Chapter 13 SERVICE DATA

Chapter 13 SERVICE DATA
1. Maintenance Schedule ......................................................................... 13-1

2. Maintenance Note ................................................................................. 13-6
2.1 Brake System ........................................................................................................ 13-6
2.2 Cooling System ................................................................................................... 13-10
2.3 Electric System.................................................................................................... 13-12
2.4 Engine System .................................................................................................... 13-16
2.5 Frame and Chassis ............................................................................................. 13-21
2.6 Fuel System......................................................................................................... 13-23
2.7 Hydraulic System................................................................................................. 13-27
2.8 Ignition System .................................................................................................... 13-30
2.9 Intake System...................................................................................................... 13-31
2.10 Front End Section................................................................................................ 13-33
2.11 Steering and Axle System ................................................................................... 13-37
2.12 T/M and Drive System ......................................................................................... 13-40
2.13 Wheels and Tires................................................................................................. 13-44
2.14 General................................................................................................................ 13-45
3. Tightening Torque for Standard Bolts and Nuts.............................. 13-46
4. Periodic Replacement Parts............................................................... 13-48
4.1 Location of Periodic Replacement Parts ............................................................. 13-49
5. Lubrication Instructions ..................................................................... 13-50
5.1 Lubrication Chart ................................................................................................. 13-50
5.2 Fuel and Lubricant Specifications........................................................................ 13-51
5.3 Adjustment Value and Oil Quantities................................................................... 13-52
6. Special Service Tools ......................................................................... 13-54
6.1 Special Service Tools (Standard Tools for Both MC and FC Trucks) ................. 13-54
6.2 Special Service Tools (for FC Truck Only) .......................................................... 13-59
6.3 Special Service Tools (for Powershift Transmission) .......................................... 13-61
13
SERVICE DATA
Chapter 13 SERVICE DATA
1. Maintenance Schedule
Every 12 months (2000 hours)


Pre-start (daily/10 hours)
1st month (200 hrs) only
Others (see Note 1)

Weekly (50 hours)
Inspection point How to check Service data
Brake drum nuts & bolts X

1 ton:0.5 to 1 mm
Brake drum & (0.020 to 0.04 in.)
Feeler gauge X
shoe clearance 2.3 ton: 0.1 to 0.35 mm
(0.004 to 0.014 in.)
Brake hose, pipes & joints Visual X
Powershift T/M: 7 mm
(0.28 in.)
Brake pedal play Scale X
Manual T/M: 7 mm
(0.28 in.)
1 ton: 150 to 200 N
(15 to 20 kgf)
[33.7 to 45.0 lbf]
Brake
2 ton: 200 to 250 N

Parking brake lever
Spring scale X (20 to 25 kgf)
operating effort
[45.0 to 56.2 lbf]
3 ton: 230 to 250 N
(23 to 25 kgf)
[51.7 to 56.2 lbf]
Service brake fluid level Visual X
Brake clutch/inching pedal
Visual/Wrench L
rod (see Note 2)
Brake master cylinder
R
hoses & rubber parts
Service brake fluid R 135 cc (8.2cu.in.)
Brake wheel cylinder
R
rubber parts
Radiator fin (see Note 2) Visual C C
Cooling fan Visual/Feel X
Engine coolant level Visual X
Radiator filler cap Visual/Feel X X
Rubber hose condition Visual/Feel X X
Gasoline engine:
Cooling
11 to 13 mm
V-belt (fan & alternator) (0.43 to 0.51 in.)
Scale X
tension (deflection) Diesel engine:
10 to 12 mm
(0.39 to 0.47 in.)
1 ton: 6.8 liter
(414.96 cu.in.)
Engine coolant 2 ton: 7.4 liter
R
(incl.reserve tank) (451.58 cu.in.)
3 ton: 8.7 liter
(530.91 cu.in.)
Abbreviation.... X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace
13-1
SERVICE DATA


Others (see Note 1)

Weekly (50 hours)
Alternator Operation/Visual X X
Back lamps Visual X
Battery electrolyte level
Visual X
(see Note 4)
Battery electrolyte specific 1.28 or higher
Hydrometer X X
gravity (see Note 4)
Driving interlock system Operation/Visual X
Electrical wires Visual/Feel X X
Electrical
Horn Operation/Aural X
Instrument panel lamps
(incl. parking brake and Operation/Visual X
seat belt)
Mast interlock system Operation/Visual X
Parking brake buzzer Operation/Aural X
Starter Operation/Aural X X
Stop lamps Operation/Visual X
Working & head lamps Operation/Visual X
Cylinder head bolt & mani-
Wrench X
fold nut
Engine (exhaust, noise,
Visual/Feel X
vibration)
Engine oil level Dip stick X
Gasoline-engine models:
Idling speed
700 rpm
(for carburetor and diesel Tachometer X X
Diesel-engine models:
Engine
engine)
750 rpm
Gasoline engine (hot):
Intake & exhaust valve 0.38 mm (0.015 in.)
Feeler gauge X X X
clearance Diesel-engine models
(cold):0.25 mm (0.010 in.)
Positive crankcase
Air blow/Visual X
ventilation valves & hoses
Engine oil R R
Engine oil filter R R
Frame assist grip Visual/Wrench X
Frame & Chassis
Loosen bolts & nuts Wrench X X

Overhead guard Feel/Wrench X
Seat adjustment Operation/Wrench X
Seat belt Operation/Visual X
13-2
SERVICE DATA
Every12 months (2000 hours)


Others (see Note 1)

Weekly (50 hours)
Tar in vaporizer
(see Note 3)
Fuel hose, pipes & joints
(see Note 3)
Fuel level
Check injection nozzle
(for D engine)
Injection nozzle
Fuel
(for LP engines with

electric control)
LPG fuel filter (see Note 3)
Change diesel fuel filter
R R
(see Note3)
Fuel hose R**
LPG fuel filter (see Note 3) R
Vaporizer rubber parts R
Oil pressure
Control valve X
gauge
Hydraulic hose, pipes &
Visual X
joints
Hydraulic oil Visual X
Hydraulic pump Visual/Aural X
Hydraulic
Hydraulic tank strainer Visual C

Hydraulic hose
R*
(high-pressure hose)
1 ton: 28 liter
(1708.66 cu.in.)
Hydraulic oil R
2, 3 ton: 39 liter
(2379.92 cu.in.)
Hydraulic tank return oil
R R
filter
Ignition
Spark plug gap Plug gauge X X
Air cleaner element

(see Note 3)
Intake
Air cleaner element

(see Note 2)
13-3
SERVICE DATA


Others (see Note 1)

Weekly (50 hours)
Lift chains Operation/Visual X

Lift cylinder mounting bolts Feel/wrench X
Load backrest Operation/Visual X
Mast & forks Operation/Visual X
Front end
Mast strip sliding surfaces Visual X

Tilt cylinder socket bolts Feel/Wrench X
Lift chains (see Note 2) L L
Mast support (see Note 2) L L
Tilt socket pins (see Note
L L
2)
Lift chains R***
Front axle Dye check/Visual X
Power steer cylinder Operation/Visual X
Rear axle Operation/Visual X
Steer gear box Operation/Visual X
Steer & Axle
Play 15 to 30 mm (0.59 to
Steer wheel Operation/Scale X
1.18 in.) at engine idling
Mounting bush of rear axle
L
(see Note 2)
King pins (see Note 2) L L
Tie rod pins (see Note 2) L L
Power steer cylinder hoses
R**
& rubber parts
Accelerator pedal Operation X
Differential oil Visual X X
Inching pedal (for power-
Transmission & Drive
Operation X
shift T/M)
T/M gear & bearing Operation X
T/M oil Visual X
Last chance filter
Visual C
(T/M control valve)
T/M strainer Visual C
Cable play:
Adjust inching pedal for
Scale X 0.5 to 1 mm
powershift T/M
(0.020 to 0.04 in.)
13-4
SERVICE DATA


Others (see Note 1)

Weekly (50 hours)
Clutch master cylinder

R
hoses & rubber parts
1 ton: 5.5 liters
Transmission & Drive
(335.63 cu.in.)
Clutch release cylinder 2 ton: 9.3 liters
R
hoses & rubber parts (567.52 cu.in.)
3 ton: 8.7 liters
(530.91 cu.in.)
Powershift T/M: 10 liter
(610.24 cu.in.)
Differential oil R
Manual T/M: 5 liter
(305.12 cu.in.)
Change T/M oil R
Tire & rims Visual X
Wheel
Wheel & nuts Torque wrench X

Knuckles Operation/Visual X
General
Oil, fuel & coolant leak Walk around X
Note 1: *: Change Every 1 to 2 years

**: Change Every 2 years
***: Change Every 2 to 4 years
Note 2: In corrosive or abrasive environments, clean, lubricate and change more frequently.
Note 3: When fuel with poor quality is used, check, drain, clean and change more frequently.
Note 4: Not required if battery is full maintenance free battery.
Note 5: Apply soap suds to the piping joints to check for any gas leakage after replacing the LPG tank.
13-5
SERVICE DATA
2. Maintenance Note
2.1 Brake System
Be sure to conduct maintenance work on level and hard ground.

Stop the engine, and remove the starter key.
Make sure that sufficient space is available for the lift truck to move around and that no one or no obstacle is
around the lift truck.
(1) Check brake drum bolts.
Brake mounting bolts

Service Hours Every 3 months (500 hrs)
Check the threads for damage or burrs.
216149
(2) Check brake drum and shoes.
Check the drum inner surface for uneven wear or

scratches.
Check shoes and lining for cracks or damage.
If oil contamination or deformation is found,
replace the brake lining with a new one.
Measure the brake lining thickness. If the lining
213751
thickness exceeds a service limit, replace the lin-
ing with a new one.
Unit: mm (in.)
Weight class
Items 2 ton class
1 ton class
3 ton class
A 4.87 (0.19) 5.7 (0.22)
Thickness of linings
B 1.0 (0.04) 1.0 (0.04)
Note: Refer to Chapter 9, Brake System, 2.2 Wheel

Brakes for details.
13-6
SERVICE DATA
(3) Check brake hose, pipes and joints.

Parking brake lever
Reserve tank
Service Hours Weekly (50 hrs) Brake pedal
Check hoses and pipes for cracks or damage. Hose Brake lamp
switch
Check for joint looseness and brake fluid oozing. Wire
cable
Master cylinder
Wheel
brake Wheel cylinder
216150
(4) Check brake pedal.

C
Service Hours Prestart (Daily/10 hrs)
Visually check the brake pedal for deformation or A

cracks.
Press the brake pedal, and check that the pedal
moves smoothly without binding.
Check that the pedal height A from the floor plate
and play C are within the specified value.
Master cylinder 213766
Unit: mm (in.)
Weight class
Items 2 ton class
1 ton class
3 ton class
Pedal height A 191.6 (7.54)
Clearance Powershift
1.0 (0.04) 1.0 (0.04)
between push model
rod and piston MC model 1.0 (0.04) 1.0 (0.04)
Powershift
7.0 (0.28) 7.0 (0.28)
Pedal play C model
MC model 7.0 (0.28) 7.0 (0.28)
Note: Refer to Chapter 9, Brake System, 3.4 Brake

Pedal Adjustment for details.
(5) Check parking brake lever.
Check the lever support pin and lever pin hole for
wear.
Check that operating effort is within the specified
value below.
Lever support pin
2 ton 200 to 250 N (20 to 25 kgf) [44 to 46 lbf]
3 ton 230 to 250 N (23 to 25 kgf) [51 to 56 lbf]
216151
13-7
SERVICE DATA
(6) Check service brake fluid level.
Check that the brake fluid level is within the range

between the maximum and the minimum level MAX
MIN
marks on the reserve tank.

Correct level
range
216152
(7) Lubricate brake and clutch/inching pedal rods.

Inching cable
Service Hours Every 6 months (1000 hrs) Greasing

Frequently lubricate brake, clutch and inching
pedal rods before operation since these areas are
prone to corrosion and wear.
Greasing
216153
(8) Change brake master cylinder hoses and rubber

parts. Hose
Service Hours Yearly (2000 hrs)

Repair kit
Disassemble the brake, and replace hoses and
rubber parts with new ones.
Spring
Remove the master cylinder, and replace the hose Cup
with a new one. Cup
Boot
Disassemble the master cylinder, and replace the
repair kit with a new one. 216318
Note: Refer to Chapter 9, Brake System, 2.1 Master

Cylinder for details.
13-8
SERVICE DATA
(9) Change service brake fluid.
Change brake fluid upon disassembly of the mas-

ter cylinder or wheel cylinder.
Perform air bleeding and make sure there is a
proper pedal play.
FMVSS-DOT 3 or DOT4
Brake fluid 213767
(SAEJ1703)

Lines Bleeding for details.
(10)Change brake wheel cylinder rubber parts. * Boot
*Cup
Clean cylinders and pistons using wash oil. Then

*Spring
check for rust, corrosion or scratches.
* Cup * Scheduled
Apply a thin coat of brake rubber grease to the cyl- replacement parts
*Boot
inder inner surface and the piston cup.
When installing the piton cup, pay attention to the
orientation, and be careful not to damage the cup.
216154
Note: Refer to Chapter 9, Brake System, 2.3 Wheel
Cylinder for details.
13-9
SERVICE DATA
2.2 Cooling System

(1) Check and clean radiator fin.
1st Month (200 hrs) only

Cooling air
Service Hours Cooling water
Every 3 months (500 hrs) Fin Radiator
Visually check the radiator fins for contamination.

Tube
If the fins are too dirty, clean the fins using com-
pressed air.
216155
(2) Check cooling fan.

Fan
Check the fan for oil or dirt contamination.

Do not use gasoline, kerosene, etc. for cleaning.
Wipe contamination off the surface with a rag or
paper.
216156
(3) Check engine coolant level.
Make sure that the coolant level is between FULL

and LOW marks on the reserve tank.
Note: Refer to the appropriate engine service manual.
FULL F
LOW L
216157
13-10
SERVICE DATA
(4) Check radiator filler cap.

Service Hours
Yearly (2000 hrs)
Check the cap for coolant leaks or oozing.

Check the cap seal for damage.
216158
(5) Check rubber hose condition.

Service Hours
Yearly (2000 hrs)
Visually check the surface for damage or cracks.

Check the clamps for coolant leaks or oozing.
216159
(6) Check V-belt (Fan and Alternator) tension.

11㨪13 mm
98 N
rox. [0.43㨪0.51 in.]
Service Hours Weekly (50 hrs) App 0 kgf}
Adjusting bolt {1 lbf]
[22 Fan pulley
Make sure that belt deflection is within 11 and 13
mm (0.43 and 0.51 in.) when a force of 98 N (10
kgf) [22 lbf] is applied at the midpoint between fan Adjusting
pulley and tension pulley. plate
Alternator Crankshaft
pulley pulley
Fixing bolt
216160
(7) Change Engine coolant.
(a) Loosen the radiator drain cock and drain the

coolant.
(b) Close the drain cock and fill a proper mixture of
antifreeze and water (see the table below).
Then start the engine to warm up.
(c) Check for any unusual noise while warming the
engine. Check that the coolant level is between 216161
FULL and LOW marks on the reserve tank
when the engine is warm.
Antifreeze solution
Ambient temperature, °C (°F) -45 (-49) -39 (-38) -30 (-22) -25 (-13) -20 (-4) -15 (5) -10 (14)
Concentration (%) 60 55 50 45 40 35 30
13-11
SERVICE DATA
2.3 Electric System

(1) Check alternator.

Service Hours
Every 6 months (1000 hrs)
Run the engine, and check the alternator for any

unusual noise or vibration.
Check battery performance by reading specific
gravity.
Note: Refer to Chapter 3, Electrical System, 4 Battery
Maintenance for details. 216162
(2) Check back-up lamps.
(a) Turn the key switch to the ON position.

(b) Place the direction lever in the reverse.
(c) Check that the back-up lamps turn on.
216163
(3) Check battery. (Electrolyte level)
Check that the electrolyte level is within the speci-

fied range.
Correct
Note: Refer to Chapter 3, Electrical System, 4 Battery
level
Maintenance for details. range
216164
13-12
SERVICE DATA
(4) Check battery. (Electrolyte specific gravity) Float

Electrolyte
1st Month (200 hrs) only surface
Service Hours
Measure the specific gravity of electrolyte in each

cell with a hydrometer. Electrolyte
Be sure to remove battery cables from the battery Glass tube
during maintenance.
Note: Refer to Chapter 3, Electric System, 4 Battery
216165
Maintenance for details.
(5) Check driving interlock system.
(a) Lift the forks slightly off the ground.

(b) Park the lift truck on level ground with no peo-
ple or obstacles around, and start the engine.
Then place the direction lever either in the for-
ward or reverse, and half rise from the opera-
tor's seat.
(c) The driving interlock indicator blinks in a few 216166
seconds.
(d) Sit on the operator's seat properly, press the
brake pedal, and place the direction lever in
the neutral.
Note: Refer to Chapter 4, Controllers, 5 Powershift
Transmission Driving Interlock system.
(6) Check electrical wires.

Main harness
Harness, rear
1st Month (200 hrs) only combination
Service Hours
Every 3 months (500 hrs) Harness, front
combination
Check the harnesses for damage, bend, or inter-
ference with other components or the lift truck
body.
Make sure that all clamps of the harnesses are
properly fitted.
Harness, front
combination 216125
(7) Check horn.
Push the horn button to check that the horn acti-

vates.
216167
13-13
SERVICE DATA
(8) Check instrument panel lamps (Including parking

brake lamp and seat belt lamp).
G D OPT
Turn the key switch to the ON position to check

that all warning lamps glow.
G : LP-Gas Models
D : Diesel Models
OPT : Optional
216168
(9) Check mast interlock system.
(a) Park the lift truck on level and hard ground.

(b) Raise the forks high enough to see them from
the operator's seat.
(c) Apply the parking brake, place the direction
lever in the neutral, and run the engine at idle
speed.
216169
(d) When the operator half rises from the seat, the
mast inter lock indicator glows in a few sec-
onds.
(e) Check that mast and forks will not move even
when the lift or tilt lever is operated.
Note: Refer to Chapter 4, Controllers, 5 Mast Interlock
system.
(10)Check parking brake buzzer.

Release
Note: Refer to Chapter 4, Controllers, 7 Parking

Brake Warning Buzzer and Lamp.
216170
13-14
SERVICE DATA
(11)Check starter.
(OFF)
1st Month (200 hrs) only (START)

Service Hours
(a) Turn the key switch from ON to the start posi-

tion.
(b) The starter is in good condition if the engine
starts and runs smoothly.
216171
(12)Check stop lamps.
(a) Turn the key switch to the ON position.

(b) Check that the stop lamps turn ON when the
bake pedal is pressed.
216172
(13)Check working and head lamps.
Check that the lamps will turn ON when the light

switch is turned ON.
216173
13-15
SERVICE DATA
2.4 Engine System

(1) Check cylinder head bolts and manifold nuts.

K21, K25
Service Hours 1st Month (200 hrs) only
Remove the valve locker cover, and tighten the 9 3 1 6 8

head bolts to the specified torque in the order
shown in the illustration. (Start with the No. 1 bolt
located in the center.)
Front
If the manifold is too hot, tighten the nuts to the
specified torque after the manifold has cooled 7 5 2 4 10
down.
Tightening torque (Reference) 216306
19.6 - 23.52 N·m
A (2.0 - 2.3 kgf·m)
[14.46 - 17.36 lbf·ft]
Tightening for break-in B E
68.6 N·m
B (7.0 kgf·m)
[50.63 lbf·ft]
C 0.0 Return
Tightening
19.6 - 23.52 N·m torque A D
D (2.0 - 2.3 kgf·m)
[14.46 - 17.36 lbf·ft] Retightening
90 - 92 °C
E
(194 - 198°F)
C Step 216305
Note: 1. Do not allow oil or dust on cylinder head,
mounting surface of cylinder block and head
gasket.
2. Apply anticorrosive oil onto head bolt thread
and surface under the head.
13-16
SERVICE DATA
Tighten cylinder head bolts progressively to the

S4S
specified torque in the numerical order as shown in
the illustration,
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 118 ± 5 (12 ± 0.5) [87 ± 3.6] 12 4 5 13
16 8 1 9 17
Front 14
15 11 7 3 2 6 10
216307
S4Q2
12 4 5 13
16 8 1 9 17
Front 15 7 2 10 18
11 3 6 14
216308
(2) Check engine (exhaust, noise and vibration).
(a) Start the engine to warm up.

(b) Press the accelerator pedal, and check that the
engine revolution smoothly increases up to the
maximum speed without any unusual noise or
vibration.
(c) Check that the color of exhaust gas is light
blue. It should not be white nor black smoke.
216175
Note: 1. Refer to the appropriate engine service man-
ual.
(3) Check engine idle speed (for Diesel and LPG
Adapter harness
engine models without electrically-controlled). (with green cap)

Service Hours
Using the service tool or a tachometer, check the

engine idle speed. Clip(Red)
Clip(Green)
Tachometer 216176
13-17
SERVICE DATA
(4) Check engine oil level.
Park the lift truck on level ground and check the oil Correct level range
level.
216177
(5) Check intake and exhaust valve clearance.

Yearly (2000 hrs)
Bring No. 1 cylinder to top dead center.

Insert a thickness gauge between the rocker arm
and the valve cap, and adjust the clearance to the
specification using the adjusting screw.
216178
Also adjust the other cylinders in order of the firing
sequence, by turning crankshaft 180 degrees
clockwise at every adjustment.
(6) Check positive crankcase ventilation valves and

hoses. Fan side
Rocker cover
Blow-by
Service Hours Every 3 months (500 hrs) control valve
Check hoses for deterioration, damage or clog-
ging. Air horn
Check for the proper operation of the blow-by con-
trol valve. Inlet manifold
216179
Blow air into the blow-by control valve from INT

side, and make sure the air is blocked. If the air Blow-by
control valve
flows through, replace the blow-by control valve
with a new one.
Blow air into the valve from the opposite side, and
35B
INT side
make sure the air flows through. If the air is
blocked, replace the blow-by control valve with a
new one.
Open
Closed
216180
13-18
SERVICE DATA
(7) Change engine oil.

Service Hours
(a) Loosen the drain plug located in the engine oil

pan, and drain the engine oil.
(b) Remove the oil filler cap, and pour oil to the
specified level.
(c) Run the engine to circulate the oil through the
216181
engine.
(d) Stop the engine. Wait for a while to let the (GASOLINE)
engine oil to pour down to the oil pan, and then
check the oil level.
Note: Refer to the appropriate engine service manual. Correct level range
Gasoline- API service classification

Engine engine model SJ or above
oils Diesel-engine API service classification
model CF or above
216182
Drain plug
216319
13-19
SERVICE DATA
(8) Change engine oil filter.

(DIESEL)

Service Hours
Change the oil filter at every oil change.

Add the amount of oil that the filter holds.
Gasoline- API service classification 216183

Engine engine model SJ or above
oils Diesel-engine API service classification
model CF or above
Filter
216184
13-20
SERVICE DATA
2.5 Frame and Chassis

(1) Check frame assist grip.
Service hours Prestart (Daily/10 hrs)
Check the grip for deterioration.

Check the grip for looseness or missing fitting
bolts.
Grip
215185
(2) Check loosen bolts or nuts.

Service hours
Check each part for looseness or missing fitting

bolts and nuts.
216186
(3) Check overhead guard.
Push the overhead guard legs, and make sure that

the overhead guard is firmly fitted to the body.
216187
13-21
SERVICE DATA
(4) Check seat adjustment.
Make sure the smooth seat adjustment controls.
Lever
216188
(5) Check seat belt.
Check the seat belt for fraying, cuts, tears, rust or

damage.
216189
13-22
SERVICE DATA
2.6 Fuel System

(1) Check and drain tar in vaporizer.

Pressure test hole
LPG outlet connector
Service hours LPG inlet connector
Loosen the drain plug when the engine is warm,

and remove tar from the vaporizer using a fuel gas
compressor.
Body
If low-quality oil is used, clean more frequently. Drain valve
Note: Refer to the appropriate engine service manual. Water hose connector
216190
(2) Check fuel hose, pipes and joints.

Injection pipe
Leak-off pipe
Service hours Weekly (50 hrs)
Rock nut
Check the fuel hose for cracks or deterioration.
Check for damaged pipes and oozing fuel from Fuel hose
Return pipe
joints.
Note: Refer to the appropriate engine service manual. Clamp
216191
(3) Check fuel level.
Read fuel level on the instrument panel level

gauge.
216192
13-23
SERVICE DATA
(4) Check injection nozzle. (Diesel engine models)
Service hours Yearly (2000 hrs)
Check nozzle opening pressure, nozzle hole con-

dition and fuel spray pattern using the nozzle tes-
ter.
Checking points of fuel spray are as follows:
Fuel is injected straight.
Fuel is injected in a spray of fine droplets.
216193
Fuel is injected without after-dribbling.
Defective spray pattern

Good Wide After- Deflected Branched

spray dribble spray spray
angle
216316
(5) Check injection nozzle. (Diesel and LPG engine

models with electrically-controlled)
Fuel tube

Service hours Holder
(c) (e)
If the contact area with O-ring is damaged or
scratched due to dust or dirt, replace the nozzle O-ring, upper
with a new one. Do not use solvents for cleaning. (Injector component)
(d) (a)
Do not use the O-ring that has scratches on it.
Check for fuel leaks after installation.
Clip (b)
(f)
Injector
216194
13-24
SERVICE DATA
(6) Clean LPG fuel filter.
Service hours Every 3 months (500 hrs)
Clean the LPG fuel filter.

If low-quality oil is used, clean and replace the filter Filter（LPG）
more frequently.
216196
(7) Change diesel fuel filter.

Priming button
Service hours
Change the fuel filter. (Diesel models)

Loosen the air vent plug, and pump the priming Air vent plug
button. Tighten the plug when fuel coming out of
the air vent plug becomes free from air bubbles.
216197
(8) Change fuel hose.

Injection pipe
Leak-off pipe
Service hours Change in every 2-4 years
Rock nut
Visually check the fuel hose, and if any sign of
deterioration is observed, replace the hose with a Return pipe
Fuel hose
new one.
Clamp
216191
(9) Change gasoline fuel filter.

(Diesel and LPG engine models without electri- Water outlet
Fuel tube
cally-controlled)
Fuel filter
1st Month (200 hrs) only Fuel hose

Service hours
Replace the gasoline engine fuel filter with a new Slinger

one. (Diesel and LPG engine models without elec-
trically-controlled) Fuel pump
If low-quality oil is used, clean and replace the filter Carburetor 216195
more frequently.
13-25
SERVICE DATA
(10)Change LPG fuel filter.
Replace the LPG fuel filter with a new one.
Filter（LPG）
216196
(11)Change vaporizer rubber parts.
Service hours Yearly (2000 hrs) Vacuum hose
Replace vaporizer hot-water hoses and vacuum

hose with new ones.
Hot water hose
216317
13-26
SERVICE DATA
2.7 Hydraulic System

(1) Check control valve.
Check valves for oil leaks.

Check for the proper operation of valves.
To hydraulic tank
To tilt cylinder
To tilt cylinder
To lift cylinder
From hydraulic pump 216199
(2) Check hydraulic hose, pipes and joints.

Hydraulic pump
Check hydraulic hose, pipes and joints. (located on the right
side of the body)
216200
(3) Check hydraulic oil.
Check for hydraulic oil contamination, and check Correct level range
the oil level.
216177
13-27
SERVICE DATA
(4) Check hydraulic pump.
Check the hydraulic pump for damages, loosening

or missing bolts and nuts, and oil leaks.
Hydraulic pump
216201
(5) Clean hydraulic tank strainer.
Service hours Every 6 months (1000 hrs) Fuel return pipe

Strainer
Clean the hydraulic tank strainer.
216202
(6) Change hydraulic hose. (High-pressure hose)
Steering valve
Tilt line
Replace the hydraulic hoses (high-pressure
hoses) with new ones. MC Control
Left side Hydraulic pump
tilt cylinder (located on the
left side of the body)
Lift line Return line
(High-pressure) (Low-pressure)
Pump discharged Return filter

line (high-pressure) Suction
strainer
Knob deviation
control valve
Steering hydraulic line Steering cylinder
Pump suction line

(Low-pressure)
216203
13-28
SERVICE DATA
(7) Change hydraulic oil.
Change hydraulic oil. Correct level range
Torque converter or
ISOVG32
Hydraulic dry-type clutch truck
oil Wet-type clutch API service classifi-
truck cation CD or above
216177
216204
(8) Change hydraulic tank return oil filter.

Service hours
Replace the return filter in the hydraulic tank with

new one. (Filter contamination or damage)
Return filter
216205
13-29
SERVICE DATA
2.8 Ignition System

(1) Check spark plug gap.

Service hours Terminal
Every 3 months (500 hrs) Insulator
Measure gaps between spark plug electrodes

using a wire gauge.
Point gap
Standard value
Unit: mm (in.)
216206
Gap between
0.9 (0.04)
electrodes
13-30
SERVICE DATA
2.9 Intake System

(1) Clean air cleaner element.
(a) Remove the air cleaner cap clamps (3 places),

and pull out the air cleaner.
210207
(b) Clean the air cleaner by blowing compressed

air from inside to outside.
216208
(c) Illuminate a light inside the air cleaner, and

check for damage or pin holes.
216209
13-31
SERVICE DATA
(2) Change air cleaner element.
Replace the air cleaner element with a new one.
210207
13-32
SERVICE DATA
2.10 Front End Section

(1) Check lift chains.
Check the lift chains for elongation.

Check right and left chain tensions.
Measure chain elongation.
Note: Refer to Chapter 12, Mast and Forks, 6.2, 14.2,

or 22.2 Chain Tension Inspection and Adjust- 216211
ment for details.
213960
(2) Check lift cylinder mounting bolts.
Check the lift cylinder for loosening, missing or

damaged mounting bolts.
Lift cylinder
216126
13-33
SERVICE DATA
(3) Check load backrest extension.
Check the load backrest extension by hand for

looseness or play.
216212
(4) Check mast and forks.

OK OK OK OK
Check mast and fork tips.
Check for damage, loosening mounting bolts, fork
chipping, or abnormal mounting position. Also
check for smooth movement.
216214
Check forks critical areas.

A: Heel section (Angle)
B: Weld section
B
A
213957
Check for bent fork tips.

Check difference in fork tip elevation between the
right and left fork tips.
C: Fork tip elevation
213958
13-34
SERVICE DATA
Check for worn fork tips.

D: Fork blade thickness
Note: Refer to Chapter 12, Mast and Forks, 6.1, 14.1

or 22.1 Forks for details.
213959
(5) Check mast strip sliding surfaces.
Check the mast strip sliding surface for wear,

cracks, rust or chips.
Note: Refer to Chapter 12, Mast and Forks, 4.2.3 In-

stalling Mast Strips for details.
216215
(6) Check tilt cylinder socket bolts.
Check the tilt socket bolts for looseness, chips,

rust, and greasing condition.
216216
(7) Lubricate lift chains.

Service hours Lift chains
Lubricate the lift chains.
NLGI No. 1 grade multi-purpose

type (calcium base),
Consistency: 320 or
Grease Chassis
type (lithium base), 216217
Consistency: 315
13-35
SERVICE DATA
(8) Lubricate mast support.

Service hours
Lubricate the mast support.

Check for smooth mast movement by tilting the
mast forward and backward. If any binding or
abnormal noise is observed, lubricate the mast
support again.
216218

Consistency: 320 or
Grease Chassis
type (lithium base),
Consistency: 315
(9) Lubricate tilt socket pins.

Service hours
Check the socket pins for movement, and if any

binding or abnormal noise is observed, lubricate
the socket pins again.
Note: In corrosive or abrasive environments, clean,
lubricate, or change the pins more frequently.
216219
Consistency: 320 or
Grease Chassis
type (lithium base),
Consistency: 315
(10)Change lift chains.

Lift chains
Replace lift chains with new ones.
If elongation exceeds the specified limit, replace
the chains with new ones.
Check the chains for breakage, damage, cracks,
or distortion.
216217
Note: Refer to Chapter 12, 6.3, 14.3 or 22.3 Checking
Chain Elongation for details.
13-36
SERVICE DATA
2.11 Steering and Axle System

(1) Check front axle.

Front axle support bolt
Check the front axle for damage, cracks, oil leaks,

loosening mounting bolts, chips, and rust.
Unit: N·m (kgf·m) [lbf·ft]
377.6 ± 37.8
Front axle support
(38.5 ± 3.9)
bolt Filler plug
[278.7 ± 27.9]
127.5 ± 9.8 Drain plug
Filler plug (13.0 ± 1.0) 216220
[94.1 ± 7.2]
83.4 ± 7.8
Drain plug (8.5 ± 0.8)
[61.5 ± 5.8]
(2) Check power steering cylinder.
Check the power steering cylinder for damage,

cracks, oil leaks, loosening mounting bolts, chips,
and rust. Check the boot for deterioration, cracks
or damage. Also check the rod for bend or rust.
216221
(3) Check rear axle.
Check rear axle for damage, cracks, oil leaks,

loosening mounting bolts, chips, and rust.
216222
13-37
SERVICE DATA
(4) Check steering gear box.
Check the steering gear box for damage, cracks,

oil leaks, loose mounting bolts, chips, binding, and
abnormal noise.
216223
(5) Check steering wheel.
Turn the steering wheel to the right and left, and

check that the steering wheel rotates smoothly.
216224
(6) Lubricate mounting bush of rear axle.

Clearance Clearance
(0.8 mm [0.3 in.] or less) (0.8 mm [0.3 in.] or less)
Rear axle center Filled with grease
Lubricate the front and back mounting bushings.
Filled with grease

Shim adjustment
Grease nipple
Rear axle mounting bolt

tightening torque:
247.4 to 334.8 N·m
(25.3 to 34.1 kgf·m)
[182.5 to 246.9 lbf·ft]
216225
(7) Lubricate king pins.

Service hours
Lubricate the right and left king pins. (4 places)
216127
13-38
SERVICE DATA
(8) Lubricate tie rod pins.

Service hours
Lubricate the right and left tie rods.
216226
(9) Change power steering cylinder hoses and rubber

parts.
Service hours Change in every 2 years
Replace the power steering hydraulic hose with a

new one.
Replace rubber parts such as seals and packings
with new ones when the steering valve or steering
cylinder is disassembled.
216221
13-39
SERVICE DATA
2.12 T/M and Drive System

(1) Check accelerator pedal.
Without starting the engine, check the accelerator

pedal for movement.
Check that the accelerator pedal moves smoothly.
216227
(2) Check differential oil.

Service hours
Check the front axle inspection port for the differ-

ential oil level.
Visually check oil for color or contaminations (such
as metal powder).
216228
(3) Check inching pedal. (Powershift model)
Check that the brake is applied and the clutch is

completely disengaged when the inching pedal is
gradually pressed. (Check clutch oil pressure or
inching rod protrusion for clutch disengagement.)
Note: Refer to Chapter 6, Powershift Transmission,
8.2 Brake (Inching) Pedal, Adjustment and 8.3
Inching Cable, Adjustment.
216229
13-40
SERVICE DATA
(4) Check T/M gear and bearing.
(a) Raise the front wheels so that they spin in the

air. Then run the engine to check for transmis-
sion revolution sound.
(b) Shift the direction lever from the forward to
backward position, and from the 1st to 2nd
gear position, and check that the gears and
bearings do not generate any abnormal noise. 216302
(5) Check T/M oil.

Oil level gauge
(a) Measure oil level with the oil level gauge.

(b) Warm up the engine with the powershift trans-
mission. Stop the engine after it becomes
warm, and measure the oil level within 15 min-
utes.
8.1 Oil Pressure Measurement. 216230
Powershift
Dexron II
transmission oil
(6) Clean last chance filter (T/M control valve).
Remove and clean the strainer.
Strainer
216231
13-41
SERVICE DATA
(7) Clean T/M strainer.
Remove the drain plug, and drain the oil. Pull out
the oil strainer assembly, and clean the strainer.
If clogging is found, replace the strainer with a new
Drain plug
one.
Note: Refer to Chapter 6, Powershift Transmission, 4
Powershift Transmission, Disassembly, 5.12.3
Oil strainer
Oil Strainer Assembly, Installation and 8.1 Oil 216235
Pressure Measurement.
Powershift
Dexron II
transmission oil
(8) Adjust inching pedal (for powershift T/M).
Properly adjust the brake pedal height and free

play.
Properly adjust the height of inching pedal.
Properly adjust the clearance between inching and
brake link mechanism.
Inching cable should be adjusted on the T/M side.
216229
8.2 Brake (Inching) Pedal, Adjustment and 8.3
Inching Cable, Adjustment.
(9) Change clutch master cylinder hoses and rubber

Vinyl tube Brake fluid
parts.
Bleeder valve
Replace the master cylinder hose and the rubber

parts inside the cylinder with new ones.
Bleed air from the cylinder after reassembly.
Lines Bleeding. Transparent
container 216232
13-42
SERVICE DATA
(10)Change clutch release cylinder hoses and rubber

parts.
Piston
Boot Body
Replace the release cylinder hoses and the rubber

parts inside the cylinder with new ones.
Push rod complete
216233
(11)Change differential oil.
Remove the drain plug, and drain the oil.

Fill oil from the filler hole to the filler hole level.
Differential oil GL-4 or GL-5
216234
(12)Change T/M oil.
Loosen the drain plug to drain the oil.

Clean the oil strainer and the last chance filter. See
(8) and (9).
Drain plug
Fill oil to the specified level from the filler hole.
Note: Refer to Chapter 6, Powershift Transmission, 4
Powershift Transmission, Disassembly, 5.12.3 Oil strainer
216235
Oil Strainer Assembly, Installation and 8.1 Oil
Pressure Measurement.
Powershift
Dexron II
transmission oil
13-43
SERVICE DATA
2.13 Wheels and Tires

(1) Check tire and rims.
Service hours Prestart (Daily/10 hrs) Limit: 5 mm

(0.20 in.)
Check the tires for damage or nails.
Check the rims for deformation or damage.
Check that the depths of tire grooves are 5 mm
(0.20 in.) or more.
216236
(2) Check wheel and nuts.
Tighten the wheel nuts to the specified torque.
216237
(3) Check knuckles.

Front of lift truck
Turn the steering wheel to the extreme right and

left to check for smooth steering.
216238
13-44
SERVICE DATA
2.14 General

Check for oil, fuel and coolant leaks. (Walk around)
Check for oil and coolant leaks around the lift truck.
216239
13-45
SERVICE DATA
3. Tightening Torque for Standard Bolts and Nuts

With spring washer
Nominal
Pitch
size
213982 213983 213984
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 192.2 19.5 141.8
16 0.63 1.5 0.06 157.9 16.1 116.5 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.6 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 305.2 537.4 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
With spring washer

Metric
fine Nominal
thread Pitch
size
213982 213983 213984
6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 39.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1216.0 123.9 896.9 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3
Remarks: 1. The tolerance on the torque is ± 10%

2. The torque is for “dry” condition.
13-46
SERVICE DATA
With spring washer
Nominal
Pitch
size
213982 213983 213984
10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.1 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 725.9 74.0 535.2
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 16.5 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
With spring washer

Metric
coarse Nominal
thread Pitch
size
213982 213983 213984
10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1008.2 113.0 817.3 1588.7 162.0 1771.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4
Remarks: 1. The tolerance on the torque is ± 10%

2. The torque is for “dry” condition.
13-47
SERVICE DATA
4. Periodic Replacement Parts

The parts listed below are important for the safe operation of the truck, and are specially designated as the parts to
be replaced at specified periods. Each service shop is requested to adhere to the replacement schedule given here
on all trucks brought into its care:
Period
Periodic replacement parts Service 1 month Every 1 Every 3 Every 6 Every 12 Every 18 Every 24
after month months months months months month
delivery (200 hrs) (500 hrs) (1000 hrs) (2000 hrs) (3000 hrs) (4000 hrs)
*Rubber parts for
1 Replace ٤ ٤
brake master cylinder
*Rubber parts for
2 Replace ٤ ٤
brake wheel cylinder
3 *LPG repair kit Replace ٤ ٤
4 *High pressure hoses Replace ٤ ٤
*Rubber parts for
5 Replace ٤
power cylinder
*Hoses for power
6 Replace ٤
steering
7 *Lift chains Replace ٤
8 *Fuel hoses Replace ٤
Engine oil filter ele-
9 Replace ٤ ٤ ٤ ٤ ٤
ment
Fuel filter element
10 Replace ٤ ٤ ٤ ٤
(Diesel)
Hydraulic tank return
11 Replace ٤ ٤ ٤ ٤
filter
Clean ٤ ٤
12 Air cleaner element
Replace ٤ ٤ ٤
13 Engine coolant Replace ٤ ٤
14 LPG fuel filter Replace ٤ ٤
15 Spark plug Replace ٤
Note: *( * )indicates important safety-related parts.
13-48
SERVICE DATA
4.1 Location of Periodic Replacement Parts
4
4
1 6
5 2
213994
13-49
SERVICE DATA
5. Lubrication Instructions
5.1 Lubrication Chart
Mast strips roller surfaces MPG

EO Lift chain
MPG Tilt sockets
GO GO Transfer and
Universal joints differential oil
(front and rear) MPG
Brake fluid BF MPG Mast supports
reservoir
Transmission oil ATF
GO
HO Hydraulic oil
EO Engine oil
MPG Tie rod pin
MPG King pins
MPG Mounting bush of rear

axle (front and rear)
Every 200 hours or 1 months

ATF : Torque converter oil
MPG : Multi-purpose grease
GO : Gear oil
EO : Engine oil
BF : Brake fluid
HO : Hydraulic oil 213995
13-50
SERVICE DATA
5.2 Fuel and Lubricant Specifications

Recommendation for ambient temperature °C(°F)
Fuel or oil Recommendation -30 -20 -10 0 10 20 30

(-22) (-4) (14) (32) (50) (68) (86)
Fuel Consult your local lift truck dealer

Gasoline models API service classification SJ, min. SAE10W-30
Engine oil
Diesel models API service classification CF, min. SAE10W-30
API service classification
Transfer and differential oil SAE80W SAE90
multipurpose type GL-4 or GL-5
Powershift transmission oil Dexron II Consult your local lift truck dealer
Powershift,
Hydraulic oil ISO VG32
dry clutch
Brake fluid F. M. V. S. S. No. 116-DOT3 or DOT4 (SAE J1703)
Wheel bearing NLGI No.2 grade multipurpose type (lithium base), consistency: 265 - 295
Grease
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
Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and dete-
riorate when mixed. It is best to stick with the same brand at successive intervals.
13-51
SERVICE DATA
5.3 Adjustment Value and Oil Quantities

Note: The values in the following table are based on the standard model.
Unit: mm (in.)
Truck model
Items DP15N GP15N GP20CN DP20CN DP20N GP20N
DP18N GP18N DP25N GP25N
Alternator drive belt deflection-when pushed 10 to 12 11 to 13
11 to 13 10 to 12
inward with 98 N (10kgf) pressure (0.39 to (0.43 to
(0.43 to 0.51) (0.39 to 0.47)
0.47) 0.51)
Type — FR2A-D — — FR2A-D
Spark plug
Gap — 0.9 (0.04) — — 0.9 (0.04)
Engine idling speed rpm 750 700 750 700
Steering wheel free play-when measured at rim
15 to 30 (0.59 to 1.18)
with engine idling
Inching pedal free play 2.5 to 7.5 (0.10 to 0.30)
Brake pedal free play Powershift truck 7 (0.28)
Parking brake lever operating 150 to 200 200 to 250
effort (15.30 to 20.39) (20.39 to 25.49)
N (kgf)[lbf] [33.72 to 44.96] [44.96 to 56.20]
Front single 6.50-10-10PR(I) 6.50-10/5.00 7.00-12-12PR(I)
Tire size Front dual 4.50-12-8PR(I) — — 5.50-15-8PR(I)
Rear 5.00-8-8PR(I) 5.00-8/3.00 6.00-9-10PR(I)
Front single 700 (7.0) [6.9]
Tire pressure,
kPa (kgf/cm2) [BAR] Front dual 700 (7.0) [6.9]
(Pneumatic)
Rear 700 (7,0) [6.9]
156.9 ±
15.7(16.0
Tightening torque for Front 157 (16.0)[115.9] ± 378(38.5)[279.0]
wheel nuts, 1.6)[115.8
N·m (kgf·m)[lbf·ft] ± 11.6]
Rear 157 (16.0)[115.9]
Lift chain elongation limit mm / 20 links 327 (12.87) 392 (15.43)
Approx.46 Approx.46 Approx.66
Fuel tank — — —
liter (cu.in.) (2807.09) (2807.09) (4027.56)
Engine cooling system-0.65 liter
6.8 7.4 6.8 8.7 7.4
reserve tank included
Refill capacities (approximate), liter
(414.96) (451.58) (414.96) (530.91) (451.58)

liter (cu.in.)
7.5 3.5 7.5 9.0 3.5
Engine
(457.68) (213.58) (457.68) (549.21) (213.58)
Engine oil
1.0 0.3 0.3
Oil filter 1.0 (61.02)
(61.02) (18.31) (18.31)
8.5 8.5 10.0 3.8
Total 3.8 (213.89)
liter (cu.in.) (518.70) (518.70) (610.24) (231.89)
Powershift Truck
Transmission oil Approx.10.0(610.24)
liter (cu.in.)
Transfer and differential gear oil
5.5 (335.63)
liter (cu.in.)
Hydraulic oil liter (cu.in.) 28 (1708.66)
Brake fluid reservoir cc 135
Battery electrolyte specific gravity, corrected to
1.26 to 1.28
20°C (68°F)
13-52
SERVICE DATA
Unit: mm (in.)
Truck model
Items
GP30N DP30N GP35N DP35N
Alternator drive belt deflection-when pushed inward 11 to 13 10 to 12 11 to 13 10 to 12
with 98 N (10kgf) pressure (0.43 to 0.51) (0.39 to 0.47) (0.43 to 0.51) (0.39 to 0.47)
Type FR2A-D — FR2A-D —
Spark plug
Gap 0.9 (0.04) — 0.9 (0.04) —
Engine idling speed rpm 700 750 700 750
Steering wheel free play-when measured at rim with
15 to 30 (0.59 to 1.18)
engine idling
Inching pedal free play 2.5 to 7.5 (0.10 to 0.30)
Brake pedal free play Powershift truck 7 (0.28)
Parking brake lever operating effort N (kgf)[lbf] 230 to 250 (23.45 to 25.49) [51.71 to 56.20]
Front single 28 × 9-15-12PR(l) 250-15-16PR
Tire size Front dual 6.00-15-10PR(l)
Rear 6.50-10-10PR(l) 6.50-10-12PR(l)
Front single 700 (7.0)[6.9] 850 (8.5) [8.3]
Tire pressure, kPa (kgf/cm2)
Front dual 700 (7.0)[6.9]
[BAR] (Pneumatic)
Rear 700 (7.0)[6.9] 900 (9.0) [8.8]
Tightening torque for wheel Front 378 (38.5)[279.0]
nuts, N·m (kgf·m) Rear 157 (16.0) [115.9] 233 (23.8)[172.0]
Lift chain elongation limit mm / 20 links 523 (20.59)
Approx. 66 Approx. 66
Fuel tank — —
liter (cu.in.) (4027.56) (4027.56)
Engine cooling system-0.65 liter reserve
7.4 8.7 7.4 8.7
Refill capacities (approximate), liter
tank included
(451.58) (530.91) (451.58) (530.91)
liter (cu.in.)
3.5 9.0 3.5 9.0
Engine
Engine oil (213.58) (549.21) (213.58) (549.21)
Oil filter 0.3 (18.31) 1.0 (61.02) 0.3 (18.31) 1.0 (61.02)
10.0 3.8 10.0
Total 3.8 (231.89)
liter (cu.in.) (610.24) (213.89) (610.24)
Powershift Truck
Transmission oil Approx.10.0 (610.24)
liter (cu.in.)
Transfer and differential gear oil
8.7 (530.91)
liter (cu.in.)
Hydraulic oil liter (cu.in.) 39 (2379.92)
Brake fluid reservoir cc 135
Battery electrolyte specific gravity, corrected to 20°C
1.26 to 1.28
(68°F)
13-53
SERVICE DATA
6. Special Service Tools

6.1 Special Service Tools (Standard Tools for Both MC and FC Trucks)
Truck model
Ref
Part number Part name Used for 1 ton 2 ton 3 ton
No.
class class class
1 91268-01900 Bolt Replacement of clutch pressure plate ٤ ٤ ٤
(To be used with washer and nut)
92301-02700 Washer ٤ ٤ ٤
F2300-10000 Nut ٤ ٤ ٤
2 F1145-10050 Bolt Replacement of clutch disc ٤ ٤ ٤

(To be used with washer)
92301-02700 Washer ٤ ٤ ٤
Adjustment of release lever ٤ ٤ ٤

3 91268-02200 Clutch gauge
clearance
Removal of pump body (FC) and

4 91268-05100 Bolt ٤ ٤ ٤
shifter case (MC)
Measurement of transmission
5 64309-17701 Gauge kit ٤ ٤ ٤
hydraulic pressure
Measurement of hydraulic pressure

6 91268-04400 Connector (FC) (To be used with 64309-17701 ٤ ٤ ٤
Gauge kit)
Removal and installation of front

7 91268-00800 Socket wrench ٤ - -
wheel hub nut
Removal and installation of front

8 03703-59001 Socket wrench - ٤ ٤
wheel hub nut
9 64309-40100 Bevel pinion puller Removal of front wheel hub ٤ - -

64309-10601 Puller seat Removal of front wheel hub ٤ - -
MH061017 Wheel hub puller Removal of front wheel hub - ٤ ٤
10 91A67-00300 Installer Installation of oil seal (inner) ٤ ٤ ٤
11 91B68-00900 Installer Installation of oil seal (outer) ٤ - -
12 91E68-00700 Installer Installation of oil seal (outer) - ٤ ٤
Installation of tapered roller bearings

13 91B68-01100 Installer ٤ - -
(outer)

14 91E68-00900 Installer - ٤ ٤
(inner)

15 91E68-00800 Installer - ٤ ٤
(inner, outer)
13-54
SERVICE DATA
Truck type
Ref
Part number Name Application 1 ton 2 ton 3 ton
No.
class class class
16 64309-15411 Spring remover Removal of return spring ٤ ٤ ٤
Removal and installation of brake ٤ ٤

17 64309-15412 Spring retainer ٤
shoe
18 64309-15413 Spring hook Installation of return spring

(Tools No. 16, 17 and 18 are included ٤ ٤ ٤
in 64309-15400 Tool set)
19 91268-10600 Steering wheel puller Removal of steering wheel ٤ ٤ ٤
13-55
SERVICE DATA
0m .)
Ǿ .6in
m
1

Ǿ
4
M10×1.5
.1 in.)
m m(4
105
1 213999 5 214011
0m .)
m
Ǿ41.6in

Ǿ
M10×1.5 G(PF)3/8 M14×1.5
.)
2. 0in
m m(
50
2 214000 6 214012
Ǿ8
6m
mm .) m(
120mm(4.7in.) 70 .8 in 3.4
(1. .5mm
(2 19 in.
(0. mm )
.)
0in
7i
n.)
26
20 in.)
(0.
(0. mm
.)
mm
8
1in
3.2
30mm Ǿ8 23 mm
4m (0.9 in.)
(1.2in.) m(
3.3
in.)
3 214002 7 214013
M8×1.25
C1.5 90mm (3.5in.)
55mm(2.2in.)
4 214003 8
214014
13-56
SERVICE DATA
12mm
(0.5in.)
M16×1.5
99.5mm(3.9in.)
m
0m
18 1in.)
(7.
Ǿ14mm

Ǿ0.6in.) 150mm(5.9in.)
9 214015 13 214867
36mm(1.4in.) 12mm
15mm(0.6in.) (0.5in.)
14mm(0.6in.)
123mm(4.8in.)
119.5mm(3.9in.)
160mm(6.3in.)
73mm(2.9in.)
150mm(5.9in.) 150mm(5.9in.)
10 214864 14 214868
19mm 12mm
(0.5in.)
(0.7in.)
12mm
(0.5in.)
129mm(5.1in.)
81.5mm(3.2in.)
58mm(2.2in.)
180mm(7.1in.)
150mm(5.9in.)
11 214865 15 214869
20mm
(0.8in.)
13mm
(0.5in.)
94.5mm(3.7in.)
68mm(2.7in.)
180mm(7.0in.)
12 214866 16 214030
13-57
SERVICE DATA
17 214031
18 214032
M12×1.25
M8×1.25
30
55 (1. mm
mm 2in
.)
(2.
2in
.)
19 214033
13-58
SERVICE DATA
6.2 Special Service Tools (for FC Truck Only)

Truck model
Ref
Part number Part name Used for 1 ton 2 ton 3 ton
No.
class class class
1 91105-00400 Emergency harness For actuating control valve in an emer-
gency ٤ ٤ ٤
(Connection of control valve to battery)
2 91105-00500 Inspection connector Male ٤ ٤ ٤
2P-M
3 91105-00600 Inspection connector Female ٤ ٤ ٤
2P-F
3P-M
3P-F
6P-M
6P-F
2P-M
2P-F
3P-M
3P-F
6P-M
6P-F
8P-M
8P-F
12P-M
12P-F
7P-M
7P-F
64P-FM
13-59
SERVICE DATA
1 214042
4 214043
Note: There are a total of 19 types of the inspection

connectors 2 thru 20. They are supplied as a
set or individually. The connector 4 is shown.
13-60
SERVICE DATA
6.3 Special Service Tools (for Powershift Transmission)

Truck type
Ref.
No.
class class class
1 67281-05100 Bolt Removal of oil pump ٤ ٤ ٤
Removal of Idler gear bearing outer race
2 91268-04100 Installer Removal of angular bearing ٤ ٤ ٤

Installation of Input spacer
Installation of bearing
3 91268-05500 Installer Installation of output gear oil seal ٤ ٤ ٤
4 91A68-00010 Clutch pack stand kit Disassembly and reassembly of clutch

pack ٤ ٤ ٤
5 91A68-00020 Stand kit Transmission assembly fixed base ٤ ٤ ٤
6 91A68-01300 Stand Idler shaft assembly fixed base ٤ ٤ ٤

Output gear fixed base
Input shaft assembly fixed base
7 91A68-01400 Plate 1 Compress of clutch spring ٤ ٤ ٤
8 91A68-01500 Plate 2 Compress of clutch spring ٤ ٤ ٤
9 91A68-01700 Installer Installation of bushing ٤ ٤ ٤
10 91A68-01800 Stand Forward gear assembly fixed base ٤ ٤ ٤

Reverse gear assembly fixed base
Oil pump assembly fixed base
11 91A68-01800 Puller Removal of input spacer & bearing ٤ ٤ ٤

Removal of forward gear assembly
Removal of reverse gear assembly
12 91A68-01900 Remover Removal of bearing ٤ ٤ ٤

Removal of input spacer & bearing
Removal of forward gear assembly
Removal of reverse gear assembly
13 91A68-02100 Stand Idler shaft assembly fixed base ٤ ٤ ٤
14 91A68-02200 Installer Installation of outer race ٤ ٤ ٤
13-61
SERVICE DATA
Truck type
Ref.
No.
class class class
15 91A68-02300 Installer & Remover Installation of outer race
Installation of bearing of transmission ٤ ٤ ٤
side
16 91A68-02701 Stand Removal of spring pin ٤ ٤ ٤

Removal of spring pin
17 91A68-02800 Installer Installation of oil seal ٤ ٤ ٤
18 91A68-03100 Installer Installation of snap ring ٤ ٤ ٤
19 91A68-03500 Stand Installation of transmission ٤ ٤ ٤
13-62
SERVICE DATA
)
in.
( 3.1
m )
202mm(8.0in.)
.5m in. 12mm
77 (2.2 (0.5in.)
mm
55
13.9mm
(0.5in.)
n.)
43 .7i
5m
m (18
M8×1.25 m(
17 5m
.1i 47
1 215232 5 n.) 215215
) )
in. .9 in.
8
m (9. m (12 Ǿ150mm
0m 32
8m
25 (5.9in.)
Ǿ3
9m
m(
1.5
in.
2 215212 6 215216
)
Unit: mm (in.)
)
89
5 (6. mm
17 31) Φ30(1.18) 25 0in.)
(0.
5 (1.
1 3.5 Ǿ138.5mm
(5.5in.)
Φ45
Φ78 (1.77)
(3.07)
3 215213 7 215217
)
in. m
.9 Ǿ150 mm 9m in.)
(12 . 4
8 mm (5.9 in.) ( 0
32
Ǿ124mm(4.9in.)
4 8
215214 215218
13-63
SERVICE DATA
n.)
0. 7i
m( Ǿ30 mm
0m ) (1.2 in.) Ǿ152mm(6.0in.)
18 in.
( 0.8
mm
20
20mm(0.8in.)
Ǿ 1.7in
42 .)
(
Ǿ60 mm 50
mm
mm
(2.4 in.) (2.

0in
9 215219 13 .)
215223
n.) in.
)
3. 9i 56
m( (2.
0m Ǿ101.6 mm mm
10 (4.0 in.) 65 mm .)
10 39in
(0. Φ80 mm
(3.15 in.)
Ǿ120 mm
(4.7 in.)
Φ71 mm
(2.80 in.)
10 215220 14 215224
28 mm
n.)
(1.10 in.) 3 0i
(6. Φ30 mm
m
0m (1.18 in.)
16
) mm .)
in. 10 39 in
5 (0.
(1 0.5
m
9m
26
21 mm
(0.83 in.) Φ71 mm
(2.80 in.)
11 215221 15 215225
Ǿ3
.)
6. 9in
0m
m(
5m
m(
17 in.)
1.2
6
(0. 22 mm
in.
mm (0.87 in.)
15
)
Ǿ
40
(1. mm
41 in.)
Ǿ 4(1.8i
57
(1.
mm )
.5m
in.
16 3 in.
5.5 n.)
)
6
6
(0.
mm
12 215222 16
215226
13-64
SERVICE DATA
.) Ǿ19mm
3. 5in (0.7in.)
m m(
90 .)
4in
m (0.
m
10
Ǿ8mm
(0.3in.)
17 215228
)
in.
39
(3. n.) Φ30 mm
m m
2 4i
86 (0. (1.18 in.)
m
6m
7
(0. mm
28
in.
)
18 215230
177 mm
(7.0 in.)
45 )
0m in.
.7
m(
17 m (19
.7
in. 0m
19 ) 50
215227
13-65
Cat Lift Trucks Service Manual GP15N-35N, DP15N-35N 99719-6M100
Mitsubishi Caterpillar Forklift Europe B.V.
Hefbrugweg 77 1332 AM
Almere, The Netherlands
Copyright © 2009 by MCFA. All Rights Reserved. CAT, CATERPILLAR, their

respective logos and “Caterpillar Yellow,” as well as corporate and product Printed in
identity used herein, are trademarks of Caterpillar and may not be used without The Netherlands
99719-6M100 permission. All registered trademarks are the property of their respective owners. 05/09

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Chapter 13 SERVICE DATA

1. Maintenance Schedule ......................................................................... 13-1

Chapter 13 SERVICE DATA

Every 12 months (2000 hours)

Every 3 months (500 hours)

1st month (200 hrs) only

Others (see Note 1)

Brake drum nuts & bolts X

2 ton: 200 to 250 N

Every 12 months (2000 hours)

Every 3 months (500 hours)

1st month (200 hrs) only

Others (see Note 1)

Loosen bolts & nuts Wrench X X

Every12 months (2000 hours)

Every3 months (500 hours)

1st month (200 hrs) only

Others (see Note 1)

(for LP engines with

Hydraulic tank strainer Visual C

Spark plug gap Plug gauge X X

Air cleaner element

Air cleaner element

Every12 months (2000 hours)

Every3 months (500 hours)

1st month (200 hrs) only

Others (see Note 1)

Lift chains Operation/Visual X

Mast strip sliding surfaces Visual X

Every 12 months (2000 hours)

Every3 months (500 hours)

1st month (200 hrs) only

Others (see Note 1)

Clutch master cylinder

Wheel & nuts Torque wrench X

Oil, fuel & coolant leak Walk around X

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

Note 1: *: Change Every 1 to 2 years

Be sure to conduct maintenance work on level and hard ground.

(1) Check brake drum bolts.

Brake mounting bolts

Check the threads for damage or burrs.

(2) Check brake drum and shoes.

Service Hours Every 3 months (500 hrs)

Check the drum inner surface for uneven wear or

Note: Refer to Chapter 9, Brake System, 2.2 Wheel

(3) Check brake hose, pipes and joints.

(4) Check brake pedal.

Service Hours Prestart (Daily/10 hrs)

Visually check the brake pedal for deformation or A

Note: Refer to Chapter 9, Brake System, 3.4 Brake

(5) Check parking brake lever.

Service Hours Prestart (Daily/10 hrs)

(6) Check service brake fluid level.

Service Hours Prestart (Daily/10 hrs)

Check that the brake fluid level is within the range

marks on the reserve tank.

(7) Lubricate brake and clutch/inching pedal rods.

Service Hours Every 6 months (1000 hrs) Greasing

(8) Change brake master cylinder hoses and rubber

Service Hours Yearly (2000 hrs)

Note: Refer to Chapter 9, Brake System, 2.1 Master

(9) Change service brake fluid.