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
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.
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 compo-
nents is important before the removal or disassem-
bly of any component.
Because of the size of some of the truck compo-
nents, the serviceman or mechanic should check the
weights noted in this Manual. Use proper lifting pro-
cedures 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 particu-
lar, 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 cloth-
ing appropriate to the welding job being per-
formed. Do not wear loose-fitting or torn cloth-
ing. Remove all rings from fingers when work-
ing 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 perform-
ing any disassembly.
WARNING
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 correct-
ly. 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.
10. Always use tools that are in good condition and 18. Loose or damaged fuel, lubricant and hydraulic
be sure you understand how to use them before lines, tubes and hoses can cause fires. Do not
performing any service work. bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect
11. Reinstall all fasteners with same part number.
lines, tubes and hoses carefully. Do not check
Do not use lesser quality fastener if
for leaks with your hands. Pin hole (very small)
replacements are necessary. Do not mix metric
leaks can result in a high velocity oil stream
fastener with standard nuts and bolts.
that will be invisible close to the hose. This oil
12. If possible, make all repairs with the truck can penetrate the skin and cause personal injury.
parked on a level, hard surface. Block truck so Use cardboard or paper to locate pin hole leaks.
it does not roll while working on or under truck.
19. Tighten connections to the correct torque. Make
13. Disconnect battery and discharge any sure that all heat shields, clamps and guards are
capacitors (electric trucks) before starting to installed correctly to avoid excessive heat,
work on truck. Hang “Do not Operate” tag in vibrations or rubbing against other parts during
the Operator’s Compartment. operation. Shields that protect against oil spray
14. Repairs, which require welding, should be onto hot exhaust components in event of a line,
performed only with the benefit of the tube or seal failure, must be installed correctly.
appropriate reference information and by 20. Relieve all pressure in air, oil or water systems
personnel adequately trained and before any lines, fittings or related items are
knowledgeable in welding procedures. disconnected or removed. Always make sure all
Determine type of metal being welded and raised components are blocked correctly and be
select correct welding procedure and alert for possible pressure when disconnecting
electrodes, rods or wire to provide a weld metal any device from a system that utilizes pressure.
strength equivalent at least to that of parent
21. Do not operate a truck if any rotating part is
metal.
damaged or contacts any other part during
15. Do not damage wiring during removal operation. Any high speed rotating component
operation. Reinstall the wiring so it is not that has been damaged or altered should be
damaged nor it will be damaged in operation by checked for balance before reusing.
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.
 HOW TO READ THIS MANUAL
Disassembly diagram (example)

1 Each disassembly diagram is followed

by Disassembly sequence and
4 Suggestions disassembly.
3

Disassembly sequence

1 Cover, Bolt, Washer (part name)

▲

2 Output shaft (part name)

▲

▲
Suggestion for disassembly
(1) Output shaft removal
Unit: mm (in.)
Clearance 0.020 to 0.105
A
between (0.00079 to 0.00413)
cylinder and 0.15
piston B
(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 M100D
M80D M120D
Items
Type Adjustable Adjustable
Flow regulator
valve Control flow capacity
100 (26.42) 115 (30.38)
liter/min (U.S.gal/min)
Simplex mast Internal diameter mm (in.) 60 (2.36) 70 (2.75)
Lift cylinders Stroke mm (in.) 1650 (65) 1650 (65)
Hydraulic system

Duplex mast Internal diameter mm (in.) 90 (3.54) 110 (4.33)

First lift cylinders Stroke mm (in.) 820 (32.28) 845 (33.27)
Duplex mast Internal diameter mm (in.) 55 (2.17) 60 (2.36)
Second lift cylinders Stroke mm (in.) 1590 (62.60) 1585 (62.40)
Triplex mast Internal diameter mm (in.) 90 (3.54) 110 (4.33)
First lift cylinders Stroke mm (in.) 820 (32.28) 845 (33.27)
Triplex mast Internal diameter mm (in.) 60 (2.36) 70 (2.75)
Second lift cylinders Stroke mm (in.) 1480 (58.27) 1530 (60.24)

1-1
HYDRAULIC SYSTEM

Lift Cylinders
Simplex Mast
Lift Cylinders (G40A)
* * * * *
6 5 7 4 11 10 9 8 1
2 3

• • • •• •
• • •
•

Parts marked with * are included in the seal kit. 206951

1 Cylinder tube 5 U-ring 9 Backup ring

2 Piston rod 6 Wiper ring 10 Bushing
3 Cylinder head 7 O-ring 11 Spacer
4 Bushing 8 U-ring

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.

202976

1 Cylinder tube 6 U-ring 11 U-ring holder

2 Piston rod 7 Wiper ring 12 Stopper
3 Cylinder head 8 O-ring 13 Spacer
4 Bushing 9 Piston ring
5 Holder 10 U-ring assembly

1-2
 HYDRAULIC SYSTEM

Duplex Mast Triplex Mast

First Lift Cylinder (H40A) First Lift Cylinders (J40A thru J70A)

* * * * * * *
6 3 8 5 4 7 13, 14 2 1 9 10 11 12

•
•
• • •
• •
•

Parts marked with * are included in the seal kit. 206950

1 Cylinder tube 6 Wiper ring 11 Check valve

2 Piston rod 7 O-ring 12 Snap ring
3 Cylinder head 8 O-ring 13 Plug
4 Bushing 9 Seal ring assembly 14 Gasket
5 U-ring 10 Slide ring

1-3
HYDRAULIC SYSTEM

Duplex Mast
Second Lift Cylinders (H40A)

* * * *
8 7 6 5 9 4 3 18 17 1 2 16 14 12 11 10 13 15

• •
•
• • • • • •
•
• •
•

Parts marked with * are included in the seal kit.

206949

1 Cylinder tube 7 Backup ring 13 Check valve

2 Piston rod 8 Wiper ring 14 Cushion spool
3 Cylinder head 9 O-ring 15 Spring
4 Bushing 10 Piston 16 Snap ring
5 Holder 11 Slide ring 17 Steel ball
6 U-ring 12 Set screw 18 Set screw

Triplex Mast
Second Lift Cylinders (J40A)

* * * * *
6 5 3 7 4 2 1 16 11 12 10 9 8 15 14 13

Parts marked with * are included in the seal kit.

207778A

1 Cylinder tube 7 O-ring 13 Cushion spool

2 Piston rod 8 U-ring 14 Pin
3 Cylinder head 9 Backup ring 15 Snap ring
4 Bushing 10 Bushing 16 Spacer
5 U-ring 11 Spring guide
6 Wiper ring 12 Spring
1-4
 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.

207779A

1 Cylinder tube 6 U-ring 11 Holder

2 Piston rod 7 Wiper ring 12 Stopper
3 Cylinder head 8 O-ring 13 Spring guide
4 Bushing 9 Piston ring 14 Spring
5 Holder 10 U-ring assembly 15 Cushion rod
16 Spring pin
17 Spacer

1-5
HYDRAULIC SYSTEM

Flow Regulator Valve

M80D thru M120D
6 3 4 5 2 1

• • •
•

202978

1 Set bolt, Lock nut 4 Spring

2 Sleeve, O-ring 5 Spring guide, O-ring
3 Piston, Spring pin, Washer spring, Valve 6 Valve body

1-6
 HYDRAULIC SYSTEM

Down Safety Valve

1 3 4 2

Cut-off flow rate Stamped number

Free flow Regulated flow

204626

1 Connector 3 Spring
2 Valve 4 Spring pin
The down safety valve is located at the bottom This valve provides a means of preventing the
side of right-hand lift cylinder. load from lowering, unsafely, rapidly, when a
hose bursts.

Cut-off flow rate

Simplex G40A G45A, G55A WARNING
model
Mast

Duplex H40A — Do not reuse down safety valve

Triplex J40A J45A, J55A after a lift line hose failure.
–0
Cut-off flow rate 90 –15 120 +5
0
–10

liter (U.S.gal)/min (23.8 –0

–4 ) (31.7 +1.3
–2.6 )

1-7
HYDRAULIC SYSTEM

Lift Cylinders
Dual-stage Panoramic Mast (Simplex Mast)

6
7
8

5
3

1 4

2
207784

Sequence
1 Nuts 4 Hose guard 7 Cylinder clamp, Cushion,
2 Fork, Lift bracket 5 High-pressure hose Collar, Shims
3 Return (low-pressure) 6 Set bolt, Shims 8 Lift cylinder, Bracket
hose

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 To hydraulic tank
hose from the right and left lift cylinders at the
connectors.

206965

3. Disconnecting high-pressure hoses

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

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 206967
fitted.

(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 com-
pleted:
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)

3
1
207785

Sequence

1 Nuts 3 First lift cylinder

2 Lift bracket assembly 4 Chain wheel support assembly
5 Second lift cylinders

Suggestions

1. Removing lift bracket assembly 2

(1) Lower lift bracket assembly 2, and place wood

blocks under the assembly. Tilt the mast 1
forward, lower the inner mast to the bottom,
then remove nuts 1 from the anchor bolts of
the first lift chains. 207786

1-11
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.

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.

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
5
slings.

207788

1-12
 HYDRAULIC SYSTEM

(3) Place wood blocks under the inner mast [dual-

stage 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

To reinstall, follow the removal sequence in 207789

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 Bad
(3) Extend and retract the lift cylinders several
times under no load condition to bleed air out 207638
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
HYDRAULIC SYSTEM

Tilt Cylinders

206971

1 Tilt cylinder pin 3 Tilt cylinder pin

2 Hoses 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 206970
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
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