Caterpillar cat m80d 3648 volt 7fg00600 service repair manual sn：a1ec4 60001

SENB8470

Service Manual M70, M80, M100, M120 Mast Disassembly & Assembly M70D

A1EC4-60001-79999 A1EC4-80001-99999

M80D

A1EC4-60001-79999 A1EC4-80001-99999

M100D

A1EC4-60001-79999 A1EC5-80001-99999

M120D

A1EC5-60001-79999 A1EC5-80001-99999

FOREWORD

The instructions are grouped by systems to serve the convenience of your ready reference.

Long productive life of your lift trucks depends to a great extent on correct servicing — the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing.

Caterpillar reserves the right to change specifications or design without notice and without incurring obligation.

SAFETY RELATED SIGNS The following safety related signs are used in this service manual to emphasize important and critical instructions: WARNING

Indicates a specific potential hazard resulting in serious bodily injury or death.

CAUTION

Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of the machine.

NOTE

Indicates a condition that can cause damage to, or shorten service life of the machine.

Pub. No. SENB8470

WARNING

SAFETY WARNING

WARNING

The proper and safe lubrication and maintenance for this lift truck, recommended by Mitsubishi, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks.

Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance.

Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.

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.

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 weighs 23 kg (50 lb.) 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 for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments.

8.

Be careful when removing cover plates.

Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, 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 liquid under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot.

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 productive glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding 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.

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.

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 lesser quality fastener if replacements are necessary. Do not mix metric fastener with standard nuts and bolts.

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 benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures.

Determine type of metal being welded and select 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 removal operation. Reinstall the wiring so it is not damaged nor it will be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

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 can 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 can result in a high velocity oil stream that will be invisible close to the hose. This oil can 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, vibrations 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.

HOW TO READ THIS MANUAL Disassembly diagram (example)

2

1 4

Each disassembly diagram is followed

by Disassembly sequence and Suggestions disassembly.

3

▲

1 Cover, Bolt, Washer (part name) 2 Output shaft (part name)

▲

Disassembly sequence

▲

Suggestion for disassembly (1) Output shaft removal Unit: mm (in.)

Clearance between cylinder and piston

A

0.020 to 0.105 (0.00079 to 0.00413)

B

0.15 (0.0059)

A: Assembly standard B: Repair or service limit

Symbols or abbreviations OP..........................Option R1/4 ......................Taper pipe thread (external) 1/4 inch (formerly PT1/4) Rc1/8 ....................Taper pipe thread (internal) 1/8 inch (formerly PT1/8) G1/4A ....................Straight pipe thread (external) 1/4 inch (formerly PF1/4-A) Rp1/8 ....................Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

HYDRAULIC SYSTEM

Specifications Truck Models M70D M80D

M100D M120D

Type

Adjustable

Adjustable

Control flow capacity liter/min (U.S.gal/min)

100 (26.42)

115 (30.38)

Simplex mast

Internal diameter mm (in.)

60 (2.36)

70 (2.75)

Lift cylinders

Stroke

mm (in.)

1650 (65)

1650 (65)

Duplex mast

Internal diameter mm (in.)

90 (3.54)

110 (4.33)

820 (32.28)

845 (33.27)

55 (2.17)

60 (2.36)

1590 (62.60)

1585 (62.40)

90 (3.54)

110 (4.33)

820 (32.28)

845 (33.27)

60 (2.36)

70 (2.75)

1480 (58.27)

1530 (60.24)

Items

Hydraulic system

Flow regulator valve

First lift cylinders Stroke Duplex mast

Internal diameter mm (in.)

Second lift cylinders Stroke Triplex mast

mm (in.)

Internal diameter mm (in.)

First lift cylinders Stroke Triplex mast

mm (in.)

mm (in.)

Internal diameter mm (in.)

Second lift cylinders Stroke

mm (in.)

1-1

HYDRAULIC SYSTEM

Lift Cylinders Simplex Mast Lift Cylinders (G40A)

* * * 6

2

5

7

* *

10 9

11

4

8

1

3 • • •

•

•

•

•

• ••

Parts marked with * are included in the seal kit.

1 2 3 4

Cylinder tube Piston rod Cylinder head Bushing

5 6 7 8

206951

U-ring Wiper ring O-ring U-ring

9 Backup ring 10 Bushing 11 Spacer

Simplex Mast Lift Cylinders (G45A, G55A

*

5

*

6 3 4

*

*

8

13 9 10 11 12

1

2 7

• • •

•

• •

Parts marked with * are included in the seal kit.

1 2 3 4 5

Cylinder tube Piston rod Cylinder head Bushing Holder

6 7 8 9 10

202976

U-ring Wiper ring O-ring Piston ring U-ring assembly

1-2

11 U-ring holder 12 Stopper 13 Spacer

HYDRAULIC SYSTEM

Duplex Mast First Lift Cylinder (H40A)

* 6

3

Triplex Mast First Lift Cylinders (J40A thru J70A)

* * 8

5

*

*

7 13, 14

4

2

• •

•

1

•

•

*

*

9

10

•

11 12

•

• •

Parts marked with * are included in the seal kit.

1 2 3 4 5

Cylinder tube Piston rod Cylinder head Bushing U-ring

6 7 8 9 10

206950

Wiper ring O-ring O-ring Seal ring assembly Slide ring

1-3

11 12 13 14

Check valve Snap ring Plug Gasket

HYDRAULIC SYSTEM Duplex Mast Second Lift Cylinders (H40A)

* * * 8

7

*

6 5

9

4

•

• •

1

3 18 17

•

2

16

14 12 11 10 13 15

•

•

•

•

• • • • •

Parts marked with * are included in the seal kit.

1 2 3 4 5 6

7 8 9 10 11 12

Cylinder tube Piston rod Cylinder head Bushing Holder U-ring

206949

Backup ring Wiper ring O-ring Piston Slide ring Set screw

13 14 15 16 17 18

Check valve Cushion spool Spring Snap ring Steel ball Set screw

Triplex Mast Second Lift Cylinders (J40A)

* 6

* 5

3

* 7

4

2

1

16

11

12 10

* * 9

Parts marked with * are included in the seal kit.

1 2 3 4 5 6

Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring

7 8 9 10 11 12

8

15 14

13

207778A

O-ring U-ring Backup ring Bushing Spring guide Spring 1-4

13 14 15 16

Cushion spool Pin Snap ring Spacer

HYDRAULIC SYSTEM Triplex Mast Second Lift Cylinders (J45A, J55A)

7

6

5

4

3

8

2

1

17 13

14

9

10 11 12 16

15

Parts marked with * are included in the seal kit.

1 2 3 4 5

Cylinder tube Piston rod Cylinder head Bushing Holder

6 7 8 9 10

207779A

U-ring Wiper ring O-ring Piston ring U-ring assembly

1-5

11 12 13 14 15 16 17

Holder Stopper Spring guide Spring Cushion rod Spring pin Spacer

HYDRAULIC SYSTEM

Flow Regulator Valve M80D thru M120D 6

3

4

•

•

5

2

1

•

•

202978

1 Set bolt, Lock nut 2 Sleeve, O-ring 3 Piston, Spring pin, Washer spring, Valve

1-6

4 Spring 5 Spring guide, O-ring 6 Valve body

HYDRAULIC SYSTEM

Down Safety Valve

3

1

4

2

Cut-off flow rate Stamped number

Regulated flow

Free flow

204626

1 Connector 2 Valve

3 Spring 4 Spring pin

The down safety valve is located at the bottom side of right-hand lift cylinder.

This valve provides a means of preventing the load from lowering, unsafely, rapidly, when a hose bursts.

Mast model

Cut-off flow rate Simplex

G40A

G45A, G55A

WARNING

Duplex

H40A

—

Triplex

J40A

J45A, J55A

Do not reuse down safety valve after a lift line hose failure.

Cut-off flow rate liter (U.S.gal)/min

90

–0 –15

(23.8 –0 –4 )

120 +5 0 –10 (31.7 +1.3 –2.6 )

1-7

HYDRAULIC SYSTEM

Lift Cylinders Dual-stage Panoramic Mast (Simplex Mast)

6 7 8

5

3 8

1

4

2

Sequence 1 Nuts 2 Fork, Lift bracket 3 Return (low-pressure) hose

207784

4 Hose guard 5 High-pressure hose 6 Set bolt, Shims

7 Cylinder clamp, Cushion, Collar, Shims 8 Lift cylinder, Bracket

Suggestions 1. Lift bracket removal (1) Tilt the mast forward, and lower the inner mast to the bottom. Slacken the lift chains, and remove the nuts from the anchor bolts.

(2) Tilt the mast back to vertical position. Raise the inner mast until the lift bracket becomes free. Then, back the truck away from the lift bracket and fork assembly.

204873A

1-8

HYDRAULIC SYSTEM

2. Removing return hose Lift the mast to the maximum lift position, and turn the key switch off. Disconnect the return hose from the right and left lift cylinders at the connectors.

To hydraulic tank

206965

3. Disconnecting high-pressure hoses Slowly push the lift lever forward to lower the lift bracket to the ground. Disconnect the highpressure hoses at the joints indicated by arrows. Use a container to catch oil flowing out of the hoses.

Right cylinder

Left cylinder

206691

4. Removing set bolts (1) Remove the set bolt at the top of each lift cylinder. Lift the inner mast to separate the cylinder rod ends. To lift the inner mast, hitch a sling around the mast with protective rag.

NOTE The rod end of either lift cylinder is shim adjusted to eliminate the difference in stroke between the cylinders. Before removing the set bolts, make a record of the amount of shims and cylinders to which the shims are fitted.

206967

(2) Tie wood blocks under the inner mast and detach the sling. Make sure the right and left wood blocks are the same in height.

202983

1-9

HYDRAULIC SYSTEM

5. Removing lift cylinders Hitch a sling to the lift cylinder from the rear side of the mast, and remove the cylinder.

Hitch the sling before removing the cylinder clamp.

206968

Installation To install, follow the reverse of removal sequence, and do the following steps once completed: 1. Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly.

2. Check the oil level in the hydraulic tank with an oil level gauge. (Make reference to Hydraulic Tank section.)

3. Check to make sure that the lift height is correct.

4. After the lift cylinders or piston rods have been replaced, check for difference in stroke between the two cylinders. (Make reference to Group 11 MAST AND FORKS.)

1-10

HYDRAULIC SYSTEM

Lift Cylinders The following describes the procedures for removing and installing the mast assembly. Note that the triple-stage full free panoramic mast (Triplex Mast) is used as an example.

Triple-stage Full Free Panoramic Mast (Duplex and Triplex Masts)

5

4

2

3 1

207785

Sequence 3 First lift cylinder 4 Chain wheel support assembly 5 Second lift cylinders

1 Nuts 2 Lift bracket assembly

Suggestions

1. Removing lift bracket assembly 2 (1) Lower lift bracket assembly 2, and place wood blocks under the assembly. Tilt the mast forward, lower the inner mast to the bottom, then remove nuts 1 from the anchor bolts of the first lift chains.

1-11

1

207786

HYDRAULIC SYSTEM

(2) Position the mast upright. Raise the inner mast until main rollers 6 of lift bracket assembly 2 become free. Then, slowly move the vehicle in reverse to separate from lift bracket 2.

6 2 201735

2. Removing first lift cylinder 3 (1) Hitch a sling to first lift cylinder 3, and suspend the cylinder with a crane. Wind the sling securely to prevent slipping.

(2) Remove the lift cylinder connecting and mounting bolts, and gently dismount first lift cylinder 3.

3

207787

3. Removing second lift cylinders 5 (1) Disconnect hoses from second lift cylinders 5.

(2) Remove stopper bolts at the upper sections of second lift cylinders 5, and lift the inner mast [dual-stage full free panoramic mast] or middle mast [triple-stage full free panoramic mast] approximately 550 mm (21.67 in.) using slings.

5

207788

1-12

HYDRAULIC SYSTEM

(3) Place wood blocks under the inner mast [dualstage full free panoramic mast] or middle mast [triple-stage full free panoramic mast].

Make sure the right and left wood blocks are the same in height.

202983

(4) Hitch a sling to second lift cylinder 5 behind the mast, remove cylinder clamp retaining bolts, and gently remove second lift cylinder 5.

Wind the sling securely to the cylinder. The cylinder cannot be lifted straight up since the mast cross-member is located above the cylinder. Tilt the cylinder and move it away from the cross-member to remove. Be careful not have the hands caught between the cylinder and mast.

5

Installation 207789

To reinstall, follow the removal sequence in reverse, and service as follows.

(1) Install chain wheel support assembly 4 parallel to a line connecting the centers of chain anchor bolt holes on first lift cylinder 3 to prevent chains from twisting.

(2) Adjust the chain tensions.

(See the section Inspection and Adjustment.)

Good

(3) Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly.

(4) After proper operation is confirmed, check the oil level.

1-13

Bad 207638

HYDRAULIC SYSTEM

Tilt Cylinders

2

•

4 1

3

206971

1 Tilt cylinder pin 2 Hoses

3 Tilt cylinder pin 4 Tilt cylinder

Start by: (1) Lower the forks to the bottom, and tilt the mast fully forward.

(2) Hitch a sling to the top crossmember of outer mast, and support the weight of the mast with a hoist.

Suggestions 1. Retracting piston rod Remove tilt cylinder pin 1. Start the engine and retract the piston rod to the full stroke, then stop the engine.

2. Disconnecting hoses Disconnect hoses 2 from the cylinder at the connectors. Use a container to catch oil from flowing out of the cylinder. Attach caps to the connectors of the cylinder to protect the threads of the connectors and to prevent oil from flowing out of the cylinder when the cylinder is removed.

1-14

206970

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