Document Página 1 de 515
Service Manual
Chassis & Mast
MC/FC
2P3000 AT34-30121-49999
2P3500 AT34-30121-49999
2PC4000 AT34-80121-99999
2P4000 AT35-30121-49999
2P5000 AT35-30121-49999
2P5500 AT36-30121-49999
2P6000 AT13F-30121-49999
2P6500 AT13F-80121-99999
2P7000 AT13F-80121-99999
2PD4000 AT18C-30121-49999
2PD5000 AT18C-30121-49999
2PD5500 AT37-30121-49999
2PD6000 AT14E-30121-49999
2PD6500 AT14E-80121-99999
2PD7000 AT14E-80121-99999
GP15NM AT34-T0100-T9999
GP18NM AT34-W0100-W9999
GP20CNM AT34-P0100-P9999
GP20NM AT17D-P0100-P9999
GP25NM AT17D-T0100-T9999
GP25NM-HP AT35-T0100-T9999
GP30NM AT13F-P0100-P9999
GP35NM AT13F-T0100-T9999
For use with S4S and K21 / K25 Engine Service Manuals.
99719-8M110
FOREWORD
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
,Document Página 2 de 515
This service manual is a guide for servicing Cat Lift Trucks. For your convenience the instructions are grouped by systems
as an easy reference.
The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what you
will learn by reading this service manual.
Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting
to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks with serial numbers in effect at the
time of printing.
Cat Lift Trucks reserves the right to change specifications or designs without notice and without incurring obligations.
The trucks listed in this manual are powered by K21, K25, K21E or K25E gasoline engines or S4S diesel engines.
For engine servicing, please refer to the applicable engine service manual.
K21, K25, K21E or K25E Gasoline engine
S4S Diesel engine
Table 1.
<Safety Related Signs>
WARNING
Indicates a potentially hazardous situation which, it not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or damage to
your machine.
NOTE: Indicates a condition that can cause damage to, or shorten service life of, the machine.
SAFETY
WARNING
The proper and safe lubrication and maintenance for these lift trucks, recommended by Cat Lift Trucks, are outlined in the
OPERATION & MAINTENANCE MANUAL.
Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance
on these trucks.
Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death.
The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use
caution when performing service work. A knowledge of the system and/or components is important before the removal or
disassembly of any component.
Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this
Manual. Use proper lifting procedures when removing any components.
Following is a list of basic precautions that should always be observed.
1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the
product.
2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective
glasses when using a hammer or sledge on any part of the truck or its attachments with a hammer or sledge. Use
welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being
performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers when working on machinery.
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
,Document Página 3 de 515
3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to
support the truck before performing any disassembly.
4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be
done, make sure the forks or other implements are blocked correctly to prevent them from dropping
unexpectedly.
WARNING
Do not operate these trucks unless you have read and understood the instructions in the OPERATION &
MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.
5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from
steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways.
When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to
perform safe repair operations.
6. To avoid back injury, use a hoist when lifting components which weigh 23 kg or more. Make sure all chains,
hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly.
Lifting eyes are not to be side loaded during a lifting operation.
7. To avoid burns, be alert of the hot sections and hot fluids in lines, tubes and compartments, even when idle or off.
8. Be careful when removing cover plates. Gradually remove the last two bolts or nuts located at opposite ends of
the cover or device and pry cover loose to relieve any springs or other pressures, before removing the last two
bolts or nuts completely.
9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent
being sprayed or splashed by liquids under pressure. Be aware that the danger of being sprayed or splashed is
even greater if the truck has just been stopped because fluids can be hot.
10. Always use tools that are in good condition and be sure you understand how to use them before performing any
service work.
11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary.
12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while
working on or under truck.
13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang "Do not
Operate" tag in the Operator's Compartment.
14. Repairs, which require welding, should be performed only with the appropriate reference information and by
personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal being
welded and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength
equivalent at least to that of parent metal.
15. Do not damage wiring during the removal process. Reinstall the wiring so it is not damaged and ensure it will not
be damaged in operation by contacting sharp corners, or by rubbing against an object or hot surface. Place wiring
away from oil pipe.
16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before
starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.
17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is
performed, which requires the mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses could cause fires. Do not bend or strike
high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do
not check for leaks with your hands. Pin hole (very small) leaks could result in a high velocity oil stream that will
be invisible close to the hose. This oil could penetrate the skin and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed
correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect
against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly.
20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or
removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when
disconnecting any device from a system that utilizes pressure.
21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed
rotating component that has been damaged or altered should be checked for balance before reusing.
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
, Document Página 4 de 515
HOW TO USE THIS MANUAL
This service manual consists of several chapters, which will give you quick references to specifications, maintenance
standards, adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi
diesel engines.
A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a
detailed table of contents at the beginning of each chapter.
Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance
Manual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and
function of the engine are described in the relevant training manuals.
If you have an inquiry, please check the engine model and serial number, and contact our service department.
1. Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also
an indication of the sequence of disassembly.
2. Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
3. Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the
text. They are also collectively indicated in the Chapter 2.
4. The tightening torque with engine oil applied on the thread is specified as [Wet]. Unless otherwise specified, the
tightening torque is of dry condition.
5. In this manual, important safety or other cautionary instructions are emphasized with the following head marks.
DANGER
Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTE: Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.
Terms Used in This Manual
Nominal value
means the basic nominal size of a part to be measured.
Standard value
means the quantitative requirement for dimension of a part, clearance between parts or performance. The values are rounded
off for the inspection job, and do not necessarily conform to the design values.
Limit value
means the value, which the measured value reaches, the part needs repair or replacement with a new one.
Abbreviations and Standards
- BTDC: Before Top Dead Center
- ATDC: After Top Dead Center
- BBDC: Before Bottom Dead Center
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
Service Manual
Chassis & Mast
MC/FC
2P3000 AT34-30121-49999
2P3500 AT34-30121-49999
2PC4000 AT34-80121-99999
2P4000 AT35-30121-49999
2P5000 AT35-30121-49999
2P5500 AT36-30121-49999
2P6000 AT13F-30121-49999
2P6500 AT13F-80121-99999
2P7000 AT13F-80121-99999
2PD4000 AT18C-30121-49999
2PD5000 AT18C-30121-49999
2PD5500 AT37-30121-49999
2PD6000 AT14E-30121-49999
2PD6500 AT14E-80121-99999
2PD7000 AT14E-80121-99999
GP15NM AT34-T0100-T9999
GP18NM AT34-W0100-W9999
GP20CNM AT34-P0100-P9999
GP20NM AT17D-P0100-P9999
GP25NM AT17D-T0100-T9999
GP25NM-HP AT35-T0100-T9999
GP30NM AT13F-P0100-P9999
GP35NM AT13F-T0100-T9999
For use with S4S and K21 / K25 Engine Service Manuals.
99719-8M110
FOREWORD
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
,Document Página 2 de 515
This service manual is a guide for servicing Cat Lift Trucks. For your convenience the instructions are grouped by systems
as an easy reference.
The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what you
will learn by reading this service manual.
Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting
to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks with serial numbers in effect at the
time of printing.
Cat Lift Trucks reserves the right to change specifications or designs without notice and without incurring obligations.
The trucks listed in this manual are powered by K21, K25, K21E or K25E gasoline engines or S4S diesel engines.
For engine servicing, please refer to the applicable engine service manual.
K21, K25, K21E or K25E Gasoline engine
S4S Diesel engine
Table 1.
<Safety Related Signs>
WARNING
Indicates a potentially hazardous situation which, it not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or damage to
your machine.
NOTE: Indicates a condition that can cause damage to, or shorten service life of, the machine.
SAFETY
WARNING
The proper and safe lubrication and maintenance for these lift trucks, recommended by Cat Lift Trucks, are outlined in the
OPERATION & MAINTENANCE MANUAL.
Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance
on these trucks.
Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death.
The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use
caution when performing service work. A knowledge of the system and/or components is important before the removal or
disassembly of any component.
Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this
Manual. Use proper lifting procedures when removing any components.
Following is a list of basic precautions that should always be observed.
1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the
product.
2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective
glasses when using a hammer or sledge on any part of the truck or its attachments with a hammer or sledge. Use
welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being
performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers when working on machinery.
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
,Document Página 3 de 515
3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to
support the truck before performing any disassembly.
4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be
done, make sure the forks or other implements are blocked correctly to prevent them from dropping
unexpectedly.
WARNING
Do not operate these trucks unless you have read and understood the instructions in the OPERATION &
MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.
5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from
steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways.
When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to
perform safe repair operations.
6. To avoid back injury, use a hoist when lifting components which weigh 23 kg or more. Make sure all chains,
hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly.
Lifting eyes are not to be side loaded during a lifting operation.
7. To avoid burns, be alert of the hot sections and hot fluids in lines, tubes and compartments, even when idle or off.
8. Be careful when removing cover plates. Gradually remove the last two bolts or nuts located at opposite ends of
the cover or device and pry cover loose to relieve any springs or other pressures, before removing the last two
bolts or nuts completely.
9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent
being sprayed or splashed by liquids under pressure. Be aware that the danger of being sprayed or splashed is
even greater if the truck has just been stopped because fluids can be hot.
10. Always use tools that are in good condition and be sure you understand how to use them before performing any
service work.
11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary.
12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while
working on or under truck.
13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang "Do not
Operate" tag in the Operator's Compartment.
14. Repairs, which require welding, should be performed only with the appropriate reference information and by
personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal being
welded and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength
equivalent at least to that of parent metal.
15. Do not damage wiring during the removal process. Reinstall the wiring so it is not damaged and ensure it will not
be damaged in operation by contacting sharp corners, or by rubbing against an object or hot surface. Place wiring
away from oil pipe.
16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before
starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.
17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is
performed, which requires the mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses could cause fires. Do not bend or strike
high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do
not check for leaks with your hands. Pin hole (very small) leaks could result in a high velocity oil stream that will
be invisible close to the hose. This oil could penetrate the skin and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed
correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect
against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly.
20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or
removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when
disconnecting any device from a system that utilizes pressure.
21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed
rotating component that has been damaged or altered should be checked for balance before reusing.
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
, Document Página 4 de 515
HOW TO USE THIS MANUAL
This service manual consists of several chapters, which will give you quick references to specifications, maintenance
standards, adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi
diesel engines.
A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a
detailed table of contents at the beginning of each chapter.
Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance
Manual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and
function of the engine are described in the relevant training manuals.
If you have an inquiry, please check the engine model and serial number, and contact our service department.
1. Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also
an indication of the sequence of disassembly.
2. Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
3. Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the
text. They are also collectively indicated in the Chapter 2.
4. The tightening torque with engine oil applied on the thread is specified as [Wet]. Unless otherwise specified, the
tightening torque is of dry condition.
5. In this manual, important safety or other cautionary instructions are emphasized with the following head marks.
DANGER
Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTE: Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.
Terms Used in This Manual
Nominal value
means the basic nominal size of a part to be measured.
Standard value
means the quantitative requirement for dimension of a part, clearance between parts or performance. The values are rounded
off for the inspection job, and do not necessarily conform to the design values.
Limit value
means the value, which the measured value reaches, the part needs repair or replacement with a new one.
Abbreviations and Standards
- BTDC: Before Top Dead Center
- ATDC: After Top Dead Center
- BBDC: Before Bottom Dead Center
http://manuals.cat-lift.com/Service/?contentId=40709&languageId=1 29/11/2016
