowered until the fork tips touch the floor, parking
brake applied, direction lever in the neutral
position, lubricant warm, engine stopped the
wheels blocked.
Mitsubishi Caterpillar Forklift Inc. 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

Normal Every 1000 service hours or 6

Conditions months, whichever comes first
Severe Dust Clean and change more
or Lint frequently in corrosive or
Level/fill Conditions abrasive environments.
plug
NOTICE:
Drain plug Have spare elements available to use while
Q00081 cleaning used elements.

1. Raise the lift bracket high enough to gain

access to the level/fill plug.
2. Use blocking under inner mast to secure the
lift bracket in this position.
3. Remove the drain plug and the level/fill plug.
4. Allow the oil to drain. Clean and install the
drain plug.
5. Fill with oil to the bottom of the level/fill hole.
6. Put the level/fill plug back in place.
7. Remove the blocking. Lower the lift bracket.
Severe Dust or Lint Conditions
Check the radiator core frequently for clogging
or dirt accumulation. Clean or wash the lift truck
as needed.
See the topic, "Air Cleaner Element, Clean and
Inspect" under "Every 50 Hours or Weekly,
Whichever comes first. "

154 154
MAINTENANCE 155

• Fuel Filter–Diesel • Fuel Filter–Gasoline

Change Change

– Fuel leaked or spilled onto hot surfaces Filter element

or electrical components could cause a
fire.
– Clean up any spillage of fuel. Filter
– Know the location of all emergency
devices (such as fire extinguisher, first
aid kit, etc. ) and how to use them.
– Disconnect the battery when changing Q00082 Q00083
fuel filters. – Filter of standard engine should be changed.
3. Use filter wrench to remove filter element.
4. Clean sealing surface of filter base.
NOTICE:
5. Apply a light coat of engine oil to the gasket
Park the lift truck in an authorized refueling area
of the new filter element.
with the forks lowered until the fork tips touch
6. Install the new filter element by hand until
the floor, parking brake applied, direction lever
the gasket contacts the filter base.
in the neutral position, engine stopped and the
7. Start the engine and check for fuel leaks.
wheels blocked.
8. Stop the engine.
The engine must be cooled down.
9. Close and secure the engine hood.
1. Raise the engine hood.
2. Remove the filter.

155 155
MAINTENANCE 156

◆ Every 2000 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 5. Retract all hydraulic cylinders and stop the
engine.

Hot oil and components could cause

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
Q00084
filler cap is cool enough to remove with
your bare hand.
Remove the hydraulic tank filler cap slowly 1. Remove the filler cap.
E00078
to relieve pressure.
6. Remove the filler cap and the dip stick. Keep
NOTICE: the oil level at the HIGH mark on the dip
Operate the lift truck to warm the oil. stick.
Park the lift truck on a level ground with the forks
lowered until the fork tips touch the floor, parking
brake applied, direction lever in the neutral Cor
rec
t le
position, engine stopped and the wheels vel
ran
blocked. ge

Q00085

2. Remove the hydraulic tank drain plug. Allow

the oil to drain. Clean and re-install the drain
plug.
3. Fill the hydraulic tank. See the topic, "Refill Q00035

Capacities. "Put the filler cap back on.

4. Start the engine and operate the hydraulic 7. Put the drain plug back in place.
controls and the steering system through a
few cycles to fill the filters and lines.

156 156
MAINTENANCE 157

• Service Brake Fluid (Manual Only) • Engine Coolant

Change Change

NOTICE: See the topic, "Engine Coolant, Check Coolant

When changing fluid, consult with your autho- Level" under "Every 10 Service Hours or Daily,
rized Cat lift truck dealer. Whichever comes first. "

– At operating temperature, the engine

MAX
coolant is hot and could be under
MIN
pressure.
Correct level – Steam could cause severe burns. Q00140
range
– Park the lift truck in an authorized
refueling area with the forks lowered until
the fork tips touch the floor, parking
Q00039 brake applied, direction lever in the
neutral position, engine stopped and the
wheels blocked.
– Check the coolant level only after the
engine has been stopped and the filler
cap is cool enough to touch with your
bare hand.
– Remove the filler cap slowly to relieve Q00091
pressure.
– Cooling system conditioner contains 1. Loosen the radiator cover retaining knob.
alkali.Avoid contact with your skin and Lift and remove the radiator cover.
eyes to reduce the risk of burns and other
injuries.
– Allow cooling system components to
cool before draining.
– Use all cleaning solutions with care.

Q00092
2. Turn the radiator filler cap slowly to relieve
the pressure, then remove the cap.
157 157
MAINTENANCE 158

Q00093 N00003 Q00096

3. Open radiator drain valve. Allow the coolant
to drain.
4. Drain the reserve tank.
5. Close the radiator drain valve.
6. Fill the cooling system with 1 kg sodium
bisulfate per 40 liters of water. Most
commercial cooling system cleaners can be
used.
7. Start and run the engine for 30 minutes.
8. Stop the engine and drain the cleaning
solution.
9. Flush the system with clean water until the
draining water is clear.
10. Close the drain valve. Fill the system with
neutralizing solution, 250 g sodium
carbonate per 40 liters of water.
11. Start and run the engine for 10 minutes.
12. Stop the engine and drain the neutralizing
solution.
13. Flush the system with clean water until
draining water is clear.
14. Close the drain valve.
15. Mix a coolant solution of distilled water and 21. Remove the reserve tank filler cap.
antifreeze. 22. Keep the coolant level at the FULL line on
16. Fill the cooling system. See the topic, "Refill the reserve tank.
Capacities. "To avoid air locks, add the
coolant slowly.
FULL
LOW
Q00097
Q00095 23. Put the reserve tank filler cap back on.
17. Start and run the engine until the coolant
level is stabilized.
18. Stop the engine.
19. Add coolant, if necessary, to maintain the
level to below the bottom of the filler hole.
20. Put the radiator filler cap back on.

158 158
MAINTENANCE 159

• Fuel Filter–LP-Gas
Change

NOTICE:
Park the lift truck in an authorized refueling area O-ring O-ring
with the forks lowered until the fork tips touch
Filter
the floor, parking brake applied, direction lever
in the neutral position, engine stopped and the
wheels blocked. The engine must be cooled
down. Close

O-ring

Q00069 Q00098

1. Close the fuel valve on the LP-Gas tank.
The fuel shutoff valve turns clockwise to
close. Run the engine until fuel in the fuel
line runs out and the engine stops. Turn the
key switch to OFF.
2. Raise the engine hood.
5. Disassemble the fuel lock filter as above.
6. Replace the filter and O-rings.
7. Re-assemble and re-install the fuel lock
filter.
8. Connect the fuel line.

Open

Q00072
Fuel lock filter Q00070
9. Open the fuel valve.
3. Disconnect the fuel line. 10. Check the filter for fuel leaks with a soap
4. Remove the fuel lock filter. solution.

159 159
MAINTENANCE 160

◆ Parts to Be Changed Periodically

The following parts must 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. 5
Changing at proper intervals will reduce the risk of injury to the operator and 4
damage to the lift truck. 9 3

Ref. No. Parts to be changed Interval

Rubber Parts of Brake 2000 service hours or 1 year,
1
Master Cylinder whichever comes first
6
Rubber Parts of Brake 2000 service hours or 1 year, 6
2
Wheel Cylinders whichever comes first
Rubber Parts and Hoses 2000 service hours or 1 year, 7
3 of Clutch Master Cylinder whichever comes first
(Manual)
2
Rubber Parts of Clutch 2000 service hours or 1 year, 10
4 Release Cylinder whichever comes first
8
(Manual) 1
Vaporizer rubber parts for 6000 service hours or 30 months, 7 2
5 6
LP-Gas whichever comes first
High Pressure Hoses of 2000 to 4000 service hours or 1 to 2
6 Q00099
Hydraulic System years, whichever comes first
7 Rubber Parts of Power 4000 service hours or 2 years,
Cylinder whichever comes first
8 Hydraulic Hoses of 4000 service hours or 2 years,
Steering System whichever comes first
Lift Chains 4000 to 8000 service hours
9
or 2 to 4 years, whichever comes first
Fuel Hoses 4000 to 8000 service hours
10
or 2 to 4 years, whichever comes first

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

160 160