Operation & Maintenance Manual

GC35K GC45K-SWB GC55K GC70K

AT87-00001-up AT87-00001-up AT88-00001-up AT89-00001-up
AT87A-00001-10230 AT87A-00001-10230 AT88A-00001-10230 AT89A-00001-10230
AT87A-10231-20230 AT87A-10231-20230 AT88A-10231-20230 AT89A-10231-20230
AT87A-20231-up AT87A-20231-up AT88A-20231-up AT89A-20231-up

GC40K GC45K-STR GC55K-STR GC70K-STR

AT87-00001-up AT87A-20231-up AT88-00001-up AT89-00001-up
AT87A-00001-10230 AT88A-00001-10230 AT89A-00001-10230
AT87A-10231-20230 GC45K AT88A-10231-20230 AT89A-10231-20230
AT87A-20231-up AT88-00001-up AT88A-20231-up AT89A-20231-up
AT88A-00001-10230
GC40K-STR AT88A-10231-20230 GC60K
AT87-00001-up AT89-00001-up
AT87A-00001-10230 AT89A-00001-10230
AT87A-10231-20230 AT89A-10231-20230
AT87A-20231-up AT89A-20231-up
Keep this manual in your lift truck as a ready reference. 99730-86101
 FOREWORD
The Occupational Safety and Health Administration (OSHA) is now mandating And, most important, a qualified person experienced in lift truck operation
operator training for all lift truck operators. should guide new operators through several driving and load handling opera-
SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on tions before they attempt to operate the lift truck on their own.
the skill and alertness of the operator. To develop the skill, the operator should: It is the responsibility of the employer to make sure the operator can see, hear
1. Know the working capabilities and limitations of the lift truck. and has the physical and mental ability to operate the lift truck safely.
2. Know the make-up of the lift truck. This manual contains information necessary for the operation and “do-it-your-
3. Read and understand the safe driving and load handling procedures con- self” maintenance of standard lift trucks. Optional equipment is sometimes
tained in this manual. installed; it can change some operating characteristics described in this manual.
Before operating such a lift truck, make sure the necessary instructions are
available and understood.
Lift truck operator training is provided through your Cat® lift truck dealer. They
will be glad to help you and answer any questions you may have about operat-
ing your new lift truck. Lift trucks are NOT intended for use on public roads.

99730-86101
100588A

i i
 HOW TO USE THIS MANUAL
The following safety signs and NOTICE are used in this manual to
emphasize important and critical instructions.
Be sure to read these precautionary
This is the safety alert symbol. It is used to alert you to instructions and all safety related
! potential personal injury hazards. Obey all safety messages decals installed on your truck
that follow this symbol to avoid possible injury or death. before you operate it.

Indicates a imminently hazardous situation

! DANGER which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation
! WARNING which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation
! CAUTION which, if not avoided, may result in minor or
moderate injury, or damage to your machine.

Cat Lift Trucks cannot anticipate every possible circumstance that might
involve a potential hazard. The warnings in this publication and on the
product are therefore not all inclusive. If a tool, procedure, work method
or operating technique not specifically recommended by Cat Lift Trucks
is used, you must satisfy yourself it is safe for you and others. You should
also ensure the product will not be damaged or made unsafe by the oper-
ation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on
the basis of information available at the time it was written. The specifi-
cations, torques, pressures, measurements, adjustments, illustrations, and 101582C
other items can change at any time. These changes can affect the service
given to the product. Obtain the most complete and current information
from your Cat lift truck dealer before starting any job. Cat lift truck deal-
ers have the current information available. Additional manuals are avail-
able from your Cat lift truck dealer.
Directional terms:
The directions “left,” “right,” “front” and “rear” are given from the view-
point of the operator facing forward.

ii ii
 TABLE OF CONTENTS iii

SAFETY RULES FOR LIFT TRUCK OPERATORS

In General............................................................................................. 1 Safety Rules ......................................................................................... 11
Warning Decals, Location.................................................................... 2 Operating Precautions .......................................................................... 18
Decals for LP-Gas Only....................................................................... 4 Working Precautions ............................................................................ 21
Warning Decals, Description ............................................................... 5 LP-Gas ................................................................................................. 26

KNOW YOUR LIFT TRUCK

Serial Number and Capacity Plate....................................................... 27 Changing Forks .................................................................................... 41
Model View .......................................................................................... 28 Safety Equipment................................................................................. 41
Operator’s Compartment...................................................................... 29 Drawbar Pin ......................................................................................... 42
Instrument Panel .................................................................................. 31 Assist Grip ........................................................................................... 42
OK Monitor (Warning Lights and Indicators) ..................................... 33 Hydraulic Tank Oil Level/Filler Hole.................................................. 43
Driving Interlock System ..................................................................... 34 Fuel Filler............................................................................................. 43
Operator’s Seat..................................................................................... 36 Fuel Shut-off Valve .............................................................................. 43
Seat Belt ............................................................................................... 37 Engine Hood ........................................................................................ 44
Fuses and Lights .................................................................................. 40 Radiator Cover ..................................................................................... 45
Fork Stoppers ....................................................................................... 41 Back-up Buzzer.................................................................................... 45

HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE

Know What Lift Truck Stability is ...................................................... 46 Capacity (Weight and Load Center) .................................................... 47
Center of Gravity (CG) ........................................................................ 46 Capacity Plate ...................................................................................... 48
Stability and Center of Gravity............................................................ 46 Do’s and Don’ts to Avoid Tipover ....................................................... 49
Lift Truck Stability Base...................................................................... 47 How to Survive in a Tipover................................................................ 52

REFUELING
Gasoline Engine Equipped................................................................... 53 LP-Gas Equipment............................................................................... 54

OPERATION
New Lift Truck Break-In ..................................................................... 55 After Starting Engine ........................................................................... 61
Before Starting Engine......................................................................... 55 Before Moving Lift Truck.................................................................... 62
Starting Gasoline Engine ..................................................................... 58 Lift Truck Operation ............................................................................ 63
Engine Won’t Start............................................................................... 59 Stopping Lift Truck.............................................................................. 67
Starting with Jumper Cables ................................................................ 60 Parking Lift Truck (After Stopping) .................................................... 68
Starting LP-Gas Engine ....................................................................... 61

OPERATING TECHNIQUES
Stacking Methods................................................................................. 69 Unloading............................................................................................. 73
Handling Loads Safety......................................................................... 70 Handling Round Objects...................................................................... 75
Inching Into and Lifting the Load........................................................ 71 Working on Grades .............................................................................. 76
Traveling with the Load....................................................................... 72
iii iii
 iv

STORING THE LIFT TRUCK

End of Each Shift Storage.................................................................... 78 Long Term Storage............................................................................... 78

TRANSPORTATION HINTS
Lift Truck Shipping.............................................................................. 79 Machine Lifting and Tiedown Information ......................................... 79

SPECIAL SITUATIONS
Care in Cold Weather........................................................................... 80 Care in Severe Dust or Lint Conditions............................................... 81
Care in Hot Weather............................................................................. 81

TROUBLESHOOTING
Changing a Tire.................................................................................... 82 Stalled Engine ...................................................................................... 90
Engine Coolant Temperature Gauge Needle Trouble with the LP-Gas Equipment ................................................... 90
Moves Into Red Zone ...................................................................... 89 Driving Interlock Indicator Light Flickers or Flashes, and
Powershift Transmission Oil Temperature Warning Light Glows....... 89 the Truck Stops Moving ................................................................... 91

MAINTENANCE
General ................................................................................................. 92 One Month After Delivery of a New Truck.........................................115
Inspection Precautions ......................................................................... 93 Every 200 Service Hours or Monthly, Whichever Comes First ..........116
Maintenance Schedule ......................................................................... 94 Every 1200 Service Hours or 6 Months, Whichever Comes First ......121
Every 10 Service Hours or Daily (Pre-start), Whichever Comes First....... 97 Every 2400 Service Hours or 1 Year, Whichever Comes First............130
Every 50 Service Hours or Weekly, Whichever Comes First..............113 Parts to be Changed Periodically .........................................................131

SERVICE DATA
Fuel Information ..................................................................................132 Specifications and Refill Capacities (Standard Models) .....................139
Coolant Information.............................................................................134 Capacity and Truck Weight (Standard Models)...................................140
Recommended Fuels and Oils .............................................................136

TO THE CAT LIFT TRUCK OWNER

The Importance of Genuine Parts ........................................................141 Service Registration .............................................................................143
Instructions for Ordering Parts ............................................................142

INDEX
Index.....................................................................................................144

iv iv
|||||||||||||||||||||||||||||||| SAFETY RULES FOR LIFT TRUCK OPERATORS |||||||||||||||||||||||||||||
◆ In General

The safety rules and regulations in this section Continuing improvement and advancement of
are representative of some, but not all rules and product design may have caused changes to
regulations that apply to lift trucks. Rules are your lift truck which are not included in this
paraphrased without representation and they publication. Whenever a question arises
have been reproduced verbatim. regarding your lift truck, or this publication,
Your lift truck was manufactured in accor- please consult your Cat lift truck dealer for the
dance with the National Fire Protection latest available information.
Association No. 505 (NFPA) and the All lift truck users should be familiar with their
American National Standards Institute, Local, Regional, and National regulations.
Inc./Industrial Truck Standards Development United States users should be familiar with the
Foundation (ANSI/ITSDF) B56.1, Safety Occupational Safety and Health Administra-
Standard for Low and High Lift Trucks and tion (OSHA), and American National
various worldwide regulations. See Standards Industrial Lift Trucks. See
www.ITSDF.org web site for more informa- www.osha.gov web site for more information
tion on the B56.1 Safety Standards for Low on Regulations (Standards - 29 CFR) Powered
Lift and High Lift Trucks. Since regulations industrial trucks - 1910.178.
vary from country to country, operate this lift You should also be familiar with areas of use of
truck in accordance with local regulations. different types of lift trucks as specified in the
The most effective way of preventing serious National Fire Protection Association (NFPA
injuries, or even death, to you and others, is for 505).
you to know how to operate the truck properly.
Drive alertly and avoid maneuvers or condi-
tions that can cause accidents. Be professional.
Do not operate a lift truck if it is in need of
maintenance, repair or appears to be unsafe in
any way. Report all unsafe conditions immedi-
ately to your supervisor and contact your
authorized Cat lift truck dealer. Do not attempt
any adjustments or repairs unless you are
trained and authorized to do so.

1 1
SAFETY RULES FOR LIFT TRUCK OPERATORS 2

◆ Warning Decals, Location

There are several specific warning decals on Be sure you can read all warning and instruc- You must replace a decal if it is damaged,
your lift truck. Their exact location and tion decals. If you cannot, clean or replace missing or cannot be read. If a decal is on a part
description of the potential hazard are reviewed them. Use a cloth with soap and water to clean that is replaced, make sure a new decal is
in this section. Please take the time to familiar- them. placed on the new part. Contact your Cat lift
ize yourself with these decals. truck dealer for new decals.

Inspection/lubrication
chart
Back-up alarm Hoist point
decal decal
(If equipped)

ECU
protect decal
(For 6-7 ton)

Radiator cap
warning decal

No one under
forks decal

No access with
No one on
engine running
forks decal
decal

No one
between mast
and body decal

Hoist point Engine coolant

decal decal
Parking brake
adjustment decal Fuel decal

103481

2 2
SAFETY RULES FOR LIFT TRUCK OPERATORS 3

Fasten Seat Belt decal Operation Warning decal Survive in Tipover decal

No Riders decal

Impact Test Rating

decal

Pinch Point
decal

Capacity plate

UL Neutral Switch decal

plate (optional)

With Backrest
Extension
decal

Direction Lever decal

Operator Restraint No Contamination

System decal decal
103482

3 3
SAFETY RULES FOR LIFT TRUCK OPERATORS 4

◆ Decals for LP-Gas Only

Location
decal L.P.G. Fuel
decal decal

Maintenance
decal

103483
Fuel Gauge
decal

4 4
SAFETY RULES FOR LIFT TRUCK OPERATORS 5

◆ Warning Decals, Description

• Parking Brake • Inspection/Lubrication Chart • No Rider

! WARNING ! WARNING ! WARNING

When leaving machine (lift truck), apply Improper operation or maintenance could To avoid serious injury, do not carry pas-
the parking brake! The parking brake is not result in injury or death. Do not operate sengers. A lift truck is designed for only
automatically applied. or work on the lift truck unless you are one operator and no riders.
Adjust lever operating force properly. properly trained.

102506A 104139 102504

Located to the left front of the operator’s seat. Located to the right front of the operator’s seat. Located to the right of the operator’s seat on the
Proper operating force: 250 to 290 N (25 to 30 engine hood.
kgf) [55 to 66 lbf].

5 5
SAFETY RULES FOR LIFT TRUCK OPERATORS 6

chains, cable and limit switches, brakes, 11. Travel with the load or lifting mechanism
! WARNING as low as possible and tilt back. Always
steering mechanism, fuel system, hydraulic
Only trained and authorized personnel hoses and guards. look in the direction of travel. Keep a clear
may operate this lift truck. For safe oper- 3. Operate the truck only from the designated view, and when load interferes with visi-
ation, read and follow the Operation and operating position. Never place any part of bility, travel with the load or lifting mech-
Maintenance Manual furnished with this your body into the mast structure, between anism trailing (except when climbing
lift truck and observe the following the mast and the truck, or outside the truck. ramps).
warnings: Do not carry passengers. 12. Use special care when operating on ramp,
4. Do not operate the truck without the over- travel slowly, and do not angle or turn.
head guard. When the truck is loaded, travel with the
5. Do not handle loads which are higher than load uphill. When the truck is empty, travel
the load backrest or load backrest exten- with the lifting mechanism downhill.
sion unless the load is secured so that no 13. Observe applicable traffic regulations.
part of it could fall backward. Yield right of way to pedestrians. Slow
6. Do not handle unstable or loosely stacked down and sound horn at cross aisles and
loads. Use special care when handling wherever vision is obstructed.
long, high or wide loads to avoid losing the 14. When using forks, move them as far apart
load, striking bystanders, or tipping the truck. as the load will permit. Before lifting, be
7. Do not overload the truck. Check capacity sure the load is centered and the forks are
102504
plate for load weight and load center infor- completely under the load.
Located to the right side of the operator’s seat mation. 15. Do not allow anyone to stand or pass under
on the engine compartment cover. 8. Start, stop, travel, steer and brake the load or lifting mechanism.
smoothly. Slow down for turns on uneven 16. Do not lift personnel except on a securely
FOR SAFETY OBSERVE THE or slippery surfaces that could cause truck attached, specially designed Work
FOLLOWING WARNINGS to slide or overturn. Use special care when Platform. Use extreme care when lifting
traveling without a load as the risk of over- personnel. Place the mast in the vertical
1. Do not operate this truck unless you have
turning is greater. position, place the truck controls in neutral
been trained and authorized to do so. Read
9. Elevate forks or other lifting mechanism and apply the brakes. Lift and lower
all warnings and instructions in the opera-
only to pick up or stack a load. Lift and smoothly. Be available to operate controls
tor’s manual and on this truck. An
lower with mast vertical or tilted slightly as long as personnel are on the Work
Operation & Maintenance Manual is sup-
back—NEVER FORWARD. Watch out for Platform. Never transport personnel on
plied with this truck or available from your
obstructions, especially overhead. forks or Work Platform.
Cat lift truck dealers.
10. Operate tilting mechanism slowly and 17. Before getting off the truck, put the direc-
2. Do not operate this truck until you have
smoothly. Do not tilt forward when ele- tion lever in neutral engaging the lever
checked its condition. Give special atten-
vated except to pick up or deposit a load. lock knob, lower the lifting mechanism
tion to Tires, Rims, Horns, Light
When stacking, use only enough backward fully, and set the parking brake. If leaving
Battery(s), Controller, Lift and Tilt
tilt to stabilize load. the truck unattended, shut the power off also.
Systems including forks or attachments,
6 6
SAFETY RULES FOR LIFT TRUCK OPERATORS 7

• Cooling System • Overhead Guard

! WARNING ! WARNING ! WARNING

Check the coolant level only after the To avoid serious injury, stay clear of the Operation without this device in place
engine has been stopped and the filler cap moving fan. may be hazardous. This overhead guard
is cool enough to touch with your hands. conforms to ANSI/ITSDF B56.1. This
Remove the filler cap slowly to relieve design also passed a vertical impact test
pressure. of 32,000 foot pounds.

103486 103486 102513

Located on the radiator cap. Located on the frame of the cooling fan. Located left inside the top frame member of the
overhead guard.

7 7
SAFETY RULES FOR LIFT TRUCK OPERATORS 8

• No One Under/On Forks • Load Backrest Extension • Pinch Point

! WARNING ! WARNING ! WARNING

Do not stand or ride on the forks. Operation without this device in place Do not touch, lean on, or reach through
Do not stand or ride on a load or pallet may be hazardous. the mast or permit others to do so.
on the forks. Do not remove the load backrest exten- Hands off!
Do not stand or walk under the forks. sion.

102505 102512 102508

Located on the mast. Located on the load backrest extension.

104497

102509

Located on the mast.

105180
91A83-01700
105181
8 8
SAFETY RULES FOR LIFT TRUCK OPERATORS 9

• Tipover Warnings ! WARNING

1. Lateral tipover can occur when unloaded if 4. Serious injury or death can occur to the
! DANGER the combination of speed and sharpness of operator if he/she is trapped between the
turn produces an overturning moment truck and the ground.
Tipover can occur if truck is improperly
which exceeds the stability of the truck.
operated. Injury or death could result.
2. Lateral tipover can occur if overloaded or IN CASE OF TIPOVER
loaded within capacity and the load is ele- 1. The operator should stay with truck if lat-
vated and if turning and/or braking when eral or longitudinal tipover occurs. The
traveling rearward of if turning and/or operator should hold on firmly to the steer-
accelerating when traveling forward pro- ing wheel, brace feet, lean forward and lean
duces an overturning moment which away from the point of impact.
exceeds the stability of the truck. 2. The operator should stay with the truck if it
Rearward tilt and/or off-center positioning falls off a loading dock or ramp. There are
of the load and/or uneven ground conditions other situations where the environment of
will further aggravate the above conditions. the land area presents a severe hazard. In
3. Longitudinal tipover can occur if over- those incidents, it may be prudent for the
loaded or when loaded within capacity and operator to leave the truck.
the load is elevated if forward tilt, braking
103484 in forward travel, or commencing rearward
travel produces an overturning moment
Located inside the left frame member of the which exceeds the stability of the truck.
overhead guard.

102515
103485
Located inside the front frame member of the Located inside the right frame member of the
overhead guard. overhead guard.

9 9
SAFETY RULES FOR LIFT TRUCK OPERATORS 10

• Back-up Alarm

! WARNING

– When operating in reverse, alarm

must sound.
– Failure to maintain a clear view in the
direction of travel could result in
injury or death.

103496

10 10
SAFETY RULES FOR LIFT TRUCK OPERATORS 11

◆ Safety Rules

! WARNING ! WARNING ! WARNING

You may need:

– Safety goggles.
– Ear protectors.
– Hard hat.

100870 100605

Authorized and trained operators only! Always be alert!

Thoroughly learn how to operate a lift truck Know how to use a first aid kit and a fire extin-
and the safe areas and surfaces to travel before guisher—and where to get prompt assistance.
you drive one.

! WARNING ! WARNING

100604
101003 100989

DO NOT travel on public roads! Dress properly for the job! NO smoking while refueling!
DO NOT wear loose clothing or accessories— DO NOT fuel while the engine is running.
flapping cuffs, dangling chains, neck ties, Keep away from flames or spark sources. Turn
scarves, or rings—that can catch in moving off all electrical switches on the truck. Fuel in
parts. a well ventilated area.
11 11
SAFETY RULES FOR LIFT TRUCK OPERATORS 12

! WARNING ! WARNING ! WARNING

101006 100607 100609

Unauthorized addition or modification is Know your lift truck and attachments! Shut down engine before servicing!
prohibited! Know the operating, inspection and mainte- DO NOT service a lift truck while engine is
DO NOT add to or modify the lift truck unless nance instructions in the OPERATION & running unless absolutely necessary to do so.
authorized in writing by the manufacturer to do MAINTENANCE MANUAL.
so. Any change to the lift truck could cause
serious injury or property damage.

! WARNING WARNING ! WARNING

!

100610 100612 101007

Know all signals and traffic rules! Avoid being splashed by scalding hot Exhaust fumes could kill you!
Know who is responsible for signaling. Learn coolant! If you operate a lift truck in an enclosed area,
to tell at a glance what the signal means, and Wait until the engine cools before opening or make sure there is adequate ventilation.
what action you should take. loosening the radiator cap. If you cannot wait,
use a heavy cloth and gloves to protect your-
self. Stand to the side, protect your face, and
slowly loosen cap.
12 12
SAFETY RULES FOR LIFT TRUCK OPERATORS 13

! WARNING ! WARNING ! WARNING

101008 103480 102835

Inspect your lift truck prior to operation! DO NOT remove the overhead guard! Keep the operator’s compartment clean!
At the beginning of each shift, fill out a daily The overhead guard is intended to protect the Keep your hands and shoes, as well as the floor
inspection sheet. Check for maintenance prob- lift truck operator from overhead obstructions and controls (steering wheel, levers and pedals)
lems and have repairs made before you operate and falling objects. clean and free of grease, mud and other mate-
the truck. rials.

! WARNING ! WARNING ! WARNING

102517 102520B 102522B

DO NOT operate an unsafe lift truck! Always stay healthy on the job! Know your lift truck is safe!
Inspect a lift truck before you operate it to be Be healthy and NEVER operate the truck DO NOT operate any lift truck that is not safe
sure it is properly maintained and in good under the influence of drugs or alcohol that to operate.
working order. may impair your ability to properly operate the
truck.

13 13
SAFETY RULES FOR LIFT TRUCK OPERATORS 14

! WARNING ! WARNING
Frequency transducer and ECU for
two speed T/M (Electronic control unit)

ECM
(Controller for engine)

201317A 103926

LP-Gas tank replacement! For handling frequency transducer, ECU

LP-Gases are flammable. Do not attempt to and ECM!
change LP-Gas tanks unless you are trained 1. Do not directly expose these equipment to
and authorized to do so. Be sure to get a trained washing water, rain, oil and every other
and qualified mechanic to change them. liquid.
2. Do not apply force, open, modify these
equipment nor operate the truck without
these equipment.
! WARNING 3. Turn key switch OFF. Disconnect battery
cable and then disconnect these equipment
before following operations:
• Removing these equipment from truck
• Factory approved welding

103498

Alarm must sound when operating this

truck in reverse! (If equipped)
Make sure the back-up buzzer sounds.

14 14
SAFETY RULES FOR LIFT TRUCK OPERATORS 15

! WARNING ! WARNING ! WARNING

101005 101010 101644

Operate only in approved areas! DO NOT operate a damaged or defective lift Be sure the assist grip is properly tightened!
Certain areas such as those containing haz- truck! Face the lift truck when mounting and dis-
ardous flammable gases, liquid or other com- A truck will operate effectively and safely mounting.
bustibles, should be avoided. when it is in proper working order. Maintain a three point contact (one foot and
two hands) with the floor and handholds.
Never get on or off a moving lift truck.
! WARNING
Never jump on or off the lift truck.
DO NOT use the controls or steering wheel as
handholds when entering or leaving the opera-
tor’s compartment.

101115C

Start engine safely!

Start the engine only when securely seated in
the operator’s compartment.

15 15
SAFETY RULES FOR LIFT TRUCK OPERATORS 16

! WARNING ! WARNING ! DANGER

101114B 101014A 100976

Adjust the seat before operation! Make sure your lift truck is in safe operat- Fasten the seat belt properly!
DO NOT adjust the seat while the lift truck is ing condition! If you DO NOT, it may not restrain you in an
in motion. Test the brakes and inching pedal while mov- accident.
ing slowly in a safe area. Make sure the mast
moves up and down smoothly.

! WARNING ! WARNING ! WARNING

101023 100635 101025

Always check overhead clearance! Use lights in dark, dim areas! Stay within the confines of the truck!
Serious accidents could be caused by the mast Even with lights on, DO NOT assume people Keep your arms and legs inside the operator’s
and overhead guard hitting pipes, beams or see you and will move out of your way. compartment.
other overhead obstructions. Watch out for
power lines.

16 16
SAFETY RULES FOR LIFT TRUCK OPERATORS 17

! WARNING ! WARNING ! WARNING

101027 101526 101036

Always be aware of floor capacity! Stay under the overhead guard! Be careful of forks that extend beyond the
Make sure the floor will support the weight of DO NOT hold on the overhead guard. load!
the loaded lift truck. If the forks extend beyond the load, use extra
caution. Make sure the fork tips do not contact
other material.

! WARNING ! WARNING ! WARNING

20
%

60
%

20
%

101035 103444 102146A

Avoid off-center loading! Check fork stoppers for engagement! Check work areas for high risk!
Set the forks as far apart as possible for maxi- If the fork stoppers are not properly engaged, When working on docks, ramps, platforms and
mum support of the pallet or load. Too small a the forks could shift and cause off-centered or other high risk areas, use adequate blocks to
fork spread can cause instability of the load. unstable loads. reduce the risk of the lift truck from falling off.

17 17
SAFETY RULES FOR LIFT TRUCK OPERATORS 18

◆ Operating Precautions

! WARNING ! WARNING ! WARNING

100998 100662 102518

Stay away from slippery surfaces! Be aware of the stability of an empty lift Position controls correctly for starting!
– Loose or slippery materials such as sand, truck! Make sure the direction lever is in the NEU-
gravel, ice, mud, etc., on your operating An empty lift truck will tip over more easily TRAL position and the parking brake lever is
surfaces can cause a skid or tipover. Avoid than a loaded one in a lowered position. set properly.
these conditions or slow down.
– Keep your operating surfaces clean and dry
at all times. Wet spots can cause a skid or
tipover. ! WARNING ! WARNING
– You need greater stopping distance on wet
surfaces. Apply brakes earlier on slippery
surfaces than on dry surfaces.
– Do not drive into a flooded area whenever
possible.

101015 100626

DO NOT allow any riders! If you cannot see where you are going, DO
DO NOT allow anyone to ride on the forks or NOT MOVE!
on any other part of the lift truck—at any time. Travel slowly around corners. Sound the horn
at cross aisles and other areas where you can-
not see clearly or where visibility is restricted.

18 18
SAFETY RULES FOR LIFT TRUCK OPERATORS 19

! WARNING ! WARNING ! WARNING

101016 100873A 101017

DO NOT pass another truck! DO NOT allow anyone to hold loads! Always look in the direction of travel!
DO NOT pass another lift truck traveling in the Always be aware of people near your lift truck.
same direction at intersections, blind spots or DO NOT proceed until they are aware of you.
at other dangerous areas.

! WARNING ! WARNING ! WARNING

101019 101021 101022B

DO NOT engage in stunt driving or horse- Travel in reverse if forward visibility is Obey all traffic rules and warning signs!
play! blocked! Drive carefully, observe traffic rules and be in
Stunt driving and horseplay is dangerous for For better visibility with large loads, travel in full control of the lift truck at all times. Use
both the lift truck operator and the fellow reverse, but always keep a lookout in the direc- special care when traveling without a load as
workers. tion of travel. the risk of overturning is greater.

19 19
SAFETY RULES FOR LIFT TRUCK OPERATORS 20

! WARNING ! WARNING ! WARNING

101026 102519 101029

Travel safely on grades with a loaded lift Be particularly careful when driving up or Travel safely on grades with an empty lift
truck! down a steep slope! truck!
Keep the load upgrade to maintain control Use extreme care to reduce the risk of the tips Keep the counterweight upgrade when travel-
when traveling up or down a grade with a heav- of forks or the bottom of pallet from touching ing up or down a grade with an empty truck.
ily loaded truck. the ground.

! WARNING ! WARNING ! WARNING

102525B 100667 101013

Start lift truck upgrade carefully! DO NOT turn on a ramp or grade! Move your lift truck safely!
When starting the lift truck upgrade, be sure to Turning on a ramp or grade can cause a lift Sound the horn and be sure no people or
use the parking brake. truck, loaded or unloaded, to tip over. objects are in your path before moving.

20 20
SAFETY RULES FOR LIFT TRUCK OPERATORS 21

! WARNING ! WARNING ! WARNING

101020 101033 101002

Allow for counterweight swing distance! A helper should NOT be near the lift truck! Always be alert for tipovers!
When turning in aisles, especially narrow People should be clear of the lift truck operat- Turning sharply with a raised load, even at a
aisles keep as far away as possible from stock ing area. slow speed, could result in a tipover. Realize
and racks. Be cautious near people. that the overhead guard is not designed to pro-
vide total protection in the event of a tipover.
◆ Working Precautions

! WARNING ! WARNING ! WARNING

101031 100924 101762

Danger! Keep out! Be careful of changes in capacity! Watch out for pedestrians at all times!
DO NOT allow any unauthorized people in the Optional attachments which change the capac- Yield the right-of-way to pedestrians at all
work area. ity are sometimes installed. Know the capacity times.
before operating the truck.

21 21
SAFETY RULES FOR LIFT TRUCK OPERATORS 22

! WARNING ! WARNING ! WARNING

101034 100648 101615

Use forks properly! DO NOT speed when approaching loads! DO NOT move when someone’s next to
Fork misuse could cause accidents, serious Bring truck to a full stop in front of a load, then truck!
injuries and equipment damage. approach carefully. If someone is standing next to your truck, don’t
move until they are out of the way.

! WARNING ! WARNING ! WARNING

101037 100652 101041

DO NOT allow anyone to walk or stand DO NOT pick up unsecured loads that Handle only stable loads!
under raised forks! extend above the backrest extension height! If a load is unstable, it could easily shift and
fall on someone.

22 22
SAFETY RULES FOR LIFT TRUCK OPERATORS 23

! WARNING ! WARNING ! WARNING

101042 101775 101039

DO NOT allow unloading from raised loads! DO NOT use damaged pallets! DO NOT abuse your forks!
Failure to follow this rules could cause serious Make sure pallets and skids are sturdy and in Fork misuse can cause accidents, serious
injury. safe operating conditions. injuries and equipment damage.

! WARNING ! WARNING ! WARNING

101040 102524B 102523B

Drive onto a trailer carefully! DO NOT allow any riders! DO NOT abuse your equipment!
Make sure the trailer brakes are applied and the DO NOT permit riders on the forks or pallet. DO NOT use the forks to open or close the
wheels are blocked while loading or unloading. doors on a railroad car or to move a car.

23 23
SAFETY RULES FOR LIFT TRUCK OPERATORS 24

! WARNING ! WARNING ! WARNING

102521B 101787 101043

Stay clear of pinch points! Shift the transmission smoothly! Use only specialized equipment designed to
Keep all parts of your body away from moving safely raise personnel to high work areas!
Avoid sudden shifting while the truck is mov-
parts such as the mast, carriage and attach- ing. This can cause damage to the transmis- Do not lift personnel except on a securely attached,
ments. Do not put any part of your body specially designed Work Platform. Use extreme
sion.
care when lifting personnel. Place the mast in the
between the head guard and the mast. If the
vertical position, place the truck controls in neutral
mast moves unexpectedly, you could get
and apply the parking brake. Lift and lower
caught there and a serious accident could smoothly. Be available to operate controls as long
occur. ! WARNING
as personnel are on the Work Platform. Never trans-
port personnel on forks or Work Platform.

100992

Always stay within the capacity!

Read the capacity chart to make sure a load is
within the capacity of your lift truck before you
handle the load.

24 24
SAFETY RULES FOR LIFT TRUCK OPERATORS 25

! WARNING ! WARNING ! WARNING

102527B 100658A

Park a disabled machine safely! Park in authorized areas only!

– If the lift mechanism is disabled and the Park a safe distance from access to fire aisles,
forks cannot be lowered, park the truck in stairways and fire equipment.
a non-operating area and attach warning DO NOT park near a flammable material stor-
tags to the forks to alert pedestrians and age area.
traffic. 102528
– Use barriers to keep anyone from standing
or passing under the forks. ! WARNING When you leave your truck, or park it:
– Remove the starter switch key and attach – Set the parking brake.
DO NOT OPERATE or similar warning – Put the directional lever in NEUTRAL and
tag to the truck. lock the NEUTRAL lock switch.
– Lower the forks fully to the floor.
– Tilt the mast forward until the forks are
flat.
– Turn the key off.

101044

DO NOT park on a grade!

25 25
SAFETY RULES FOR LIFT TRUCK OPERATORS 26

◆ LP-Gas

Only trained, authorized personnel should fill All defective or damaged LP-Gas tanks must The storage and handling of liquid fuels in the
or exchange LP-Gas tanks. be removed from service. U.S.A. should be in accordance with the NFPA
Personnel engaged in filling LP-Gas tanks Inspect the LP-Gas fuel lines and fittings with No. 30, “Flammable and Combustion Code.”
should wear protective clothing such as a face a soap solution after filling the tank or when Outside the U.S.A., store and handle in accor-
shield, long sleeves and gauntlet gloves. looking for leaks. dance with local regulations.
Do not refuel or store LP-Gas powered lift The lift truck should be refueled only at desig-
trucks near underground entrances, elevator nated safe locations. Safe outdoor locations are
shafts, or other places where LP-Gas could col- preferable to those indoors.
lect in a pocket and cause potential danger for DO NOT completely fill the tank. The fuel
an explosion. expands when it gets warm and it may over-
Do not leave the lift truck, for even a short time, flow. This will create a fire hazard.
near equipment that generates high tempera- Only trained, authorized personnel should fill
tures. Ovens and furnaces are examples. The or exchange LP-Gas tanks.
heat may raise the pressure of the fuel and open Do not drop, throw, roll or drag LP-Gas tanks.
the relief valve. 100717A Do not strike LP-Gas tanks or any associated
Close the service valve on the tank when LP- parts of the tanks or fuel systems.
The careless handling of LP-Gas tanks can
Gas fueled lift trucks are parked overnight or result in a serious accident. To reduce the risk Check the LP-Gas tank for secure mounting.
stored for long periods indoors with the fuel of damage to tanks, use extreme care when Loose tanks can cause pressure fuel lines to
tank in place. transporting them. leak resulting in serious injury.
Close the valves on empty tanks.
Examine LP-Gas tanks before filling and
before reuse. Look for damage to the valve, liq-
uid gauge, fittings and hand wheels.
Check for dents, scrapes or other damage to the
pressure vessel and for dirt or debris in the
openings.

26 26
 ||||||||||||||||||||||||||||||||||||||||||||||||| KNOW YOUR LIFT TRUCK |||||||||||||||||||||||||||||||||||||||||||||||
◆ Serial Number and Capacity Plate

Capacity Plate
For quick reference, record your lift truck’s serial numbers in the spaces provided.

UL Plate

Instruction Plate 103446

UL Plate 103488

Manufacturer Name Plate

103509

Engine Serial Number

Name Plate 101522

Lift Truck Serial Number

102529

27 27
KNOW YOUR LIFT TRUCK 28

◆ Model View

Overhead Guard

Counterweight

Head Light
Operator’s Seat

Mast

Rear Combination Light

Lift Cylinder
Operator’s Seat Belt

Instrument Panel
Engine Hood

Backrest Extension
Rear Wheel

Fork
103480

Fuel Tank

Stop light

Tilt cylinder Backup light

Front Wheel 100709

Rear combination light (If equipped)

28 28
KNOW YOUR LIFT TRUCK 29

◆ Operator’s Compartment

Direction lever Parking brake lever Horn switch

This truck is equipped with a neutral switch. Be sure Release Push to sound horn
to put the transmission in NEUTRAL when starting
the engine. Apply

Unlocked Locked
(left) (right)
Forward (F) 101363 102592

Neutral (N)

Reverse (R) 101619A

• The knob locks the direction lever in the

NEUTRAL position.

! WARNING
– Lock the direction lever before starting Electronic Transmission
the engine. Control Unit (E.C.U.)
– Lock the direction lever when parking
(6 & 7 ton models only)
the machine — or before servicing,
adjusting or repairing it.

102531

Inching pedal By varying the position of this pedal, Brake pedal Accelerator pedal Foot operated direction
the operator can move the truck slowly ;;; Idling control (optional)
;;;
Release
;;; ;;;;;;
;;; ;;;;;;
Released
for inching while maintaining engine
;;;
Clutch
disengaged
;;; speed. Full application of the pedal Apply ;;; ;;;;;;
Full throttle
;;;;;;
Brake puts the transmission in neutral and ;;;;;;
applied 100037 applies the service brakes. 100038
;;;;;;
100039

29 29
KNOW YOUR LIFT TRUCK 30

• Steering Tilt Lever • Lift Control Lever • Tilt Control Lever

Steering tilt Forward

lever Lower

Unlock

Lock Raise
Backward
103434 103663 103664

Move the lever in arrow direction to unlock the Lifting speed is controlled by the speed of the Tilting speed is controlled by the speed of the
steering wheel. Adjust it to accommodate engine (the position of the accelerator pedal) engine (the position of the accelerator pedal)
operators or to make getting on and off the and the position of the control lever. and the position of the control lever.
truck easier. Lowering speed is controlled by the position of The lever will return to the NEUTRAL posi-
Push down the lever to lock the steering wheel. the control lever regardless of the speed of the tion when released.
engine. The mast will not tilt forward even if the con-
The lever will return to the NEUTRAL posi- trol lever is moved forward when the engine is
tion when released. stopped.

• Forward Tilt Lockout (optional)

! WARNING
Attachment
Always adjust the steering wheel tilt control
angle while stopped at a safe place, as lever
adjustment while driving may lead to
accidents.
Switch

103568

Forward tilt restricted to mast vertical unless

operator depresses override button mounted in
tilt lever knob. Full forward tilt can be achieved
102531 with button depressed.
30 30
KNOW YOUR LIFT TRUCK 31

◆ Instrument Panel
Engine coolant temperature gauge Hourmeter Fuel gauge
0.1 hour
(6 minutes)
Normal Empty
(white) (red)
Full

Overheat
(red)
Normal
(white)
102792 1 hour 102386 102388

The gauge needle is normally in the white zone. Starts registering the operating hours of the Indicates the amount of fuel in the tank when
If the needle moves into the red zone, see the engine when the key is turned to the l (ON) the key is turned to the l (ON) position. To get
topic. Engine coolant temperature gauge position. Periodic maintenance recommenda- an accurate gauge reading, be sure the truck is
needle moves into red zone. tions are based on these engine hours. level.

! CAUTION
OK monitor
Be sure to come to a complete stop before
When any warning light glows during oper- turning the selector switch.
ation, stop the truck and take corrective
action.

1st speed mode/automatic mode selector

switch
This switch was changed and moved to the
overhead guard.
Fuse box
102868

Mode Travel speed Remarks

Transmission

1st speed 0 to 9.5 km/h [0 to 5.9 mph]

Two Speed

Transmission shifts up and down

Automatic two speed
2nd speed 9.5 to 22.8 km/h [5.9 to 14.2 mph] automatically.
For jobs calling for low travel
Constant 1st speed
speed and greater drawbar pull.
0 to 13.3 km/h [0 to 8.3 mph] 104573

31 31
KNOW YOUR LIFT TRUCK 32

OK monitor bulb check Anti-restart starter switch and key

(OFF)
The following warning lights should glow
when the key switch is turned to the l (ON) l (ON)

position. (START)
The lights will go out when the engine is
started; if not, the charging system has a
defect.
Optional
Optional (For LP-Gas model)

Key
102453A

Has a built-in mechanical lockout that prevents

Optional For Gasoline model the key from being turned to the (START)
For Diesel model
position while the engine is running. Turn the
103922
key back to the (OFF) position before
If the lights fail to glow with the key switch in recranking the engine.
the l (ON) position, the bulbs have burnt out.
102868
Consult your Cat lift truck dealer. Removes all power from instrument
panel and electrical circuits except
(OFF)
for horn and lights.
position
Light switch 1 2 Applies power to all electrical cir-
Light l
cuits except for starter circuit.
Pull Instrument panel light
(ON)
Tail lights

Clearance lights Applies power to the starter motor to

Position 1 Position 2
crank the engine. A switch spring
Head lights
100048A (START) returns the key to the l (ON) position
License plate light (op.) when the key is released.
NOTICE: The lights may be turned on by
pulling the switch outward regardless
of the starter switch position. Turn off
the lights when the truck is not being
operated to prevent the battery from
discharging.

32 32
KNOW YOUR LIFT TRUCK 33

◆ OK Monitor (Warning Lights and Indicators)

Powershift transmission oil Air cleaner warning light Alternator not charging LP-Gas residual pressure alarm
temperature warning light (optional) warning light light (optional)
Glows when the oil temperature is Glows when the air cleaner ele- Glows when the charging system Lights when the residual quantity
high and the danger of overheat- ment is clogged. If the light glows, is out of operation. If the light becomes small.
ing is present. clean or replace the element. glows, check the alternator drive
If this light glows, see the topic, belt for slippage or breakage.
Powershift transmission oil tem-
perature warning light glows.

Engine coolant level warning

light (optional)
Brake fluid level warning light
Glows when the fluid level is Glows when the coolant level in
lower than the specified level. the radiator is too low. If the light
Have the brakes checked by your glows, refill the radiator at the
Cat lift truck dealer. reserve tank.

103490
ECM Warning Light
Engine oil pressure warning light Glows when ECM (engine control
If this light glows during operation, stop the engine and check the oil level. module) is abnormal. Consult your
Add oil as required. Cat lift truck dealer. Moved to
overhead guard leg box on new
models.
! CAUTION

Do not operate the engine when the oil level is low or when this light is on.
Engine overheating may result. If the light glows when the oil level is nor-
mal, have the engine checked by your Cat lift truck dealer.
33 33
KNOW YOUR LIFT TRUCK 34

◆ Driving Interlock System

1st speed mode/automatic mode selector
In normal operation your lift truck will drive in switch (6 and 7 ton models only)
a creep mode when the direction lever is placed
in the forward or reverse position at engine Automatic mode
idling (not depressing the accelerator pedal). If (1st speed 2nd speed)
the operator then leaves the operator’s seat, the
operator presence switch of the seat is activated
to shift the forward or reverse position into the 1st speed mode
neutral position electrically (the lever itself
remains in the forward or reverse position), and 104575
cut off the engine output to stop the lift truck.
In this case, the parking brake does not syn-
chronize with the driving interlock and is not 104789
automatically applied the moment the interlock
is activated.
Depending on the condition of the road (grade, ! CAUTION
Driving interlock indicator light
for example), therefore, the lift truck may be 1. Prior to operating the lift truck, be sure Flickers if the operator leaves the seat with
accelerated, instead of being stopped. to check the driving interlock for func- the direction lever in the forward or reverse
tion. position while the engine is idling.
• Operator Presence Switch 2. While driving the lift truck, if you lift
your hips above the seat for over 2 sec-
onds, the driving interlock system will Neutral indicator light
Operator presence
switch be activated, the same as in case of Glows when the direction lever is placed in
engine idling. Neutral (N) position.
Always drive the lift truck correctly
with safety in mind.
3. To restore the lift truck to its normal ECM warning light
driving condition, sit properly in the
Glows when ECM (engine control module) is
operator's seat and depress the brake
abnormal.
pedal to hold the lift truck. Then, return
104131
the direction lever to the neutral posi- Consult your Cat lift truck dealer.
This switch is built in the seat. tion and then shift it back into the for-
ward or reverse position.
4. When replacing the operator's seat, be
sure to use Cat lift truck genuine seat
with operator presence switch.
34 34
KNOW YOUR LIFT TRUCK 35

• Neutral System • Foot Operated Direction Control (Optional) • Rear View Mirror
The lift truck is provided with a device that pre-
vents the engine from being started when the ! WARNING
direction lever is not in the neutral position.
Always adjust the rear view mirror before
starting at a safe place, as adjustment
while driving could lead to accidents.

With this option, the forward-reverse lever is

replaced by a directional control that is part of the Rear view
mirror
accelerator pedal. Depress the left side of the con-
trol to go forward; depress the right side to go in
reverse. Speed is increased by further depressing
the control. Toggle the neutral switch located on
the steering column between neutral or drive for
104016
operation. is for neutral and is used for for-
ward or reverse travel.
103491
! CAUTION
Before starting the engine, sit properly in
the operator's seat and make sure that:
• No one is around the lift truck.
• The parking brake is applied.
• The direction lever is in the neutral
position.

35 35
KNOW YOUR LIFT TRUCK 36

◆ Operator’s Seat
• Adjustment of suspension • How to tip the seat forward
• Adjustment

! WARNING

Adjusting
knob
Increase

Gauge

Decrease

104134 Lever 102716

100974A
Adjust the suspension before sitting on the seat. To open the engine hood on a truck equipped
Turn the knob until the gauge indicates the with the LPG system, tip the seat forward first
Adjust the seat before starting the engine. After weight of the operator. Turning the knob clock-
adjusting, jiggle the seat to make sure it is prop- to get clear of the LPG tank.
wise, increases the gauge indication, and turn-
erly locked. DO NOT adjust the seat while the To tip the seat forward
ing it counterclockwise decreases the gauge
truck is in motion. indication. The release lever is located on the left side of
the seat. Pull this lever all the way in the direc-
tion of arrow, hold the lever in that position, and
tip the seat forward by pushing the backrest.
• Fore-and aft Adjustment • Lumbar Support Adjustment
To reposition the seat
Reposition the seat by pushing the backrest
Front to back adjustments:
152 mm (6 in.)
Adjusting back and then push the lever to lock.
knob Lower

Raise
! WARNING
Lever This industrial truck is equipped with an
operator restraint system. Should it
104135
become necessary to replace any of the
100973 components including the seat assembly
Turn the knob clockwise to raise the backrest. for any reason, it must only be replaced
Move the lever to the left, slide the seat to one Turn the knob counterclockwise to lower it.
of the seven positions, and release the lever. with components approved by the manu-
facturer.

36 36
KNOW YOUR LIFT TRUCK 37

◆ Seat Belt

! DANGER ! WARNING ! WARNING

100976 100977 100978

The seat belt will help to restrain you in acci- If the seat belt is torn, the pulling motion is Also, replace the seat belt assembly if it was
dents such as a tipover or mast and attachments interrupted during extension of the belt, or the worn during an accident.
collision. If you are unrestrained in a tipover, belt cannot be inserted into the buckle properly.
you can fall outside of the operator’s compart- Replace the seat belt assembly.
ment and be crushed by the lift truck. If you are
unrestrained and the lift truck comes to a sud-
den stop, you will continue moving forward
The seat belt shall be examined at the regular
until you hit a solid object.
service intervals. It is recommended that it be ! WARNING
Wear your seat belt anytime you operate a lift replaced if any of the following conditions are
truck. Seat belts can “jack-knife” drivers—
found. the upper body bends tightly at the
– Cut or frayed strap waist. If you are pregnant or have suf-
– Worn or damaged hardware, including fered an abdominal disease or injury,
anchor points consult a doctor before using the seat
– Buckle or retractor malfunction belt.
– Loose stitching

37 37
KNOW YOUR LIFT TRUCK 38

To Fasten To Release

! WARNING
Plate
If you fasten the belt across your
abdomen, the belt will dig into your
abdomen in an accident and could cause
serious internal injuries.

Buckle
100981 100983

1. Grip the plate (connector) of the belt and Push the button in the buckle to release the belt.
pull the belt from the retractor. Then insert The belt will automatically retract when
NOTICE: It is not necessary to adjust the belt the plate into the slot of the buckle until a released. Hold the plate of the belt and allow
length. snap is heard. the belt to slowly retract.
The belt is designed to fit any body 2. Make sure the belt is not twisted.
size.
Tug on it to confirm a tight fit.

100982A

3. Be sure to fasten the belt as low as possible

across your hips, not across your abdomen.

38 38
KNOW YOUR LIFT TRUCK 39

IMPORTANT

The following maintenance guidelines detail how to inspect seat belt for “cuts, fraying, extreme or
unusual wear of the webbing, etc., and damage to the buckle, retractor, hardware, or other factors”
which indicate that belt replacement is necessary.
1. Check the web wear at the buckle/latch area. The webbing must be closely examined to deter-
mine if there are any cuts, fraying or extreme wear in the webbing. Cuts, fraying, or excessive
wear would indicate the need for replacement of the seat belt system.
2. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed,
or buckle is damaged or casing broken.
3. The retractor web storage device, is mounted on the seat. The retractor is the heart of the occu-
pant restraint system and can be damaged if abused, even unintentionally. Check retractor web
storage device operation to ensure that it locks properly and that it spools out and retracts web-
bing properly.
4. Hardware for seat belt mounting points should be evaluated for corrosion, all attachment points
of system should be checked for tightness of bolts and nuts.
5. Check web in areas exposed to ultraviolet rays from the sun or extreme dust or dirt. If the origi-
nal color of the web in these areas is extremely faded, the physical strength of this web may have
deteriorated. If this condition exists replace the system.

39 39
KNOW YOUR LIFT TRUCK 40

◆ Fuses and Lights • Lights Won’t Come On

Check for burned-out or “blown-out” Lamp type Capacity
! CAUTION
fuses first.
– Always replace fuses with fuses of the Meter panel lamp 14V-3W
correct amperage. Tail/Stop lamp 12V-8W/23W
– If fuse burns out immediately and you Headlamp 12V-27W
cannot locate the cause, have your Cat
lift truck dealer make a circuit check. Back-up lamp 12V-10W
Check the fuses one by one by
– Use a replacement light bulb of the operating the light switch and seeing if Working lamp (opt) 12V-27W
same wattage. each light comes on. Lights are suspected
to have burned out.

Code Capacity Circuit A

A 10A Direction lever 100846
B
10
B 15A Instrument panel (for monitor C 15
and gauge), back-up, tail/stop D
15

and turn signal (opt) lights, 15

ECU (for T/M controller) E 15

C 15A Spare power source F

10 One light of the circuit fails to light.
10
D 15A Instrument panel (for panel G 15

light), head and working (opt) H

10 All lights of the circuit fail to light.
lights
J
E 15A Head lights 102535A
F 10A Spare fuse
G 10A Horn
Check to see if fuse has been blown out.
H 15A Fuel pump Puller
J 10A ECU (for engine)

100845
101442

To remove the fuse or insert a replacement

fuse, use the puller found in the fuse panel lid.

40 40
KNOW YOUR LIFT TRUCK 41

◆ Fork Stoppers ◆ Changing Forks

• To Remove
Remove a fork from the carriage to replace it or
! WARNING to access other parts of the truck for mainte- ! WARNING
When adjusting the fork spread, be care- nance. Slide the forks, one at a time, to the DO NOT try to move a fork without a lift-
ful not to pinch your hand between forks installation/removal notch on the bottom car- ing device. Each fork can weigh in excess
and lift bracket. riage bar. Tilt the carriage forward, then lower of 45 kg (100 lb.)
it until the hook fork disengages the forks from
the carriage. Use a lifting device to move the
forks away from the truck.
◆ Safety Equipment

1. Carriage Bars
– Overhead guard
2. Hook Fork – Load backrest extension
3. Blocks

➀ ➁
DO NOT use a lift truck without safety equip-
ment in proper operating order.
103445

For load stability, adjust the forks as wide as

possible. ➂ 102791
To adjust the fork spread, move the levers or
twist the knobs upward and reposition the • To Install
forks. Spread the forks to fit the load.
Position the forks side-by-side on the floor in a
location where they can be approached from
the rear by the lift truck. Slowly drive the lift
truck, with the carriage fully lowered and fully
! CAUTION
tilted forward, to a point just to the rear of the
– After adjusting the fork spread, restore forks. Carefully slide the forks, one at a time,
the stoppers to the original position to onto the carriage so the top hook of the fork is
lock the forks. placed above the top carriage bar. Raise the car-
– Position each fork the same distance riage to engage the top hooks allowing the bot-
from the center of the backrest extension. tom hooks to pass through the
installation/removal notch. Then carefully slide
each fork on the carriage so both the upper and
lower hooks engage the carriage. Lock the
forks in place by engaging the fork lock pins.
41 41
KNOW YOUR LIFT TRUCK 42

◆ Drawbar Pin ◆ Assist Grip

! WARNING ! WARNING ! WARNING

DO NOT use the drawbar pin for towing DO NOT grab the steering wheel or lever.
loads. DO NOT jump on or off the truck.

100864A

Drawbar
pin Precautions for Use of the Drawbar Pin

1. When hitching a cable to the pin, make

100330A 101644
sure the pin is inserted safely.
Use the drawbar pin for: 2. Take up slack slowly—DO NOT jerk. Keep Grasp the assist grip with the left hand, the seat
– Pulling the truck out of a drop-off or ditch. the cable taut. If the cable is slack, the sud- backrest with the right hand, and step up with
– Loading the truck on a hauling truck. den impact of the load can snap it, resulting the left foot to get on the truck safely.
in an accident.
3. A helper should stand at a safe distance and
watch the pin. Stop pulling with the truck,
relieve tension, and reduce load if the pin
starts to come out.

42 42
KNOW YOUR LIFT TRUCK 43

◆ Hydraulic Tank Oil Level/Filler Hole ◆ Fuel Shut-off Valve

! CAUTION
Confirm the engine type before filling the
tank with the recommended fuel.

100695C 102536

The oil level/filler hole is located on the right The fuel shut-off valve is located near the air
side of the truck inside the engine hood. To cleaner inside the engine hood. In an emer-
check the oil level, use the dipstick located in gency or when performing maintenance, close
the hole. this valve.

◆ Fuel Filler
! WARNING ! WARNING

103197 100989 102538

The fuel filler is located on the left side of the Never fill the tank near an open flame or when After refueling, close the cap tightly and wipe
truck. The cap can be removed by turning it the engine is running. When filling, keep the up spillage.
counterclockwise. funnel or fuel hose nozzle in contact with the
tank’s metal. This reduces the risk of an electric
spark igniting the fuel.

43 43
KNOW YOUR LIFT TRUCK
◆ Engine Hood

WARNING To open
!
Keep fingers away from this area 1. The seat backrest must be folded down and
the seat assembly must be slid fully for-
ward before opening the engine hood.
2. To fold the seat backrest down, pull the seat
backrest release lever all the way in the
direction of the arrow, hold the lever in that
position, and tip the seat forward by push-
ing the backrest.
Lever 3. Pull the seat assembly adjust lever to the
102589 102534A
left and slide the seat assembly fully for-
The engine hood swings up to fully expose the ward and release the lever.
engine compartment for daily inspection, serv- 4. Push down on the hood with one hand and
icing and lubrication. use the other to release the engine hood
latch.
Inspection Points Inside Engine
Lever
Former 5. Lift the engine hood and tilt it all the way
Compartment
back.
– Engine oil level
– Engine coolant level
– Hydraulic oil level To close
– Air cleaner element 1. Place your hand against the seat backrest
– Alternator drive belt and slowly lower the engine hood.
– Battery electrolyte level 2. Push down on the hood until it is securely
102541 latched.
! WARNING 3. Place your right hand on the seat backrest
When closing the engine hood, be careful not to pinch your New
and use your left to pull the seat backrest
hand. lock lever and open the seat.
4. Using the seat assembly adjust lever, slide
seat assembly back to desired position.

102539 103588

44 44
KNOW YOUR LIFT TRUCK 45

◆ Radiator Cover ◆ Back-up Buzzer (If equipped)

! WARNING

– When operating in reverse, alarm

Knobs must sound.
– Failure to maintain a clear view in the
direction of travel could result in
injury or death.
– The operator is responsible for the
safe operation of this truck.

102581

To open
1. Turn the knobs counterclockwise.
2. Lift and remove the cover.

To close
Install the cover, and turn the knobs clockwise.

45 45
 ||||||||||||||||||||||||||| HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE |||||||||||||||||||||||||
◆ Know What Lift Truck Stability Is ◆ Center of Gravity (CG) ◆ Stability and Center of Gravity

;;;;;
CG Truck Combined CG CG Load

;;;;; ;;;;;;;;;
;;;;; ;;;;;;;;;
;;;;;;;;;
CG
;;;;;;;;;
100991 100915 100858

Counterbalanced lift truck design is based on CG is defined as the point of an object where its The stability of the lift truck is determined by
the balance of two weights on opposite sides of weight is evenly distributed. If the object is uni- the location of its CG, or if the truck is loaded,
a fulcrum (the front axle). The load on the forks form, its geometric center will be the same as the combined CG. The lift truck has moving
must be balanced by the weight of the lift truck. its CG. If it is not uniform, the CG could be a parts and, therefore, has a CG that moves. The
The location of the center of gravity of both the point on either side of the normal geometric CG moves forward or backward as the mast is
truck and the load is also a factor. This basic center. When the lift truck picks up a load, the tilted forward or backward. The CG moves up
principle is used for picking up a load. The abil- truck and load have a new, combined CG. or down as the mast moves up or down. The
ity of the lift truck to handle a load is discussed CG and, therefore, the stability of the loaded
in terms of center of gravity and both forward lift truck, is affected by a number of factors
and sideways stabilities. such as:
– The size, weight, shape and position of the
load.
– The height of the lifted load.
– The amount of forward or backward tilt.
– Dynamic forces created when the lift truck
is accelerated, braked or turned.
– Condition and grade of surfaces on which
the lift truck is operated.

46 46
HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 47

◆ Lift Truck Stability Base ◆ Capacity

(Weight and Load Center)

;;;;;;;;;;;;;
CG load CG-Truck will tipover.

;;;;;;;;; ;;;;;;;;;;;;;
;;;;;;;;; ;;;;;;;;;;;;;
Combined CG
;;;;;;;;; ;;;;;;;;;;;;;
;;;;;;;;; ;;;;;;;;;;;;;
;;;;;;;;;;;;;
CG truck

100859

These factors must be considered when the lift

100860

In order for the lift truck to be stable (not

;;;;;;;;;;;;; 100676

The capacity of the lift truck is shown on the

truck is unloaded, as well, because an empty tipover forward or to the side), the CG must capacity plate. It is determined by the weight
lift truck will tip over to the side more easily stay within the area of the lift truck stability and load center. The load center is determined
than a lift truck carrying a load in the lowered base—a triangle drawn between the front by the location of the CG of the load. The load
position. wheels and the pivot of the rear axle. If the CG center shown on the capacity plate is the hori-
moves forward of the front axle, the lift truck zontal distance from the front face of the
will tip over forward. If the CG moves outside forks, or the load face of an attachment, to the
of the line on either side of the stability base, CG in the load. The location of the CG of the
the lift truck will tip over to the side. vertical direction is the same as the horizontal
dimension.
Keep in mind that, unless otherwise indicated,
the capacity shown on the capacity plate is for
a standard lift truck with standard backrest,
forks and mast, and having no special-purpose
attachment. In addition, the capacity presumes
the load center is no further from the top of the
forks than it is from the face of the backrest. If
these conditions do not exist, the operator may
have to reduce the safe operating load because
the truck stability may be reduced. The lift
truck should not be operated if its capacity
plate does not indicate the capacity.

47 47
HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 48

◆ Capacity Plate
• For example

The capacity plate shown above is for a 5.5 ton

! CAUTION model standard lift truck whose capacity is
1. Capacity plate originally affixed to lift 5500 kg (12000 pounds) at 600 mm (24 in.)
trucks sold by Cat Lift Trucks shall not load center. The chart specifies this lift truck
be removed, altered or replaced without can lift up to 5500 kg (12000 pounds) if the
Cat Lift Trucks’ approval. load center is not more than 600 mm (24 in.)
2. Cat Lift Trucks assumes no responsibil- forward from the face of the backrest. Before
ity for lift trucks placed in service with- attempting to pick up or lift a load, make sure
out a valid Cat Lift Trucks capacity its weight is within the capacity of the truck at
plate. the load center involved.
3. If necessary to change your specifica- NOTICE: If the load is not uniform, the heav-
tion, contact your Cat lift truck dealer. iest portion should be placed closer
to the backrest and centered on the
forks.

48 48
HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 49

◆ Do’s and Don'ts to Avoid Tipover

! WARNING ! WARNING ! WARNING

100992 100993 100994

DO handle loads only within the capacity DO NOT go over rough terrain! DO avoid fast starts, turns and sudden
shown on the capacity plate! If unavoidable, slow down. stops!
These movements can cause the lift truck to tip
over.

! WARNING ! WARNING ! WARNING

100665 100995 100667

DO watch “tail swing.” DO check surface strengths! DO NOT turn, or angle, on ramps and
Always maintain a safe distance from the edge Stay away from soft ground to avoid tipover. grades, with or without a load!
of docks, ramps and platforms.

49 49
HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 50

! WARNING ! WARNING ! WARNING

100996 100997 100670

DO NOT tilt elevated loads forward! DO NOT elevate tilted loads! DO NOT pick up an off-center load!
This can cause the lift truck to tip over forward. This can also cause the lift truck to tip over. Such a load increases the possibility of a
tipover to the side.

! WARNING ! WARNING ! WARNING

100998 100671 100999

DO avoid slippery surfaces! DO NOT attempt to pick up or deposit a DO NOT go over obstacles—curbs, ditches,
Sand, gravel, ice or mud can cause a tipover. If load unless the lift truck is level! ridges and railroad tracks!
unavoidable, slow down.

50 50
HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 51

! WARNING ! WARNING ! WARNING

101000 101616 101617

DO NOT travel with forks higher than 15 to DO NOT make fast or sharp turns with a DO NOT turn too sharply, even with an
20cm (6 to 8 in.) above the ground! loaded or unloaded truck! empty raised mast, to avoid a tipover!
The CG moves up increasing the possibility of
a tipover.

! DANGER ! DANGER ! WARNING

103442 100649 100868

DO fasten your seat belt! DO NOT jump off your truck if it starts to DO wear a hard hat!
The belt will keep you from being thrown out tip over! It will help protect your head from serious
of the truck in a tipover. Stay in your seat to reduce the risk of serious injury.
injury or death.

51 51
HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 52

◆ How to Survive in a Tipover

! DANGER

Remember, your chances for survival

with your seat belt fastened in a tipover
are better if you stay in your truck. If
your truck starts to tip over:
1. DO NOT jump off!
2. Firmly hold on to the steering wheel.
3. Brace your feet.
4. Lean away from impact.
5. Lean forward.

(1) (2)

(3) (4)

(5)

101002 101524

52 52
||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| REFUELING ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ Gasoline Engine Equipped

1. Park the lift truck only at a location desig-

! WARNING nated safe. Place the transmission in NEU-
– Explosive fumes may be present dur- TRAL, lower the forks to the ground,
ing refueling. engage the parking brake and shut off the
– Do not smoke in refueling areas. engine.
– Lift trucks should be refueled only at
designated safe locations. Safe outdoor
locations are preferable to those
indoors.
– Stop the engine and get off the lift
truck during refueling.

NOTICE: DO NOT allow the lift truck to

become low on fuel or completely
103197
run out of fuel. Sediment or other
impurities in the fuel tank could be 2. Open the filler cap.
drawn into the fuel system. This 3. Fill the fuel tank slowly. Close the filler
could result in difficult starting or cap. If spillage occurs, wipe off excess fuel
damage to components. and wash down the area with water.
Fill the fuel tank at the end of each NOTICE: Drain water and sediment from the
day of operation to drive out mois- fuel tank as required by prevailing
ture laden air and to prevent con- conditions. Also, drain water and
densation. DO NOT fill the tank to sediment from the main fuel storage
the top. Fuel expands when it gets tank before it is filled and as a
warm and may overflow. weekly routine. This will help pre-
vent water or sediment being
pumped from the storage tank into
the lift truck fuel tank.

53 53
REFUELING 54

◆ LP-Gas Equipment

For Standard LP-Gas Tank 6. Inspect the replacement tank for damage
! WARNING
1. Park the lift truck on level ground with the such as dents, scrapes or gouges and for
parking brake applied, transmission in leakage at valves or threaded connections.
Only trained and authorized personnel
NEUTRAL, forks lowered and the engine 7. Check for debris in the relief valve and for
should fill or exchange LP-Gas tanks.
running at low idle. damage to various valves and the liquid
Personnel engaged in filling LP-Gas
tanks should wear protective clothing 2. Close the fuel valve at the LP-Gas tank. level gauge.
such as face shield, long sleeves and Run the engine until it stops, then turn off 8. Inspect the couplings for deterioration,
gauntlet gloves. the starter switch. damage or missing flexible seals.
Do not refuel or store LP-Gas powered 3. Disconnect the fuel supply line. 9. Position the LP-Gas tank on the brackets
lift truck near underground entrances, 4. Loosen the retaining clamps, remove the and make sure the locating hole on the tank
elevator shafts, or other places where tank. is positioned and inserted to the pin on the
LP-Gas could collect in a pocket and bracket.
cause potential danger for an explosion. 10. Clamp the tank securely.
Examine all LP-Gas tanks before filling, ! WARNING 11. Connect the fuel supply line.
and again before reuse, for damage to 12. Turn the fuel valve on by slowly turning it
the valves, liquid gauge, fittings and LP-Gas tank must not extend past the counterclockwise. If the fuel valve is
hand wheels. counterweight. opened too quickly, a back pressure check
All defective or damaged LP-Gas tanks valve will shut off the fuel supply. If this
must be removed from service. 5. Check to be sure the replacement tank is of happens, close the fuel valve completely,
The careless handling of an LP-Gas tank the correct type. wait five seconds, and then open the fuel
can result in a serious accident. valve very slowly.
To reduce the risk of damage to tanks, use LOCATION
extreme care when transporting them.
33-1/2# tank (A) Use pin (B)

43-1/2# tank (B) Use pin (A)

NOTICE:
1. MOUNT THE TANK PROPERLY. Use
holes in the collar for horizontal mounting
and the slot in the foot ring for vertical
mounting to insure full usage of the fuel. B A

2. Open the valve slowly so the hose and tank B A

100717A
pressure can equalize or the valve may shut
off. 13. Inspect the LP-Gas fuel lines and fittings
3. For proper operation of LP-Gas system, with a soap solution after filling the tank or
use HD5 LPB fuel. 101618
when looking for leaks.

54 54
||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| OPERATION ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ New Lift Truck Break-In ◆ Before Starting Engine

Correct break-in is important for operation and

long life of your truck. The first 100 service ! WARNING ! CAUTION
hours of operation is the break-in period for 1. After starting the engine, BE SURE to
BE SURE TO READ the SAFETY
your truck. Read these precautionary instruc- run it at idle speeds with no load for
RULES FOR LIFT TRUCK OPERA-
tions carefully. about 5 minutes. During this time,
TORS for your safety and the safety of
fellow workers. BE SURE to perform check all the OK Monitor indicator
the DAILY (PRE-START) INSPEC- lights. AVOID long periods of idling.
TION. This may cause cylinder wall glazing
! CAUTION and prevent the piston rings from seat-
Should the truck become unsafe during ing properly. DO NOT pump the accel-
operation in any way whatsoever, you must erator pedal and DO NOT REV up the
report it immediately to the designated engine. This may cause cylinder wall
authority. The truck must not be used again scuffing and scoring.
until it has been restored to safe operational 2. If the truck does not have to be put to
condition. work immediately, or the operation is
light and slow, break in the truck under
a simulated working condition.
3. Try NOT to drive the truck continuously
at the same speeds as the parts tend to
! CAUTION better adjust themselves to other parts if
Before starting the engine, sit properly in various speeds are used.
104576 4. ALSO, try NOT to make severe brake
the operator’s seat.
Your truck has an operator presence switch (a applications to allow the brake linings
switch built in the seat). to seat against the brake drums.
The starting mechanism in vehicles with pow- 5. Operate the truck under a lighter load
ershift transmission is disabled until the opera- and lower speeds than normal.
tor is seated. 6. Change oils and relubricate at shorter
When the key switch is in I (ON) position, driv- intervals than normal.
ing interlock indicator light in the switch box 7. Carefully check on and around the truck
on the overhead guard flickers unless an opera- for loose bolts and nuts. Retighten them
tor sits on the seat properly. as needed.

55 55
OPERATION

• Gasoline/LP-Gas Dual Fuel Type

Instruction for changeover of fuel between LP-Gas • To change from gasoline to LP-Gas
and gasoline 1. Turn the key switch to (OFF) position and
• To change from LP-Gas to gasoline place the fuel selector switch to OFF position.
1. Turn the key switch to (OFF) position and 2. Turn the key switch to (START) position.
close the valve on the LP-Gas container. Leave The engine should not start.
the fuel selector switch in LPG position. If the engine starts, leave it running until it
2. Turn the key switch to (START) position. stops by itself.
The engine should not start. 3. Turn the key switch to (OFF) position and
If the engine starts, leave it running until it then place the fuel selector switch to LPG posi-
stops by itself. tion.
3. Turn the key switch to (OFF) position and Open the valve on the LP-Gas container.
then place the fuel selector switch to GAS posi- Now the engine can be started using the LP-
tion. Gas.
Now the engine can be started using gasoline.

! WARNING NOTICE:
If operating on gasoline and with no LP tank
The LP-Gas and the gasoline are flam- installed, hook the LP hose to the bracket by screw-
mable. Leakage of these may cause fire. ing the coupling into place. It will secure the hose.
Before changing the fuel from LP-Gas to
gasoline, be sure to check the fuel line for
deterioration and loose connection in
accordance with the instruction shown in
this manual.

! CAUTION
If this truck will be operated with LP-Gas for
a long time, check gasoline fuel line in
accordance with STORING THE LIFT
TRUCK in this manual and make sure all
gasoline fuel lines are empty.

56 56
OPERATION 57

Close Lock
Released

Applied
Open
Neutral

102536 101363 101623A

Open the fuel shutoff valve. – Pull the parking brake lever. – Be sure the lock knob is in the LOCK posi-
tion and the direction lever is in the NEU-
TRAL position.
– The engine will not start unless the direc-
tion lever is in the NEUTRAL position.
– If the engine stalls, place the direction lever
! WARNING in the NEUTRAL position; turn the key to
the (OFF) position; and turn it to the
Always adjust the rear view mirror before (START) position to start the engine.
starting at a safe place, as adjustment
while driving could lead to accidents.

Rear view
mirror
100976

Be sure to fasten the seat belt before operating

the truck.
Remember, the belt will not restrain you in an
accident if it is not fastened properly.

103491

57 57
OPERATION 58

◆ Starting Gasoline Engine ◆ Starting LP-Gas Engine

If the engine won’t start: 1. Turn the tank fuel valve I (ON) by slowly
turning the valve counterclockwise.
Observe the LP-Gas gauge (if equipped).
Turn the key to the (OFF)
Turn the key to the (OFF)
(START) position (START) (OFF) position and (START) (OFF) l (ON)
(START)
to crank the engine recrank the engine.
(no more than 10 sec-
onds at a time).

100724 100728A

If the engine won’t start, see the topic, Engine

201315A
Won’t Start.
2. Turn the key switch to (START) posi-
tion. Release it when the engine starts.
Release the key when
! CAUTION
3. If the engine does not start, do not press on
the engine starts. – DO NOT leave the key in the l (ON) the accelerator. Turn the key switch to the
position when the engine is NOT run- (OFF) position, then repeat step 2.
ning. This may cause the battery to run
down and damage the ignition coil.
! WARNING
– DO NOT crank the engine for more than
10 seconds at any one time. This may LP-Gas fuel is flammable and could cause
100725 cause damage to the starter and run injuries and fires.
down the battery. Inspect LP-Gas fuel lines and fittings for
leaks.
Inspect tank for secure mounting.
Let the engine warm up for about 5 minutes.

58 58
OPERATION 59

◆ Engine Won’t Start

Consult your Cat lift truck dealer if the engine still fails after you have attempted Does the starter crank the engine?
several times.

Gasoline Engine Model

(OFF)
(START)
101055A

No Yes
Turn the key to the (START)
position and crank the engine
several times. The head lights do Is the fuel gauge
100724 not come ON or are showing there is
dimmed. fuel in the tank?

! CAUTION
DO NOT start the engine by 100703 102388
pushing or towing the truck. This
Depress the accelerator pedal could cause serious injury and
and start the engine. damage to the truck. The battery is dead. Refuel.
(Tier II Models—DO NOT
depress the accelerator pedal
upon startup.)
100730

– The head lights should be OFF

for easier starting.
100734 100735

59 59
OPERATION 60

◆ Starting with Jumper Cables

This lift truck has a 12 volt starting system.

! WARNING ! WARNING Use only equal voltage for jump starting. Use
Batteries give off flammable vapors of a welder or higher voltage will damage the
DON’T try to start the engine by pushing
which may explode. electrical system.
the truck.
Keep flames and sparks away from bat- Turn on (close) the battery switch prior to the
BE SURE to connect the cable end 4 to
teries. They could cause vapors to boost connection to prevent damage to electri-
the ENGINE BODY. If it is connected to
explode. Do not allow jumper cable ends cal components on the stalled lift truck.
the negative (–) terminal of the battery,
to contact each other or the lift truck. sparks could ignite the gases. Many “dead” batteries can be recharged.
Do not smoke when checking battery 2. Connect the jumper cables in the sequence
electrolyte levels. shown.
Electrolyte is an acid and could cause DO NOT short across the positive (+) and
injury if it contacts skin or eyes. ! CAUTION negative (–) terminals.
3. After connecting the cables, increase the
Always wear eye protection when starting Connect the jumper cables away from the speed of the other vehicle’s engine and
a lift truck with jumper cables. moving parts in the engine compartment. start the engine of the stalled truck with a
Improper jump start procedures can “run-down” battery.
cause an explosion that could result in 4. After the engine starts, disconnect the
injuries. jumper cables in the reverse sequence.
Turn off all lights and accessories on the NOTICE: You can buy jumper cables from
stalled lift truck. ➃ your Cat lift truck dealer.
Always connect battery positive (+) to ➂
battery positive (+) and battery negative Truck being
started
(–) to engine body.
Jump only with a battery source of the
same voltage as the stalled lift truck. ➁ ➀
“Good” Battery
100842

To start a truck with a “run-down” battery, use

a booster battery or jumper cables from the bat-
tery of another vehicle.
1. Position another vehicle, with its engine
running, within jumper cable distance.
NOTICE: Use a 12 volt jumper system to
jump start the truck.
60 60
OPERATION 61

◆ After Starting Engine

Check the OK monitor and gauges frequently 2. During warm-up, check to see that systems
during operation to be sure all systems are are operating properly.
working properly.
– Are all the OK monitor warning lights
! WARNING OFF?
– Is the engine coolant gauge needle in the
If a monitor light comes on, correct the WHITE zone?
problem before operating the lift truck. – Are exhaust noise and smoke color nor-
mal?
– No excessive vibration?
1. Run the engine at idle speeds with no load
for about 5 minutes.

! CAUTION
– BE SURE to warm up the engine
regardless of the weather.
– Failure to warm up the engine can cause
poor lubrication and incomplete fuel
combustion resulting in poor engine
performance.

61 61
OPERATION 62

◆ Before Moving Lift Truck

! WARNING
1st speed mode/automatic mode selector
switch
This switch was changed and moved to the
overhead guard.

102473A 101013

1. Turn the 1st speed mode/automatic mode Look around and behind the truck and sound
selector switch to the desired position. the horn before moving.
– Selector switch: For 6 and 7 ton models
only. 104573

101056A

2. Use the lift control lever to raise the forks

to a safe traveling height of 15 to 20 cm (6
to 8 in.) from the floor.
3. Use the tilt control lever to tilt the mast
back all the way.
62 62
OPERATION 63

◆ Lift Truck Operation

Unlock

Forward

Reverse

100738B 101622A 101427 100739

1. Depress the inching pedal all the 2. Place the lock knob in the 3. Push the parking brake lever. 4. Gradually depress the accelerator
way. UNLOCK position and move the pedal while releasing the inching
direction lever to the FORWARD pedal.
or REVERSE travel position.

! CAUTION
DO NOT “ride” the inching pedal during traveling. This produces a partly
disengaged condition in the transmission and may result in premature clutch
plate wear and premature brake lining wear.

63 63
OPERATION 64

• Changing Speed • Changing Direction

! WARNING ! WARNING

100740 101062A 101431B 101013

Use the accelerator pedal to increase NEVER move the direction lever to the Before making directional changes, BE SURE to watch for people or haz-
travel speed. Use the brake pedal to NEUTRAL position during traveling. slow the truck down to a walking ards in the direction of travel.
slow down. This causes the engine to overspeed. speed, no faster than 4 kph (2.5 mph),
or come to a complete stop.

! CAUTION ! CAUTION
Before operating the speed selec- Directional changes faster than
tor, BE SURE to come to a com- stated will cause premature dam-
plete stop. age to the driveline. For greater
operator safety and maximum
service life of driveline compo-
nents, it is recommended the oper-
ators bring the truck to a complete
stop before changing direction.

64 64
OPERATION 65

• Operating Techniques • Steering (Turning)

101726A Car Lift Truck 100745 100746

Turn the steering wheel with both hands. When A lift truck is different from most other vehi- 1. When working in close quarters, drive
handling loads, stop the truck and move the tilt cles because it is steered by the rear wheels. more slowly when making turns.
and lift control levers with the right hand. This causes an exaggerated tail swing. 2. Start the turn as close to the inside corner
as the tail swing will permit.

! WARNING ! WARNING ! WARNING

101066 101067 101068

Turning with the forks elevated, with or with- Turning at high speeds, with or without a load, Be aware of tail swing distance. Be sure the tail
out a load, can cause a tipover. can also cause a tipover. swing area is clear, before turning, to avoid
injury to pedestrians.

65 65
OPERATION 66

• Inching

100747 100748A 100749A

The purpose of the inching pedal is to provide 1. Stop ahead of the load platform, lock the 4. When the left foot is slowly taken off the
precise lift truck inching control at very slow parking brake lever, set the direction lever inching pedal, the lift truck will advance
travel speed and high engine rpm. You can to NEUTRAL, place the mast vertically, slowly.
move your truck slowly while maintaining the and raise the fork to the height of the pallet 5. Insert the fork slowly, taking care it does
engine speed by varying the position of the insertion openings. not hit the pallet.
inching pedal. Use this pedal when approach- 2. Depress the inching pedal all the way, 6. Stop after inserting the fork until the root
ing the load and when loading and unloading. move the direction lever to FORWARD, of the fork comes into light contact with
and release the parking brake. the pallet.
3. Gently depress the accelerator pedal.

! CAUTION
DO NOT “ride” the inching pedal during
traveling. This produces a partly disengaged
condition in the transmission and may result
in premature clutch plate wear and prema-
ture brake lining wear.

66 66
OPERATION 67

◆ Stopping Lift Truck

! WARNING

Lock

Neutral

100752 100755 101623A 101070

1. Release the accelerator pedal. 2. Depress the brake pedal. 3. Move the direction lever to the Avoid sudden stops. This can cause
NEUTRAL position, and place the load to fall off the forks or the
the lock knob in the LOCK posi- truck to tip over.
tion.

67 67
OPERATION 68

◆ Parking Lift Truck (After Stopping)

Lock
(OFF)
l (ON)

Neutral

101623A 101409 103449 100885A

1. Move the direction lever to the 2. Pull the parking brake lever all 3. Tilt the mast forward just a little 4. Turn the key back to the (OFF)
NEUTRAL position, and place the way. and lower the forks to the floor position to stop the engine.
the lock knob in the LOCK posi- until the fork tips touch the floor. When leaving the truck, BE
tion. SURE to remove the key.
5. Return the key to a key rack if
WARNING specified.
!
Park safely
– Select a hard level surface.
– BE SURE to park in a park-
ing lot if available.
– If the lift mechanism is dis-
abled and the forks cannot
be lowered to the floor,
attach a warning tag to the
tip of the fork and position
the forks away from pedes-
trians.
Get off safely
– Get off after the truck has
come to a complete stop and
the above procedure has
been followed.
– NEVER jump off.

68 68
||||||||||||||||||||||||||||||||||||||||||||||||| OPERATING TECHNIQUES ||||||||||||||||||||||||||||||||||||||||||||||
◆ Stacking Methods

Stability of the loads depends upon how well the stack is formed.

• Stacking Loads Differing in Size • Stacking Small Identical Loads • Stacking Large Identical Loads

100892 100893 100894

Be sure larger containers in a load are at the As in brick laying, place layers of containers This is one of the most common patterns for
bottom of the stack and smaller ones at the top; alternately so each container will stand astride stacking large identical containers. Better load
or heavier containers at the bottom and lighter parts of two or more containers in the layer stability is achieved by reversing the end-to-
ones at the top. below. This type of stack is more stable and less side direction on each succeeding layer.
likely to fall down.

69 69
OPERATING TECHNIQUES 70

◆ Handling Loads Safely

! WARNING ! WARNING ! WARNING

20
%

60
%

20
%

101075 100761

Handle ONLY stable loads. A load having Handle ONLY loads within the capacity of Set the forks as far apart as possible for maxi-
unstable items can easily shift and fall on your lift truck as shown on the capacity plate. If mum support of the load.
someone. DO NOT handle a load if any part of the combined center of gravity of the truck and
it is likely to fall, or if the pallet or skid is dam- load is located forward of the front axle, or if
aged. Neatly stack and band loose or unstable the load exceeds the capacity, the truck can tip
loads. over forward.

100856

Not every load can be handled using only the

forks. Some loads will require a special attach-
ment.

70 70
OPERATING TECHNIQUES 71

◆ Inching into and Lifting the Load

20 to 30 cm
(8 to 12 in.) 10 cm
(4 in.)

;;;;;;;;;;;;;;;;;
101076
;;;;;;;;;;;;;;;;;
101077
;;;;;;;;;;;;;;;
101078
;;;;;;;;;;;;;;;;;
101079

1. Move the truck slowly and stop Direction lever—NEUTRAL Direction lever—FORWARD Direction lever—NEUTRAL
the truck 20 to 30 cm (8 to 12 in.) 2. Tilt the mast forward to the verti- 3. Slowly move the truck forward 4. Carefully lift the load about 10
short of the load. Make sure the cal position, and again make sure and slide the forks into the pallet cm (4 in.) off the other material.
truck is square with the load and the forks are at the correct height. until they are fully under the load. Slowly return the lift control
the forks are at the correct height. lever to the NEUTRAL position.

! WARNING ! WARNING ! WARNING

101080 100869 100648

When you pick up loads that extend Center the weight of the load between Avoid approaching the load at high
above the backrest extension height, the forks. speed.
band them together to reduce the risk
of items from falling.

71 71
OPERATING TECHNIQUES 72

◆ Traveling with the Load

20 to 30 cm
(8 to 12 in.)

;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;

15 to 20 cm (6 to 8 in.)
;;;;;;;;;;;;;;;;;
101081 101082 101083 101084

1. Make sure the load is centered on Direction lever—REVERSE Direction lever—NEUTRAL Direction lever—FORWARD
the forks. Then tilt the mast all 2. Look behind you. 3. Slowly move the truck 20 to 30 4. Look around to be sure your
the way back to cradle the load. cm (8 to 12 in.) away from the drive area is clear and then move
stack, then stop the truck. the truck into the working zone.
Lower the load to a position 15 to
20 cm (6 to 8 in.) from the
ground.

! WARNING ! WARNING ! WARNING

101525 100670 101021

Slack lift chains means there is a rail DON’T pick up an off-center load. If the load blocks your view, or when
or lift bracket hang up. Raise the mast Make sure the weight of the load is you travel down a grade with the
before you move. centered between the forks. load, drive in reverse. Always look in
When stacking: the direction of travel.
1. Watch your lift chains.
2. If they go slack, stop; raise the
load and lower it again.
72 72
OPERATING TECHNIQUES 73

◆ Unloading

20 to 30 cm
(8 to 12 in.)

10 to 15 cm
(4 to 6 in.)

;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;

101085 101086 101087 101088

1. Stop the truck 20 to 30 cm (8 to Direction lever—NEUTRAL Direction lever—FORWARD Direction lever—NEUTRAL

12 in.) short of the unloading 2. Lift the load 10 to 15 cm (4 to 6 3. Slowly move the truck forward to 4. Tilt the mast forward to the verti-
zone. in.) higher than the stack. position the load just above the cal position.
stack.

73 73
OPERATING TECHNIQUES 74

;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;

101089 101090 101091 101092

5. Carefully lower the load onto the Direction lever—REVERSE 8. When you disengage the forks, 10. Tilt the mast back (6º or more).
stack. 7. Look behind you and carefully stop the truck. Direction lever—REVERSE
6. Lower the forks just enough to back the truck away from the Direction lever—NEUTRAL 11. Look around to see that it is safe
disengage them. load. 9. Lower the forks to a position 15 to drive in your work area.
to 20 cm (6 to 8 in.) from the 12. Drive up to your next position.
ground.

! WARNING ! WARNING

– NEVER travel with the mast tilted forward or

with the load in the elevated position. This will
increase the possibility of the lift truck tipping
over.
– NEVER tilt the mast with the load in the ele-
vated position.
– NEVER leave the lift truck with the load in the
101093 elevated position.
Be careful not to drag the forks. 100781

74 74
OPERATING TECHNIQUES 75

◆ Traveling Alarms (optional)

Lift trucks are used in a very wide variety of You should consider factors such as the capac- and must take an active part in protecting their
conditions. Noise levels, the number of lift ity for people to become accustomed to hearing own safety and that of others. This includes not
trucks on site, the operational area, the loads to the alarm, the confusion of multiple alarms, placing themselves in the path of a moving
be handled, the presence of pedestrians, light- increased noise levels, or the fact that the driver truck. The truck driver is responsible for the
ing conditions and many more all vary greatly may depend too much on the alarm, which safe operation of the lift truck, and must have a
from one application to another. The manufac- could cause unsafe conditions in the work- clear view of the path when traveling back-
turer of the lift truck has no control over the place. Pedestrians and other lift truck operators wards or forwards.
environment in which it will be deployed, or in the workplace may become accustomed to The alarms must also be maintained to ensure
where it may be resold at a later time. hearing the alarm—paying little heed to them. they are kept in proper operational condition.
Only the user has first-hand knowledge of the This could lead to a situation where pedestrians Any operational damage or any attempts to dis-
deployment site conditions. It is the user who or other lift truck operators nearby do not react connect or disable the alarms must be repaired.
must make decisions regarding the use and con- to a potential hazard. The user is responsible for maintenance of
figuration of the lift truck, based on the specific Pedestrians and other lift truck operators in the such items.
application. workplace must be aware of their surroundings

75 75
OPERATING TECHNIQUES 76

◆ Working on Grades
The Engine Stalls on a Grade
• Starting on a Grade (Safe Travel Position)
– Keep the forks or the load at a safe travel
height, which is 15 to 20 cm (6 to 8 in.)
from the ground.
– Tilt the mast back more than 6º when the
truck is empty. Tilt it all the way back
when the truck is loaded.

6° Tilt back

101071

1. Apply the parking brake and lower the

forks to the ground.
2. Depress the brake pedal. Place the direc-
tion lever in the NEUTRAL position and 15 to 20 cm
start the engine. (6 to 8 in.)

3. Push the direction lever to FORWARD 101072

direction travel.
4. Raise the forks or load to the safe travel
position.
5. Quickly shift your right foot from the
brake pedal to the accelerator pedal. While
gradually depressing the accelerator pedal,
release the parking brake.

76 76
OPERATING TECHNIQUES 77

• Traveling on a Grade • Stopping on a Grade

101026 101074

Travel forward up a grade and in reverse down

a grade when the truck is loaded.
! CAUTION
Depress the brake pedal when you have to
bring the truck to a stop on a grade.
! WARNING DO NOT hold the truck by depressing the
accelerator pedal. This can cause clutch
– DO NOT continuously use the brake plate wear or torque converter failure.
pedal only. This can result in brake
failure and an accident.
– DO NOT use the inching pedal when
When traveling up or down a steep grade:
traveling down a grade. This pre-
1. DO NOT stop the engine.
vents the engine from acting as a
2. DO NOT make any turns.
brake.
3. DO NOT travel across the grade.

77 77
||||||||||||||||||||||||||||||||||||||||||||||||| STORING THE LIFT TRUCK ||||||||||||||||||||||||||||||||||||||||||||||
◆ End of Each Shift Storage ◆ Long Term Storage
If your lift truck is to be put in storage for any • Engine Cooling System
! WARNING length of time, take the following precautions Protect the cooling system from freezing by
Perform a thorough walk-around for safety and to reduce the risk of deterioration draining the system or by adding an antifreeze
inspection for any damage. Report all of truck components. mixture.
damage or faulty operation immediately.
DO NOT operate a lift truck that has a • Fuel System • Engine Cylinders
maintenance problem. – Gasoline engine trucks Over a long storage period, the cylinders may
Gasoline evaporates, leaving a sticky gum rust from moisture condensation within the
deposit in the fuel pump and carburetor. cylinders. To reduce the risk of rusting of cylin-
1. Park the truck in an authorized area. Drain the fuel from the tank and run the
2. Block the wheels securely. der walls, remove the spark plugs and squirt a
engine until the fuel in the lines is used up. small amount of engine oil into the cylinders.
3. Check under the truck for oil or coolant – LP-Gas engine truck
leaks. Crank the engine several times with the starter
These trucks present a storage problem due to spread the oil uniformly on the cylinder
4. Clean or wash the truck to keep it free of to fire hazards. Store them in an outdoor
dirt and oil. This will make it easier to spot walls. Replace the spark plugs. Repeat this pro-
shelter or detached garage. If the shelter is cedure prior to starting after storage.
loose or defective parts. attached to another building, the separating
walls should have a fire resistance rating of
more than one hour. The shelter should • Battery
! CAUTION have sprinklers and floor-level ventilation. Remove the battery from the truck and
recharge. Store in a dry, cool place.
Do not expose ECU box to rainwater. Take
care not to sprinkle water over ECU box • Hydraulic System More precautions may have to be taken accord-
when washing your machine. After positioning your truck for storage, retract ing to the place of storage, storage period and
all the hydraulic cylinders to minimize rod season. When you put your truck in storage,
exposure. This will reduce the risk of rusting of consult your Cat lift truck dealer.
! WARNING the sliding contact surfaces of the rods.
If brake linings have become wet after To prevent rusting of the cylinder interior and • Controller
cleaning the truck or after driving rods, and deterioration of the seals, periodically Moisture is harmful to the controller. When
through a large area of water, stopping operate each cylinder for lift, tilt and the attach- washing, do not splash water or steam over the
distance may be reduced. In such a case, ment to full stroke. ECM inside the engine compartment.
gently apply brakes several times while
driving slowly in a safe area until linings
have dried out and normal braking
action is restored.
78 78
||||||||||||||||||||||||||||||||||||||||||||||||| TRANSPORTATION HINTS ||||||||||||||||||||||||||||||||||||||||||||||
◆ Lift Truck Shipping ◆ Machine Lifting and Tiedown
Information
Always block the trailer or rail car wheels NOTICE: Improper lifting or tiedowns may
! WARNING before loading the lift truck. cause a load to shift and cause
Check travel route for overpass clear- Position the lift truck on the truck bed or rail injury and/or damage.
ances. Make sure there is adequate car. 1. Weight and instructions given herein apply
clearance if the vehicle being trans- Place the direction lever in NEUTRAL and to lift trucks manufactured by Cat Lift
ported is equipped with a high mast or apply the parking brake. Trucks.
cab. Turn the key switch to the (OFF) position 2. Use proper rated cables and slings for lift-
Remove ice, snow or other slippery and remove the key. ing. Position the crane so the lift truck is
material from the shipping vehicle and Block the wheels and secure the lift truck with level when lifted.
loading dock. tiedowns. 3. Spreader bar widths should be sufficient to
prevent contact with the lift truck.
Do not steer the truck after it has been secured
4. Use the tiedown locations provided for lift
on the truck or rail car. It may loosen the
truck tiedown.
tiedowns.
Check the state and local laws governing
weight, width and length of a load.
Contact your Cat lift truck dealer for shipping
instructions for your lift truck.

101624

79 79
||||||||||||||||||||||||||||||||||||||||||||||||||||| SPECIAL SITUATIONS ||||||||||||||||||||||||||||||||||||||||||||||||||
◆ Care in Cold Weather
• Fuel Oils and Lube Oils • Battery • Engine Coolant
Electrolyte
Float
level

Glass tube
Electrolyte

101101 100801 103200

– Maintain the specific gravity of electrolyte – Antifreeze used in the engine cooling sys-
! CAUTION above 1.260 as corrected to 27°C (80°F). tem of a new lift truck shipped from the
– When you park your truck overnight, leav- factory provides sufficient freeze protec-
– Cloud point should be 6°C (11°F)
ing it outside a garage, remove the battery tion to -30°C (-22°F).
below the lowest ambient tempera-
and keep it warm. – If ambient temperatures are below -30°C
ture.
– The electrolyte of a fully charged battery (-22°F), add antifreeze.
– Use engine oil and gear oil to fit the
will not freeze to -35°C (-31°F).
ambient temperature. NOTICE: For type and concentration of
antifreeze, consult your Cat lift
NOTICE: For type and concentration of truck dealer.
antifreeze, consult your Cat lift
truck dealer. ! CAUTION
– After distilled water has been added to
the battery, run the engine for a while.
This mixes the added water with the
electrolyte and will reduce the risk of
freezing and damaging the battery.
– DO NOT attempt to restore a battery’s
charge by pouring boiling water over it.
This can break the battery case, result-
ing in acid contact with skin or eyes.

80 80
SPECIAL SITUATIONS 81

◆ Care in Hot Weather ◆ Care in Severe Dust or Lint

• Fuel Oils and Lube Oils • Engine Coolant Conditions

! WARNING
Be careful NOT to have scalding hot
coolant or steam blow out of the reserve
tank. Remove the radiator cap only after
engine cools.

Coolant evaporates rapidly and the engine is

101102 likely to get overheated when the truck is oper- 101104

Use fuel oil, engine oil and gear oil to fit the ated continuously or on a grade. During such Check and service the air cleaner element more
ambient temperatures. an operation, observe the engine coolant tem- frequently.
perature gauge for symptoms of overheating.
NOTICE: For selection of fuel oil, engine oil
and gear oil, consult your Cat lift
truck dealer. ! CAUTION Recommended
inspection period
Every 50 service hours or
weekly, whichever comes first
If the engine coolant temperature gauge
needle moves into the red zone, the engine
is suspected of getting overheated. Check the radiator core more frequently for
• Battery clogging or trash build-up. Clean or wash the
truck as necessary.
In hot, dry weather, check the battery cells for NOTICE: If the engine coolant temperature
proper electrolyte level more often than in cold gauge needle moves into the red
weather. Add distilled water whenever the level zone, see the topic, Engine
is low. Coolant Temperature Gauge
Needle Moves Into the Red Zone.

81 81
|||||||||||||||||||||||||||||||||||||||||||||||||||||| TROUBLESHOOTING |||||||||||||||||||||||||||||||||||||||||||||||||||
◆ Changing a Tire

! WARNING ! WARNING WARNING

!
– Make sure the replacement tire is of
the same size, type and load range.
– Use the tire recommended by Cat
Lift Trucks. See manufacturer
name plate for correct tire size.

101105 101107 ! WARNING

DO NOT attempt to change the tire with the Stop raising the truck when the tire clears the – Consult your Cat lift truck dealer for
truck loaded. Injury and/or damage could ground. DO NOT raise the truck more than proper tire changing procedure.
result. necessary. – Changing of tire and adjustment pro-
cedure must be made by a trained
mechanic or dealer personnel.
– Perform all maintenance with
WARNING proper equipment.
! WARNING !

100832 100833

BE SURE no one is on the truck when raising DO NOT place any part of your body under the
the front or rear tires. truck. SECURELY SUPPORT the truck with
blocks after jacking it up.

82 82
TROUBLESHOOTING 83

To Raise Front Wheel

• Front Tire
1. Park the truck on level ground with parking
brake applied, transmission in NEUTRAL,
forks lowered and engine stopped.
2. Prepare tools, jack and wheel blocks.

Jack Capacities
6 tons (14,000 lbs)
3.5 to 4 ton models
102543 minimum
9 tons (20,000 lbs) 101106
Change the tire if its height measures less than 4.5 to 5.5 ton models
minimum
following data. 12 tons (27,000 lbs)
Position the jack under the frame and raise the
6 to 7 ton models truck until the front tire clears the ground.
minimum
• Service Limits of Tires
Next, place stands on both sides under the
Unit: mm (in.)
frame to support it.
Front 48.3 (1.9)
3.5 to 5.5 ton models
Rear 45.7 (1.8)
Front 48.3 (1.9)
6 to 7 ton models Other Method
Rear 48.3 (1.9)

NOTICE: When changing tires, change them

in sets, even if only one of the tires Tilt
is damaged. If new and used tires 100830A Tilt backward forward

are used on the same axle, tilting of

the mast and rapid tire wear will 3. Block the diagonally opposite wheel.
result.

“Self-jacking” Method
Block
Tilt the mast all the way back, place blocks
under the mast, and tilt the mast forward. 100913
Next, place stands on both sides under the Tilt the mast all the way back, place blocks
frame to support it. under the mast, and tilt the mast forward.

83 83
TROUBLESHOOTING 84

Wheel nut

Counterbore

206654 100834A Ten wheel nuts for 6, 7 ton models 102545

To Remove Wheel To Install Wheel

! CAUTION
1. Loosen the wheel nuts about two rotations. Be careful NOT to strip the bolt threads 1. Install the wheel and tighten the wheel nuts
when removing the wheel. finger tight until their clamping surfaces
NOTICE: Only loosen the wheel nuts. DO come into full-face contact with the coun-
NOT remove them. terbores in the rim.

2. Position the jack under the truck at the NOTICE: Make sure the clamping sur-
specified jacking point. faces of the wheel nuts and
3. Raise the truck by operating the jack until counterbores are free of dirt.
the tire just clears the ground.
4. Remove the wheel nuts (loosened in step 1).
5. Firmly grip the wheel with both hands and
remove it from the truck.

84 84
TROUBLESHOOTING 85

3. Lower the truck fully and restore the jack

and tire.
4. After tire replacement, drive the truck for a
while and then recheck the torque of the
wheel nuts.

102546A

2. Lower the truck by operating the jack until

the tire just touches the ground. Then
tighten the wheel nuts in the sequence
shown, in two or three steps, to the speci-
fied torque.

Tightening Torques For Wheel Nuts

551 N•m (56.2 kgf•m) [406.5 lbf•ft]

– Eight wheel nuts for 3.5 to 5.5 ton models.

– Ten wheel nuts for 6 & 7 ton models.

85 85
TROUBLESHOOTING 86

• Rear Tires

To Remove Wheel 6. Raise the tire.

1. Park the truck on level ground with parking

brake applied, transmission in NEUTRAL,
14 forks lowered and engine stopped.
➆ ➇,➉
2. Prepare tools, parts, jack and wheel blocks.
Tools:
➃➁ – Spring balancer
11 – Bearing installer B
➀ Block
13 – Puller
➅ 12
Replacement part:
➄,➈ ➂ Jack Stand C 100393A
102547 – Lock washer ➂
➀ Cap, rear wheel – Oil seal ➆ Crane Capacities
➁ Nut (outside) – Cap, rear wheel (if required) ➀
➂ Lock washer – Bearing (if required) ➄,➇,➈,➉ 3.5 to 5.5 ton models
7 tons (16,000 lbs)
minimum
➃ Nut (inside) – Tire assembly ➅
9 tons (20,000 lbs)
– Packing 11 6 to 7 ton models
➄ Bearing (inner race) minimum
➅ Tire assembly 3. Remove the rear wheel cap ➀ mounting
➆ Oil seal bolts 12 and spring washers 13 , and then
➇ Bearing (outer race) remove the rear wheel cap ➀ and the pack-
➈ Bearing (outer race) ing 11 from the rim. ! CAUTION

➉ Bearing (inner race) Blocks should be used for the front wheels
11 Packing (B) and jack stands (C) for side frames
12 Bolt together with the crane.
13 Spring washer
14 Retainer oil seal Spring washer 13

Bolt 12

Cap, rear wheel ➀

102548

4. Straighten the lock washer ➂ tangs.

5. Loosen the nut ➁.

86 86
TROUBLESHOOTING 87

To Install Wheel
7. Block the front wheels (B). 13. Using an installer, fix and press the bearing
8. A crane may be used to raise the counter- (outer) ➇ and ➈ to the tire assembly ➅.
weight. In such a case, use the lifting holes ➉ 14. Fix the oil seal ➄ and the retainer oil seal
in the counterweight. ➄ ➆,➇ ➉ to the new tire assembly ➅.
9. Use jack stands for the side frames (C) to 15. Fill the rim void with grease and oil seal lip
support the truck (with the right and left portion. Do not overfill the oil seal lip por-
➃➁
tires slightly clearing the floor). 11 tion to prevent leakage.
10. Remove the nut ➁, lock washer ➂ and nut ➀
13
➃. ➅ 12

11. Remove the tire assembly ➅ from the rear ➄,➈ ➂

102547
axle by wobbling it.
12. Using a puller, remove the bearing (outer Sequence: Oil seal
13 Spring washer
race) ➇, ➈ and the oil seal ➆ and the
12 Bolt
retainer oil seal ➉ from the tire assembly.
11 Packing Fill with grease

➉ Retainer oil seal

NOTICE: Replace the bearing (inner and
➈ Bearing (outer race)
outer) if distorted when the tire
assembly is removed. ➇ Bearing (outer race)
➆ Bearing (inner race) 102550

➅ Tire assembly
➄ Oil seal
➃ Nut (inside)
➂ Lock washer
➁ Nut (outside)
➀ Cap, rear wheel

87 87
TROUBLESHOOTING 88

16. Tighten the nut ➃ with torque of 137 N•m 17. Insert the cap ➀.
(14 kgf•m) [101 lbf•ft] back-off by 80°, 18. Raise the lift truck and remove the blocking
then insert the lock washer ➂. Install the of the side frames.
nut ➁ with minimum torque and check 19. Lower the lift truck to the ground.
bearing preload using the “Tangential
Force for Bearings” chart. If not within Tightening Torque for Outside Nut
specification, increase torque on the nut ➁. 3.5 to 5.5 ton models
177 N•m (18 kgf•m)
If acceptable, bend the lock washer ➂ and [130 lbf•ft]
fill with grease. 196 N•m (20 kgf•m)
6 to 7 ton models
[145 lbf•ft]

Bar
Tangential Force for Bearings
40 to 49 N
3.5 to 4.5 ton models (4.1 to 5.0 kgf)
[9 to 11 lbf]
41 to 49 N
4.5 to 5.5 ton models (4.2 to 5.0 kgf)
[9.3 to 11 lbf]
44 to 53 N
102551 6 to 7 ton models (4.5 to 5.4 kgf)
[9.9 to 11.9 lbf]

Bar
! CAUTION
After tire replacement, drive the truck for a
while and then recheck bearing preload.

Spring balancer

101653A

Checking bearing preload.

88 88
TROUBLESHOOTING 89

◆ Engine Coolant Temperature Gauge ◆ Powershift Transmission Oil

Needle Moves into Red Zone Temperature Warning Light Glows
! WARNING

101434C 100813 101440F

1. Park the truck in a safe area. – DO NOT attempt to remove the radiator 1. Park the truck in a non-traffic area.
2. Open the engine hood to ventilate the filler cap if the engine is overheated. This 2. Apply the parking brake. Place and lock
engine compartment. could cause injury from scalding hot the direction lever in the NEUTRAL posi-
3. Allow the engine to idle for a while. DO coolant or steam blowing out of the radia- tion.
NOT attempt to stop the engine. tor. Allow the engine to run at low idle for a
4. Stop the engine after the coolant tempera- – DO NOT add cold water to an overheated while.
ture gauge needle has moved into the engine. This can cause damage to the 3. After the warning light has gone out, oper-
WHITE zone. engine. Wait for the engine to cool, if pos- ate the truck again.
5. Check for: sible. If not, slowly pour water into the
– Lack of coolant. radiator.
– Loose or broken fan belt. – Immediately stop the engine if the fan belt ! CAUTION
– Engine oil level. is broken.
– Foreign material build-up in radiator air If the warning light does not go out, or if it
passages. glows often, consult your Cat lift truck
dealer.

89 89
TROUBLESHOOTING 90

◆ Stalled Engine ◆ Trouble with the LP-Gas Equipment

! WARNING

If you smell gas or notice something wrong There is a possibility of fire after a collision or
with LP-Gas equipment during operation, when a truck turns over. If this happens, close
immediately stop the truck in a safe area, turn the LP-Gas fuel valve of the LP-Gas tank as
the starter switch to the (OFF) position, soon as possible.
close the fuel valve of the LP-Gas tank, and Use a dry-chemical (powder) or carbon diox-
101111
try to find the cause. (It is advisable to have a ide type extinguisher. Never use water. When
If the engine stalls, hydraulic pressure is lost in test kit on hand for detecting gas leakage.) possible, however, have large quantities of
the power steering system. If this happens, stop If the internal pressure of the LP-Gas tank water poured over the LP-Gas tank to cool it
your truck in a safe area and restart the engine. rises too high and causes the relief valve to down while the fire is being extinguished.
Before restarting the engine: open to let out the excess pressure, sprinkle
– Make sure the fuel tank is NOT empty. water over the tank. At the same time, extin-
– Correct the cause of engine stalling such as guish any fire or flame source (such as a pilot
overloading. light) and eliminate the possibility of creating
sparks near the truck. Ventilate the work
area.
When gas leakage is evident, close the fuel valve
as soon as possible. Extinguish the fire or flame
sources nearby to prevent spark conditions.

90 90
TROUBLESHOOTING 91

◆ Driving Interlock Indicator Light Flickers or Flashes, and the Truck Stops Moving

The driving interlock indicator Are you seated? Place the direction lever to the neutral position and sit securely.
light starts flickering and the
truck stops moving.

NO

104577 104579 104144

YES
The driving interlock indicator Stop working and move the truck to a safe area. Shut down the engine
light is OFF but the truck fails to and consult your Cat lift truck dealer.
move.

TROUBLE

104578 101463

91 91
|||||||||||||||||||||||||||||||||||||||||||||||||||||||||| MAINTENANCE |||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ General

Taking proper care of your lift truck is a vital

! WARNING ! WARNING
part of the overall planned maintenance pro-
gram. – Make sure the service area is safe. Lines, Tubes and Hoses
Your participation in this program will provide – Park the truck on a level ground with DO NOT bend or strike high pressure
an early warning to help identify potential the forks lowered, parking brake lines. DO NOT install bent or damaged
maintenance problems. applied, transmission in NEUTRAL, lines, tubes or hoses.
Do-it-yourself maintenance does not include and engine stopped. Repair loose or damaged fuel and oil
repairs. If your truck requires any repairs, con- – Follow the recommended safety pro- lines, tubes or hoses. Leaks can cause
sult your Cat lift truck dealer. The dealer’s lift cedures. fires. Contact your dealer for repair or
truck mechanics are well trained and know how – Use only the right tools for the job. replacement.
to safely make repairs. Service Manuals are
Check lines, tubes and hoses carefully.
also available from your Cat lift truck dealer.
DO NOT use your bare hands to check
Follow these rules to help save you from injury for leaks, use a board or cardboard.
and to service your truck properly. Tighten connections to the recom-
Close
mended torque. If any of the following is
found on a part, replace the part.
– End fittings damaged or leaking.
– Outer covering chafed or cut and
Open
wire reinforcing exposed.
! CAUTION
– Outer covering ballooning locally.
Should the truck become unsafe during – Evidence of kinked or crushed hose.
operation in any way whatsoever, you must – Metal embedded in the outer cover.
102536 report it immediately to the designated – End fittings displaced.
The fuel shut off valve is located near the air authority. The truck must not be used again Make sure all clamps, guards and heat
cleaner inside the engine hood. To avoid an until it has been restored to a safe opera- shields are installed correctly to reduce
accident, close this valve when performing tional condition. the risk of vibration, rubbing against
maintenance. other parts, and excessive heat during
operation.

92 92
MAINTENANCE 93

◆ Inspection Precautions

! WARNING ! CAUTION A daily (Pre-Start) inspection is the key to

– Avoid mixing lubricants. In some cases safety. At the beginning of each shift, check
If it is necessary to make an inspection
different brands of lubricants are not your lift truck to make sure it is in safe operat-
while the engine is running, ALWAYS
compatible with each other and deteri- ing condition before putting the truck into
USE TWO WORKERS—one, the opera-
orate when mixed. It is best to stick operation.
tor, at the controls and the other check-
ing within visual contact of the operator. with the same brand at successive serv- Always inspect your truck under the following
ice intervals. conditions.
– Before refilling, clean filler holes. After
filling, clean up spills.

– Lift truck level

– Mast in vertical position
! WARNING – Fork tips on ground
– Engine stopped
– Control levers in neutral
– Wheels blocked

100879

If your truck requires any repair, attach a “DO

NOT OPERATE” or similar warning tag to the
steering wheel or other control, remove the key
from the starter switch, and contact your Cat
lift truck dealer.

93 93
MAINTENANCE 94

◆ Maintenance Schedule
• Every 10 Service Hours or Daily (Pre-Start),
Whichever Comes First, continued
As the operator, you are responsible for the performance of daily pre-start
inspection. You are also responsible for those items listed under Every 50 Item Service Page
Service Hours or Weekly, Whichever Comes First to keep your lift truck
in proper working condition. Brake pedal Check 98
For periodic inspection and periodic change of rubber parts, however, rely Inching pedal Check 99
on the expert knowledge of the factory-trained servicemen, and the service
facilities at your Cat lift truck dealer’s workshop. Parking brake lever Check 99
Seat belt Check 99
• One month after delivery of a new truck
• Every 200 service hours or monthly, Seat adjustment Check 99
whichever comes first
Periodic inspection time intervals • Every 1200 service hours or 6 months, Horn Check 100
whichever comes first
• Every 2400 service hours or 1 year, Steering wheel Check 100
whichever comes first
movement

• Every 10 Service Hours or Daily (Pre-Start), Amount of fuel (truck level) Check 100
Whichever Comes First Stop lights (if equipped) Check 100
Item Service Page OK monitor Check 100
Damaged or faulty operation found Lift chains Check/adjust 101
the day before Check 97 Engine Check 102
Oil, fuel or coolant leaks Check 97 Service brakes Check 102
Lights Check 97 Backup lights (if equipped) Check 102
Load backrest extension Check 97 Engine crankcase Check oil level 103
Tilt cylinder socket bolts Check 98 Engine coolant Check 105
Overhead guard Check 98 coolant level
Assist grip Check 98 Hydraulic oil Check 107
Accelerator pedal Check 98 oil level

94 94
MAINTENANCE 95

• Every 10 Service Hours or Daily (Pre-start), • Every 200 Service Hours or Monthly, Whichever Comes First
Whichever Comes First, continued
Item Service Page Item Service Page
Service brakes Check 108 Wheel nuts Retighten 116
fluid level Differential Check 116
Wheel nuts Check 109 oil level
Tires and rims Check/inspect 109 Powershift transmission Check 117
Mast and forks Check 110 oil level

Battery Check electrolyte 111 Engine crankcase Change oil 118

level Gasoline and LP-Gas and filter

Seat activated transmission interlock Check 112 Mast strip roller surfaces Lubricate 119
Lift bracket side rollers Lubricate 119
• Every 50 Service Hours or Weekly, Whichever Comes First
Item Service Page Lift chains Lubricate/ 119
inspect
Air cleaner Clean/inspect 113
Brake pedal Lubricate 119
Alternator drive belt Check/adjust 114
Tilt socket pins Lubricate 120
Accessory drive belt Check/inspect 114
Tilt cylinder pins Lubricate 120
Mast supports Lubricate 115
Tie rod ends Lubricate 120
• One Month After Delivery of a New Truck
Rear axle center pins Lubricate 120
Item Service Page
Hydraulic tank return oil filter Change 115
Fuel filter—Gasoline Change 115
Fuel filter—LP-Gas Change 115
Bolts, nuts Retighten 115

95 95
MAINTENANCE 96

• Every 1200 Service Hours or 6 Months,

Whichever Comes First
Item Service Page
Powershift transmission Change 121
Hydraulic system Change return 122
oil filter
Differential Change oil 123
Air cleaner Change 123
element
* Fuel filter—Gasoline Change 124
* Fuel filter—LP-Gas Change 125
Engine coolant Change 127

• Every 2400 Service Hours or 1 Year, Whichever Comes First

Item Service Page
Hydraulic oil Change 130
Service brake fluid Change 130

96 96
MAINTENANCE 97

◆ Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First

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

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

! WARNING

101047 101400A

Check on the floor for oil, fuel or coolant leaks. – Is the backrest extension free of distortion,
cracks and other defects? Shake the back-
• Lights rest to check for excessive rattle.
– Are all the lights in safe working condi-
tion?
100678A – Are their lenses clean and not defective?
Fill out a daily inspection sheet. Remember, – Do the tail and head lights come ON prop-
the complete performance of a daily inspection erly when you switch them on.
is the best protection against injury and prop-
erty damage.

97 97
MAINTENANCE 98

• Tilt Cylinder Socket Bolts • Overhead Guard • Accelerator Pedal

– Can you depress the accelerator pedal
smoothly without any sign of rubbing?

101049
102552
1. Check the front and rear overhead guard
– Are the bolts tightened properly? mounting bolts on each side. Tighten bolts
Use a wrench. to 285 N•m (26.3 kgf•m) [190.2 lbf•ft] for 100699
NOTICE: After retightening the bolt, put a front and 178.5 N•m (18.2 kgf•m) [131.6
mark across the bolt and tilt cylin- lbf•ft] for rear.
der socket. This permits you to eas- 2. Inspect overhead guard for bent or cracked
ily notice loosening of the bolt. sections. Contact your Cat lift truck dealer
if repairs are needed.
Tightening Torque for the Bolt
262 ± 13 N•m (27 ± 1.4 kgf•m) • Assist Grip
[193 ± 9.6 lbf•ft]
B00090P

Foot operated direction control (optional).

• Brake Pedal
– Do you have sufficient pedal travel?
– Is the free-play adjusted properly?

102553
Correct Free Play:
Inspect, and if necessary, tighten the screws of Unit: mm (in.)
the assist grip.
All models 5 (0.2)

98 98
MAINTENANCE 99

• Inching Pedal • Parking Brake Lever • Seat Belt

– Can you pull the lever all the way with rea-
sonable effort?
– Can you hold your truck on a grade by
pulling the brake lever?
– Lever operating effort:
250 to 290 N (25 to 30 kgf) [55 to 66 lbf]
(3.5 to 5.5 ton models)
410 to 450 N (41 to 45 kgf) [90 to 100 lbf]
100700 (6 to 7 ton models) 100977

– Does the truck inch when you slowly – Is the seat belt in safe condition?
depress the inching pedal? Adjustment Replace the belt assembly if the belt is
torn, cut, or if the plate and/or buckle is
defective.
Release Apply

• Seat Adjustment

101437

Turn the knob clockwise to increase the lever’s

tension; counterclockwise to decrease it.
Adjustment is correct when the lever requires
an effort of 250 to 290 N (25 to 30 kgf) [55 to
66 lbf] (3.5 to 5.5 ton models), 410 to 450 N
(41 to 45 kgf) [90 to 100 lbf] (6 to 7 ton mod-
101050
els) to snap it over center.
– Can you depress the pedals all the way?
NOTICE: See the topic, Adjustment under
Operator’s Seat.

99 99
MAINTENANCE 100

• Horn • Amount of Fuel (Truck level) • OK Monitor

102591 102394 103492

– Does the horn sound properly when you – Is the amount of fuel in the tank enough for – Do all the warning lamps glow when the
push the switch? the day’s work? key is in the l (ON) position?

NOTICE: When a lamp does not light with

the key in the l (ON) position, the
bulb may be burned out.
Contact your local Cat lift truck
• Steering Wheel • Stop Lights (If equipped) dealer for repair or replacement.

101726B 100709A

– Is the free play 15 to 30 mm (0.6 to 1.2 – Do all stop lights come ON properly when
in.)? Check the play at the rim of the you depress the brake pedal?
wheel by rotating the wheel in both direc-
tions.
– Is wheel installation loose? Check by
shaking the wheel up and down.

100 100
MAINTENANCE 101

• Lift Chains
Check and Adjust To Adjust

! WARNING
– Check the lift chains periodically and ➀
determine if they are still in usable
condition.
– Check the lift chains for wear, cracks
and worn or seized link pins.
– Improper maintenance of the lift
➁
chains could cause accidents. If 102009 102557
something is wrong with the chains,
consult your Cat lift truck dealer for 2. Lift the forks high enough to put their full 1. Loosen the locknut ➀. Then turn the nut ➁
repair or replacement. weight on the carriage and chains. to adjust tension.
– DO NOT put your foot under the 3. Check to be sure the lift chains have equal 2. Hold the nut ➁ and tighten the locknut ➀
fork. tension. to following torque.
4. If the chains are loose or the tension is not
equal, have the chains adjusted. Tightening Torque
1. Check the lift chains for wear. Use the fol-
lowing chart to determine if it is still in Unit: N•m (kgf•m) [lbf•ft]
usable condition.
3.5 to 4 ton models 210 (21.4) [155]
Lift Chain Elongation Limit:(/20 links)
4.5 to 7 ton models 290 (29.6) [214]
3.5 to 4 ton models 523 mm (20.6 in.)

4.5 to 7 ton models 654 mm (25.7 in.)

102708

101 101
MAINTENANCE 102

• Engine • Service Brakes • Back-up Lights (If equipped)

– Do the brakes apply and stop the truck
! WARNING properly—without dragging, chattering,
Exhaust fumes could kill you! If it is nec- squealing?
essary to start the engine in an enclosed
area, make sure there is adequate ventila-
tion.
Fire hazards! Clean up spillage of fuel,
oil, or other flammable materials in the
engine compartment. Know the location 100709A
of all emergency devices (such as fire
When you move the direction lever into
extinguisher, first aid kit, etc.) and how to
REVERSE position:
use them.
– Do all backup lights come ON?
– Does the backup buzzer sound (if
equipped)?

101649

– Is exhaust smoke normal?

– Listen for abnormal noise or excessive
vibration.

102 102
MAINTENANCE 103

• Engine Crankcase
Check Oil Level Adding Engine Oil
3. Maintain the correct level range on the dip
! WARNING stick. ! CAUTION
Hot oil and components could cause seri- – Perform the work on level ground.
ous injury. Do not allow hot oil or com- – Clean the filler hole to prevent dirt
ponents to contact your skin. from dropping into the engine.
Correct level range – DO NOT overfill.
– Clean up spillage.
Park the lift truck with the forks lowered, park-
ing brake applied, transmission in NEUTRAL,
and the engine stopped. 1. Remove the oil filler cap.
1. Raise the hood.
2. Remove the dipstick and wipe it clean, then 100693A
insert it all the way. 4. Close and secure the hood.

102559

102558

103 103
MAINTENANCE 104

2. Add engine oil as required. 4. Close and tighten the filler cap.
For engine oil, see the topic,
Recommended Fuels and Oils.

Correct level range

102560 100693A

3. After adding oil, make sure the level is in

the correct range on the dipstick.

104 104
MAINTENANCE 105

• Engine Coolant
Check Coolant Level Adding Coolant

! WARNING ! WARNING ! CAUTION

At operating temperature, the engine Keep fire away from undiluted antifreeze – Antifreeze/summer coolant (ASC) con-
coolant is hot and under pressure. as it is FLAMMABLE. tains rust inhibitors. It is not necessary
Steam could cause injuries. DO NOT let to add other chemicals.
it contact your skin and eyes. – Recommended concentration range of
To avoid having scalding coolant or steam ASC is 30% to 60% by volume. ASC
blow out of the radiator, do not remove of less than 30% concentration does not
the radiator cap unless the engine is cold. provide sufficient corrosion protection.
Muffle the cap in a thick cloth and turn it Concentrations over 60% adversely
slowly to release all pressure before
! CAUTION
affect freeze protection and heat trans-
removing the cap. DO NOT add water only. This dilutes the fer rates.
antifreeze/summer coolant protection and – Avoid mixing different brands of
adversely affects the engine. Be sure to pre- coolant.
The lift truck must be level, the forks lowered,
mix antifreeze/summer coolant with tap – Select an ASC suitable for use in
the parking brake applied, the transmission in
water (soft water). See the topic, Engine engines using aluminum alloy parts.
NEUTRAL and the engine stopped and cold.
Cooling System Capacity under – Select an ASC which contains silicate
1. Raise the hood. of less than 0.2% by weight.
Specifications.
2. Maintain the coolant level between the
FULL and LOW marks on the reserve If coolant has to be added frequently, have
tank. your Cat lift truck dealer check the cooling
system.

Correct
level
range

101465

3. Close and secure the hood.

105 105
MAINTENANCE 106

1. Remove the reserve tank cap and add

coolant to the FULL mark. ! WARNING
2. When adding coolant, maintain the same
concentration of antifreeze solution.

100899

Antifreeze solution is TOXIC. In case of con-

tact with your skin, FLUSH IMMEDIATELY
101299A
WITH WATER. Have your Cat lift truck
NOTICE: The engine cooling system is pro- dealer discard antifreeze solution drained from
tected to –30°C (22°F) with 50% the engine.
concentration of antifreeze/summer
coolant (ASC) when shipped from
the factory.
3. Put the reserve tank cap back on.

106 106
MAINTENANCE 107

• Hydraulic Oil
Check Oil Level Adding Hydraulic Oil
4. Add oil needed to raise it to the correct
! WARNING level range on the dipstick. ! CAUTION
Hot oil and components could cause When adding hydraulic oil:
serious injury. Do not allow hot oil or – Perform the work on level ground.
components to contact your skin. – Clean the filler hole to prevent dirt
Remove the hydraulic tank filler cap from dropping into the tank.
only after the engine has been stopped – DO NOT overfill.
and the cap is cool enough to remove – Clean up spillage.
with your hands.
Remove the hydraulic tank filler cap
slowly to relieve pressure.
100695C
1. Remove the hydraulic tank filler cap.
2. Add oil to the hydraulic tank.
1. Operate the lift truck for a few minutes to For Hydraulic Oil, see the topic,
warm the oil. Recommended Fuel and Oils.
2. Park the lift truck on a level surface, with Correct level range

the forks lowered, mast tilted back, parking

brake applied, transmission in NEUTRAL
and the engine stopped.
3. Remove the hydraulic tank filler cap by
turning it counterclockwise.

100698

5. Put the hydraulic tank filler cap back on.

6. Check for oil leaks. 100815A
7. Close and secure the hood.
3. After adding oil, make sure the level is in
the correct range on the dipstick.
4. Insert the dipstick into the filler port and
install the hydraulic tank filler cap
securely.
100814 5. Close and secure the hood.
107 107
MAINTENANCE 108

• Service Brakes
Check Fluid Level
2. Maintain the brake fluid level between the
! WARNING MAX and MIN marks on the reservoir.
If the brake fluid in the reservoir
decreases rapidly, the brake system is Adding Brake Fluid
leaking. 1. Remove the reservoir cap.
2. Add brake fluid to the reservoir.
Have your Cat lift truck dealer check the
3. Put the reservoir cap back on.
system.

! CAUTION
Before refilling the reservoirs, clean the
ports to reduce the risk of dirt from getting
inside the reservoirs.

Park the lift truck with the forks lowered, park-

ing brake applied, transmission in NEUTRAL,
and the engine stopped.

1. Check the brake fluid level at the reservoir.

Correct
level
range

103497

108 108
MAINTENANCE 109

• Wheel Nuts • Tires and Rims

Check – Tighten, when required Check and Inspect

– Wheel nuts should be visually inspected

everyday. Any loose nuts should be tight-
ened and any missing or damaged nuts
should be replaced.
Retightening
– Always stand behind the tread of the tire,
NOT in front of the rim.
– Tighten the nuts evenly and in a diagonal
sequence to the specified torque. 102543

– Is the tread area thickness more than serv-

ice limit? (See the topic, Changing a
Tire.)
If the thickness is less than service limit,
the tire must be replaced. Do not replace
the tire yourself. Consult your Cat lift truck
dealer for tire replacement.
– Are all the rims free of distortion or
102563 cracks?

– Are the wheel nuts tightened properly?

Use a torque wrench.
! WARNING
Tightening Torque For Wheel Nuts
Make sure the replacement tire is of the
same size, type and load range.
551 N•m (56.2 kgf•m) [406.5 lbf•ft]

109 109
MAINTENANCE 110

• Mast and Forks

Check

101064 101628 101629

– Does the mast move up and down smoothly If the truck is being used to carry maximum 2. Check the difference in height of one fork
when you operate the lift control lever? capacity loads, the forks should be checked tip to the other when mounted on the fork
– Does the mast tilt forward and back daily. carrier. A difference in fork tip height can
smoothly when you operate the tilt control 1. Carefully inspect the forks for cracks. result in uneven support of the load and
lever? Special attention should be given to the cause problems when entering loads.
– Are there any oil leaks from the cylinders heel section A, all weld areas and mount- The maximum allowable difference in fork tip
and hydraulic lines? ing brackets B. elevation C is 5 mm (0.19 in.) for pallet forks.
Forks with cracks should be removed from Replace one or both forks when the difference
service. in fork tip height exceeds the maximum allow-
“Wet Test” magnetic particle inspection is gen- able difference.
erally preferred due to its sensitivity and the
ease of interpreting the results. Portable equip-
ment is usually recommended so it can be
moved to the lift truck.
Contact your Cat lift truck dealer for further
information.
103444
– Are the stoppers properly engaged?
– Are the forks free of distortion and cracks?
– Are the welds of the hangers free of
cracks?

110 110
MAINTENANCE 111

• Battery
Check Electrolyte Level
Correct level range 3. Using a battery hydrometer, check the spe-
cific gravity of the battery cells. Take the
reading at eye level.

Specific gravity
corrected to Battery condition
101630 101403 20°C (68°F)
1.260 to 1.280 Fully charged
3. Check the fork blade D. The fork should 1. If the electrolyte level is low, remove the
be withdrawn from service if the thickness filler caps and add distilled water to the 1.220 to 1.260 Three-fourths charged (to be
is reduced to less than the tolerant thick- cells. Before removing the caps, clean the recharged)
ness. top of the battery. Below 1.220 Completely discharged (to be
Fork blade length may also be reduced by 2. After adding the water, tighten the caps recharged and retested)
wear, especially on tapered forks and platens. securely.
Remove the forks from service when the blade
length is no longer adequate for the intended
loads. ! WARNING
If acid gets in your eyes, FLUSH THEM ! CAUTION
Unit: mm (in.) IMMEDIATELY WITH LARGE If distilled water has to be often added, have
Tolerant thickness Std. Limit AMOUNTS OF WATER AND SEE A your Cat lift truck dealer check the battery.
DOCTOR AT ONCE.
3.5, 4.0, 4.5 ton models 50 (2.0) 45 (1.8)
4.5 to 5.5 ton model 60 (2.4) 54 (2.1)
6, 7 ton models 65 (2.6) 58 (2.3)

111 111
MAINTENANCE 112

• Seat Activated Transmission Interlock

Check
Raise the forks a little from the floor.
! CAUTION
• Check this system on a level and hard
surface.
• Do not park the truck on a grade to pre-
vent it from traveling by itself.
• Make sure that the sufficient space is
available for the lift truck to move
around and that no one or obstacle is
around the truck.

101416B

With the engine idling (not depressing on the

accelerator pedal), place the direction lever to
the forward or reverse position, and then half
rise from the operator's seat and after a couple
of seconds.
• The transmission should electrically shift
into neutral with the driving interlock indi-
cator light flickering. If you are on a grade,
the truck will continue to roll because the
truck is in neutral.

To restore the lift truck to its normal driving

condition, sit properly in the operator's seat and
depress the brake pedal to hold the lift truck.
Return the direction lever to the neutral posi-
tion, then place the lever to the forward or
reverse position.

112 112
MAINTENANCE 113

◆ Every 50 Service Hours or Weekly, Whichever Comes First

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

• Air Cleaner
! CAUTION
Clean and Inspect
Install the dust pan with its arrow mark up.

! WARNING 1. Raise the hood.

Element

Wing nut
101197
Dust pan
6. Direct air inside the element along the
length of the pleats, and lightly tap it.
100901
When using compressed air for cleaning, 101318
wear an approved face shield and pro-
tective clothing. 2. Remove the dust pan by releasing the
Use maximum air pressure of 2 kgf/cm2 latches at three places.
(30 psi) for cleaning purposes. 3. Unscrew the wing nut, and remove the ele-
ment by pulling it.
NOTICE:
Never service the air cleaner with the engine
running.
Do not clean the elements by striking them
against another object. 101199

Always inspect the element before and after 7. Insert a light inside a clean, dry element
cleaning. Use a light inside the element. Cover and check. Discard the element if tears or
Do not use elements with damaged pleats, gas- rips are found.
kets or seals. 8. Put the element back in place.
101198
Park the lift truck on a level surface, with the 9. Reinstall the dust cap.
forks lowered, the parking brake applied, the 4. Remove the cover from the dust pan, and 10. Close the hood.
transmission in NEUTRAL and the engine clean the inside of the pan by removing
stopped. dust.
5. Clean the inside of the air cleaner housing.
113 113
MAINTENANCE 114

• Alternator Drive Belt • Accessory Drive Belt

Check and Adjust (Serpentine Belt)
Serpentine belts utilize a spring-loaded ten-
Deflection
! CAUTION sioner which keeps the belt properly adjusted.
Inspect the belt for:
– After stopping the engine, check and
adjust the rotating part. • Cracks or wear
– After adjusting the belt, tighten the • Chunking of the belt
bracket bolt securely. • Splits
– If the belt is too tight, unnecessary • Material hanging loose from the belt
stresses are placed on the alternator • Glazing or hardening
100696
bearing and belt. Such stresses will
shorten the service life of both. NOTICE: If the deflection is out of the correct If any of these conditions exist the belt should
– Keep the belt free of oil and grease to range, readjust the belt. be replaced with an OEM replacement belt.
reduce the risk of slipping. Also, check the belt to make sure
that it is not worn, frayed, or has
separated piles.
NOTICE: If it is difficult to adjust or replace
the belts, consult your Cat lift truck
dealer.

Park the lift truck on a level surface, with the

forks lowered, the parking brake applied, the
transmission in NEUTRAL, and the engine
stopped.

1. Raise the hood.

101417
2. Push the belt downward with about 98 N
(10 kgf) [22 lbf] pressure midway between 3. Loosen the alternator bracket bolts (indi-
the pulleys as shown. cated by the black arrows), and move the
alternator out or in.
11 to 13 mm 4. Close and secure the hood.
Deflection (0.4 to 0.5 in.)

114 114
MAINTENANCE 115

◆ One Month After Delivery of a New Truck

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

• Hydraulic Tank Return Oil Filter • Fuel Filter – LP-Gas

Change Change
– Replace return filter. – Replace fuel filter.

See Hydraulic System, Change Return Oil See Fuel Filter – LP-Gas, Change in the
Filter in the Every 1200 Service Hours. Every 1200 Service Hours.

102564
• Fuel Filter – Gasoline • Bolts, Nuts
Lubricate 1 fitting on each support for a total of
2 fittings. Change Retighten
– Replace fuel filter. – Bolts and nuts of overhead guard should be
retightened.
See Fuel Filter – Gasoline, Change in the
Every 1200 Service Hours.

115 115
MAINTENANCE 116

◆ Every 200 Service Hours or Monthly, Whichever Comes First

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

• Wheel Nuts • Differential

Retighten Check Oil Level
– Nuts should be retightened. Park the lift truck on a level surface, parking Adding Oil
brake applied, transmission in NEUTRAL and See the topic, Differential, Change Oil under
See Wheel Nuts, Check – Tighten, when the engine stopped. Every 1200 Service Hours or 6 Months,
required. 1. Raise the lift bracket high enough to gain Whichever Comes First.
access to the level/fill plug.
2. Use blocking under the inner mast to
secure the lift bracket in this position.

202983

102565

3. Remove the level/fill plug. Maintain lubri-

cant level to the bottom of the level/fill
hole.
4. Clean the level/fill plug and put it back in
place.
5. Remove the blocking. Lower the lift
116 bracket. 116
MAINTENANCE 117

• Powershift Transmission
Check Oil Level Adding Oil

! WARNING 4. Remove the dipstick/filler cap. Check the See the topic, Powershift Transmission,
oil level. Change the Oil under Every 1200 Service
Hot oil and components could cause Hours or 6 Months, Whichever Comes First.
injury. Do not allow hot oil or compo-
nents to contact your skin.

1. Operate the lift truck a few minutes to

warm the oil.
2. Park the lift truck on a level surface with
the forks lowered, parking brake applied,
transmission in NEUTRAL, and the engine
stopped. 102567

3. Remove the floor plate.

5. Maintain the correct level range indicated
on the dipstick/filler cap.

Correct level range

102566 101631

117 117
MAINTENANCE 118

• Engine Crankcase – Gasoline and LP-Gas

Change Oil and Filter

! WARNING 5. Remove and discard the oil filter element. 9. Start the engine and allow the oil to fill the
6. Wipe the sealing surface of the oil filter filter and passages.
Hot oil and components could cause element mounting base. 10. Check for oil leaks.
serious injury. Do not allow hot oil or 7. Apply a small amount of clean engine oil to 11. Stop the engine and measure the oil level.
components to contact skin. the oil filter element gasket. Install the new Maintain the correct level range on the dip-
filter element. stick.
1. Operate the lift truck a few minutes to
warm the oil.
2. Park the lift truck on a level surface with
the forks lowered, parking brake applied,
transmission in NEUTRAL and the engine
stopped.
3. Raise the hood.
4. Remove the drain plug at the side of the
engine oil pan. Allow the oil to drain. Clean
and put the drain plug back in place. 102569 102558

8. Fill the crankcase. See Refill Capacities

and Lubrication Specifications charts.

Correct level range

102568 102559 100693A

12. Close and secure the hood.

118 118
MAINTENANCE 119

• Mast Strip Roller Surfaces • Lift Chains • Brake Pedal

Lubricate Lubricate and Inspect Lubricate

102570 102572 103493

Lubricate 1 fitting on each side of the inner Lubricate each chain on the left and right of the Lubricate 1 fitting.
mast for a total of 2 fittings. mast.

• Lift Bracket Side Rollers 1. Brush a film of engine oil onto the chain
Lubricate links, or spray with chain and cable lubri-
cant.
2. Raise and lower the lift bracket a few times
to work lubricant into the chain links.
NOTICE: Lubricate chains more fre-
quently than normal where the
atmosphere can cause corrosion
of components or when the
truck must work in rapid lift
cycles.
3. Inspect the chain anchors and individual
102571 links for wear, loose pins or cracked leaves.
Lubricate 1 fitting on each side roller for a total
of 2 fittings.

119 119
MAINTENANCE 120

• Tilt Socket Pins • Tie Rod Ends

Lubricate Lubricate

102573 102575

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

• Tilt Cylinder Pins • Rear Axle Center Pins

Lubricate Lubricate

102574 102576

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

120 120
MAINTENANCE 121

◆ Every 1200 Service Hours or 6 Months, Whichever Comes First

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

• Powershift Transmission
Change Oil and Wash Strainer

1. Remove the drain plug ➀. Allow the oil to 3. Remove the floor plate.
! WARNING
drain. Remove the cover ➁, the O-ring seal 4. Remove the dipstick/filler cap. Fill the trans-
Hot oil and components could cause and the strainer. mission with oil. See Refill Capacities. Put
serious injury. Do not allow hot oil or the dipstick/filler cap back in place.
components to contact your skin. 5. Start the engine.
6. Run the engine at low idle.
7. Stop the engine.
8. Remove the dipstick/filler cap. Check the
oil level.
Park the lift truck on a level surface with the 9. Add oil, if needed, to reach the correct
➀
forks lowered, parking brake applied, transmis- level range on the dipstick/filler cap.
sion in NEUTRAL and the engine stopped. ➁ 10. Check for oil leaks at the strainer and drain
plug.
102577
11. Put the floor plate back in place.
2. Wash the strainer and the plug in clean,
nonflammable solvent. Dry the strainer and
the plug. Wipe off the O-ring seal, check
and replace if necessary. Install the strainer,
the O-ring seal, and the cover. Put the drain Correct level range
plug back in place.

101631

102566
121 121
MAINTENANCE 122

• Hydraulic System
Change Return Oil Filter and Wash Strainer
3. Remove the hose. 8. Wash the strainer in clean, nonflammable
! WARNING solvent.
9. Inspect the gasket and replace it, if neces-
Hot oil components could cause personal
sary.
injury. Do not allow hot oil or compo-
10. Put the strainer, gasket, cover and battery
nents to contact your skin.
back in place.
At operating temperature, the hydraulic ➀ 11. Remove the filler cap. Check the oil level.
tank is hot and can be under pressure. ➁ 12. Add oil, if needed, to reach the correct
level range on the dipstick.

Park the lift truck with the forks lowered on a 103461

level surface, parking brake applied, transmis-
sion in NEUTRAL and the engine stopped. 4. Remove the gasket and strainer ➀.
5. Remove the gasket and return oil filter ➁.
1. Raise the hood.
Discard the filter element.
2. Remove the battery and tank cover.

100695C

Correct level range

102579 103494

6. Clean the filter parts and replace the seal 100698

and gasket, if necessary. Install a new filter
13. Put the dipstick and filler cap back in place.
element.
14. Check for oil leaks.
7. Put the filter body assembly back in place
15. Close and secure the hood.
and tighten the retaining bolts.

122 122
MAINTENANCE 123

• Differential • Air Cleaner

Change Oil Change Elements
Park the lift truck on a level surface, parking 5. Fill with oil to the bottom of the level/fill Cat Lift Trucks strongly recommends that the
brake applied, transmission in NEUTRAL, hole. air cleaner element be changed if it is dirty. If
forks lowered, lubricant warm and the engine 6. Put the level/fill plug back in place. you attempt to clean the element, handle it
stopped. 7. Remove blocking. Lower the lift bracket. carefully.
1. Raise the lift bracket high enough to gain
access to the level/fill plug ➁. Recommended change intervals
2. Use blocking under inner mast to secure
the lift bracket in this position. Every 1200 service hours
Normal conditions or 6 months,
3. Remove the drain plug ➀ and the level/fill whichever comes first
plug ➁. Every 200 service hours
4. Allow the oil to drain. Clean and reinstall Severe dust or
or monthly,
lint conditions
the drain plug. whichever comes first

Care in Severe Dust or Lint Conditions

Check the radiator core frequently for clogging
or dirt accumulation. Clean or wash the truck
as needed.
See the topic, Air Cleaner, Cleaning and
Inspecting under Every 50 Hours or Weekly,
whichever comes first.
202983

➁
➀ 102580

123 123
MAINTENANCE 124

• Fuel Filter –
Gasoline Change
3. Install the new filter. To replace the gasoline fuel filter use the
! WARNING following steps:
Fuel leaked or spilled onto hot surfaces 1. Raise the hood.
or electrical components can cause a fire. 2. The fuel filter is located on the left side of
Clean up any spillage of fuel. Know the Engine
the truck.
side 3. Place a drain receptacle under the truck to
location of all emergency devices (such as capture any fuel which may drain from the
fire extinguishers, first aid kits, etc.) and lines.
how to use them. 4. Disconnect the fuel inlet and outlet fittings.
Disconnect the battery when changing 5. Remove the filter from the mounting bracket.
fuel filters. 6. Discard the filter in a safe and proper manner.
101638 7. Reinstall a new filter into the securing
bracket and tighten retaining fastener.
NOTICE: When installing the new filter, cor- 8. Ensure the gasoline filter is mounted in the
NOTICE: Engine must be stopped and cool. rectly position the “IN” (tank side) proper direction of flow.
Park the lift truck in an authorized and “OUT” (engine side) sides of 9. Reconnect the inlet and outlet fittings and
refueling area, with the forks low- the filter element. tighten to specification.
ered, parking brake applied, trans- 10. Remove drain pan and discard any drained
4. Start the engine and check for fuel leaks. gasoline in a safe manner.
mission in NEUTRAL and the 5. Stop the engine. 11. Start the engine and check for leaks, repair
engine stopped and cool. 6. Close and secure the hood. if necessary.
1. Raise the hood.
2. The fuel filter is located on the left side of
the truck. Remove the filter.

• Fuel Filter Tier II–

Engine
side
Gasoline Change
NOTICE: Park the lift truck in an authorized
refueling area, with the forks
lowered, parking brake applied,
transmission in NEUTRAL. Engine
101637
must be stopped and cool.

124 124
MAINTENANCE 125

• Fuel Filter – LP-Gas

Change

NOTICE: Engine must be stopped and cool.

Park the lift truck in an authorized
refueling area, with the forks low-
ered, parking brake applied, trans-
mission in NEUTRAL, and the
engine stopped and cool.

103459 206746

5. Remove the screws from the cover.

A
Close

206702

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

The fuel shutoff valve turns clockwise to B
close. Run the engine until fuel in the fuel 103460
line runs out and the engine stops. Turn
3. Disconnect the fuel line. 206730
the key switch to OFF.
2. Raise the hood. 4. Remove the bolts A and bracket B. 6. Remove the cover and gasket.

125 125
MAINTENANCE 126

To replace the LP-Gas fuel filter use the

following steps:
1. Close the fuel valve on the LP-Gas tank.
The fuel shutoff valve turns clockwise to
close. Run the engine until fuel in the fuel
line runs out and the engine stops. Turn the
key switch to OFF.

206731

7. Replace the screen in recess as shown.

8. Reinstall the filter and bracket.
9. Connect the fuel line.
Close

206702

2. The fuel filter is located on the left side of

the truck.
Open 3. Disconnect the fuel hose from the LP-Gas
tank and the filter assembly.
102681 4. Raise the hood and disconnect the fuel hose
Open
from the bottom of the filter assembly.
10. Open the fuel valve. 5. Remove the nut from the bottom of the filter
11. Check the filter for fuel leaks with a soap 102681
and remove the filter assembly.
solution. 6. Remove the relief valve, nipple and the
elbow from the filter assembly and add to 10. Open the fuel valve.
• Fuel Filter Tier II– LP–Gas the new filter. 11. Check the fuel lines for leaks with a soap
Change 7. Install the new filter assembly to the truck. solution.
8. Reconnect the fuel hose to the bottom of
NOTICE: Park the lift truck in an authorized
refueling area, with the forks low- the assembly.
ered, parking brake applied, trans- 9. Reconnect the fuel hose to the inlet side of
mission in NEUTRAL. Engine the assembly and the LP-Gas tank.
must be stopped and cool.

126 126
MAINTENANCE 127
• Engine Coolant
Change
See the topic, Engine Coolant, Check Level 2. Turn the radiator filler cap slowly to
under Every 10 Service Hours or Daily, ! WARNING
relieve the pressure, then remove the cap.
whichever comes first.

! WARNING
At operating temperature, the engine
coolant is hot and under pressure.
Steam could cause severe burns.
Park the lift truck in an authorized refu-
eling area, with the forks lowered, park- 100899
ing brake applied, transmission in NEU- 102582
TRAL, and the engine stopped and cool. Antifreeze solution is TOXIC. In case of con-
Check the coolant level only after the tact with your skin, FLUSH IMMEDIATELY
engine has been stopped and the filler cap WITH WATER. Have your Cat lift truck
is cool enough to touch with your bare dealer discard antifreeze solution drained from
hand. the engine.
Remove the filler cap slowly to relieve 1. Loosen the radiator cover retaining knob.
pressure. Lift and remove the radiator cover.
Cooling system conditioner contains
alkali. Avoid contact with your skin and
eyes to reduce the risk of burns and other
injuries. Allow cooling system compo-
nents to cool before draining.
Use all cleaning solutions with care.
Antifreeze is TOXIC. In case of contact
with your skin, FLUSH IMMEDIATELY
WITH WATER. For disposal of the
antifreeze coolant drained from the 102581
engine, consult your Cat lift truck dealer.

127 127
MAINTENANCE 128

3. Open radiator drain valve. Allow the 6. Fill the cooling system with 1 kg (2 lb) 14. Close the drain valve.
coolant to drain. sodium bisulfate per 40 liters (10 gallons) 15. Mix a coolant solution of water and
of water. Most commercial cooling system antifreeze.
cleaners can be used. 16. Fill the cooling system. See Refill
7. Start and run the engine for 30 minutes. Capacities. To avoid air locks, add the
8. Stop the engine and drain the cleaning coolant slowly.
solution.
9. Flush the system with clean water until the
draining water is clear.
10. Close the drain valve. Fill the system with
neutralizing solution, 250 g (1/2 lb)
102584 sodium carbonate per 40 liters (10 gallons)
of water.
4. Drain the reserve tank.
11. Start and run the engine for 10 minutes.
12. Stop the engine and drain the neutralizing
solution.
102585
13. Flush the system with clean water until
draining water is clear. 17. Start and run the engine until the coolant
level is stabilized.
18. Stop the engine.
19. Add coolant, if necessary, to maintain the
level to below the bottom of the filler tube.

101465A

5. Close the radiator drain valve.

101641

20. Put the radiator filler cap back on.

128 128
MAINTENANCE 129

21. Remove the reserve tank filler cap.

22. Keep the coolant level at the FULL line on
the reserve tank.

101299

101465A

23. Put the reserve tank filler cap back on.

129 129
MAINTENANCE 130

◆ Every 2400 Service Hours or 1 Year, Whichever Comes First

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

• Hydraulic Oil
Change 4. Remove the hydraulic tank drain plug.
Allow the oil to drain. Clean and put the
! WARNING plug back in place.

Hot oil and components could cause

serious injury. Do not allow hot oil or
components to contact your skin. Correct level range
The engine has been stopped and the
filler cap is cool enough to remove with
your hand.
Remove the filler cap slowly to relieve
pressure.
102586 100698

Park the lift truck with the forks lowered on a 5. Fill the hydraulic tank. See Refill 9. Put the dipstick and the filler cap back in
level surface parking brake applied, transmis- Capacities. Put the filler cap back on. place.
sion in NEUTRAL and the engine stopped. 6. Start the engine and operate the hydraulic
1. Operate the lift truck to warm the oil. controls and the steering system through a
2. Park the lift truck with forks lowered, park- few cycles to fill the filters and lines. • Service Brake Fluid
ing brake applied, transmission in NEU- 7. Retract all hydraulic cylinders and stop the Change
TRAL, and engine stopped. engine.
3. Remove the filler cap. 8. Remove the filler cap and the dipstick. NOTICE: When changing fluid consult with
Keep the oil level at the HIGH mark on the your Cat lift truck dealer.
dipstick.

100814

100695C 103505
130 130
MAINTENANCE 131

◆ Parts to be Changed Periodically

The following parts should be periodically changed as noted below.
These parts are made of materials which will deteriorate as time goes by. Further, it is difficult to deter-
mine visually whether or not they are still in good condition. Changing at proper intervals will reduce
the chance of injury to the operator and damage to the truck.

Ref.
Parts to be changed Interval
No.
1 Cups and dust seals of the 2400 service hours or 1 year,
wheel cylinders whichever comes first
2 Cup and dust seal of the 2400 service hours or 1 year,
master cylinder whichever comes first
3 Brake booster 2400 service hours or 1 year,
whichever comes first.
When changing, consult your
Cat lift truck dealer.
4 Hydraulic hoses of steering 4800 service hours or 2 years,
system which ever comes first
5 Fuel hoses 4800 to 9600 service hours or 2 to 4
(Include LP-Gas) years, whichever comes first
6 Inner rubber parts of the 4800 service hours or 2 years,
power steering cylinders whichever comes first
7 Lift chains 4800 to 9600 service hours or 2 to 4
years, whichever comes first
8 Hydraulic hoses on and 2400 to 4800 service hours or 1 to 2
around mast years, whichever comes first
9 Tube of brake fluid cup 2400 service hours or 1 year, 102587
whichever comes first
10 Brake hoses 2400 service hours or 1 year,
whichever comes first
11 LP-Gas repair kit 2400 service hours or 1 year,
(Converter and fuel lock filter) whichever comes first
NOTICE: Periodic changes of these parts are not covered by Warranty.
131 131
||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| SERVICE DATA ||||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ Fuel Information
Use only fuel recommended in this section.

• Gasoline (Gas) Specification

Your lift truck must use unleaded gasoline only.
Oxygenated Gasoline
Some gasolines sold at service stations contain oxygenates such as ethanol, methanol, and MTBE (Methyl
Tertiary Butyl Ether), although they may not be so identified. The use of fuels containing oxygenates is
not recommended.
Ethanol (Gasohol)
A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your lift truck pro-
vided the octane rating is at least as high as that recommended for unleaded gasoline.
Methanol
Do not operate your lift truck on gasoline containing methanol (wood alcohol). The use of this type of
alcohol can result in lift truck performance problems and could damage critical fuel system parts.
MTBE (Methyl Tertiary Butyl Ether)
A mixture of 15% or less MTBE and unleaded gasoline may be used in your lift truck provided the octane
rating is at least as high as that recommended for unleaded gasoline.
NOTICE: If you experience driving problems which you suspect are fuel related, try switching to a
different fuel.

132 132
SERVICE DATA 133

• Liquefied Petroleum (LP-Gas)

Specifications
Use grade HD5 LPB. LP-Gas is a highly
volatile fuel with an octane rating of 100 to
140. Follow local ordinances regarding storage
and/or filling of LP-Gas tanks.

133 133
SERVICE DATA 134

◆ Coolant Information

NOTICE: Clean the cooling system if it is contaminated, The tendency of silicates and phosphates to
Cat Lift Trucks recommends that the coolant the engine overheats or foaming is observed in precipitate out-of-solution increases with
mix contain 50% commercially available auto- the radiator. increasing water hardness. Hard water, or
motive antifreeze, and 50% water. Old coolant should be drained, the system water with high levels of calcium and magne-
To reduce the risk of damage to your engine, cleaned and new coolant added – as recom- sium ions, encourages the formation of insolu-
never add coolant to an overheated engine. mended – using a commercially available auto- ble chemicals, especially after a number of
Allow the engine to cool first. motive antifreeze. heating and cooling cycles.
Dowtherm 209 full-fill coolant will lower the Filling at over 20 liters (5 U.S. gallons) per Cat Lift Trucks prefers the use of distilled
water pump cavitation temperature and cooling minute can cause air pockets in the cooling water or deionized water to reduce the potential
boiling point. These lowered temperatures will system. and severity of chemical insolubility.
cause overheating at a lower ambient tempera- After draining and refilling the cooling system,
ture than an ethylene glycol and water mix. If run the engine with the radiator cap off. Run it
Dowtherm is used, follow the instructions pro- until the coolant reaches its normal operating Acceptable Water
vided and use only the inhibitor package rec- temperatures and the coolant level stabilizes. Water content Limits ppm
ommended by the supplier. Add coolant as necessary to fill the system to Chlorides (Cl) 50 maximum
If the lift truck is to be stored in, or shipped to, the proper level. Sulfates (SO4) 50 maximum
an area with freezing temperatures, the cooling Operate with a thermostat in the cooling sys- Total hardness 80mg/l
Total solids 250 maximum
system must be protected to the lowest tem all year-round. Cooling system problems
pH 6.0 to 8.0
expected outside (ambient) temperature. can arise without a thermostat.
The engine cooling system is protected with a ppm = parts per million
commercially available automotive antifreeze • Coolant Water
Using water that meets the minimum accept-
when shipped from the factory. Hard water, or water with high levels of cal- able water requirement may not prevent
In cold weather, check the specific gravity of cium and magnesium ions, encourages the for- dropout of these chemical compounds com-
the coolant frequently to ensure adequate pro- mation of insoluble chemical compounds by pletely but should control the dropout rate at
tection. combining with cooling system additives such acceptable levels.
as silicates and phosphates.

134 134
SERVICE DATA 135

• Antifreeze
NOTICE: Make Proper Antifreeze Additions.
Cat Lift Trucks recommends that the coolant Do not add pure (100%) antifreeze to the cool-
mix contain 50% commercially available auto- ing system. Add antifreeze mixed with water
motive antifreeze, or equivalent, and acceptable using the same freeze protection ratio that is in
water to maintain an adequate water pump cav- your cooling system.
itation temperature for efficient water pump
performance.
Premix the coolant solution to provide protec-
tion to the lowest expected outside (ambient)
temperature. Pure undiluted antifreeze will
freeze at -23°C (-10°F).
Use a greater concentration (above 50%) of
commercially available automotive antifreeze
only as needed for anticipated outside (ambi-
ent) temperatures. Do not exceed the coolant-
to-water mix ratio recommendations provided
with the commercially available automotive
antifreezes.

Most commercial antifreezes are formulated for

gasoline engine applications and will, there-
fore, have high silicate content.

135 135
SERVICE DATA 136

◆ Recommended Fuels and Oils

Recommendation for ambient temperatures °C (°F)

Fuel or oil Recommendation -30 -20 -10 0 10 20 30
(-22) (-4) (14) (32) (50) (68) (86)
Fuel Consult your local Cat lift truck dealer
Engine oil API service classification SH, min. SAE10W-30
API service classification
Gear oil SAE80W SAE90
multipurpose type GL-4 or GL-5
Powershift transmission oil Dexron II Consult your local Cat lift truck dealer
Hydraulic oil ISO VG32
Brake fluid F.M.V.S.S. No. 116–DOT3 or DOT4 (SAE J1703)
Wheel bearings 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

NOTICE: Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when
mixed. It is best to stick with the same brand at successive service intervals.
For refill capacities and measurements, see Specifications in this section.

136 136
SERVICE DATA 137

Below oils are reference only.

• Engine Oils (Gasoline) • Powershift Transmission Oils

Spec
ificat
ions API service classification SH Dexron
Vis
cos
ity
Manufacturer SAE10W-30 —
Mobil Mobil Motor Oil 10W-30 Mobil ATF
Shell Shell Fleet 10W-30 Shell Donax TC
Exxon XD-3 10W-30 Exxtrans
Castrol Castrol GTX 10W-30 Castrol Dexron ® III/Mercon ®

• Brake Fluids/
Clutch Oil
Spec
ificat
ions
Vis
cos
ity
Manufacturer SAEJ1703
Mobil Mobil Universal Brake Fluid
Shell Shell Advance Brake Fluid
Exxon Brake Fluid DOT-3
Castrol Castrol GT LMA Brake Fluid

• Antifreeze/Summer
• Gear Oils • Greases
Coolant
Spec
ificat API service classification GL-4 or GL-5 NLGI No. 1 NLGI No. 2
ions
Vis
cos
ity Full Force
Manufacturer SAE80W SAE90 Consistency 310 - 340 Consistency 265 - 295
Mobil Mobilube HD 80W-90 Mobilux EP 1 Mobilux EP 2 USI Chemical

Shell Shell Spirax HD 80W-90 Retinax HD NLGI 1 Retinax HD NLGI 2 Marcus

Exxon Gear Oil GX80W-90 Ronex Extra Duty 1 Ronex Extra Duty 2 Peak
Castrol Castrol Hypoy 80W-90 Castrol EPL1 Castrol EPL2

137 137
SERVICE DATA 138

• Hydraulic oils
Spec
ificat
ions
Vis
cos
ity
Manufacturer ISO VG32
Mobil Mobiltrans HD 10W
Shell Tellus T-32
Exxon Nuto H32
Castrol Castrol Hyspin AWH-M32

NOTICE:
Brands of oil are subject to change without notice. When you buy oil, check
specification. (For example: API service classification SH, SAE10W-30)

138 138
SERVICE DATA
◆ Specifications and Refill Capacities (Standard Models)

Truck model GC40K GC45K-SWB GC55K GC70K

GC35K GC45K GC60K
Item GC40K-STR GC45K-STR GC55K-STR GC70K-STR

Alternator drive belt deflection - when pushed 11 to 13

with 98 N (10 kgf) [22 lbf] pressure, mm (in.) (0.4 to 0.5)
Gap, mm (in.) 1.01 (0.040)
Spark plugs
Type AC-DELCO #41-932
Engine idling speed, rpm 750 to 800
Steering wheel free-play - when measured 15 to 30
at rim with engine idling, mm (in.) (0.6 to 1.2)
Brake pedal free-play, mm (in.) 5 (0.2)
Parking brake lever effort, N (kgf) [lbf] 250 to 290 (25 to 30) [55 to 66]
Front 22 x 9 x 16 22 x 12 x 16 28 x 12 x 22
Tire size
Rear 18 x 7 x 12-1/8 18 x 8 x 12-1/8 22 x 8 x 16
Tightening torque for
Front 551 (56.2) [406.5]
wheel nuts, N•m (kgf•m) [lbf•ft]
Lift chain elongation limit,
523 (20.6) 654 (25.7)
mm (in.)/20 links

139 139
SERVICE DATA 140

Truck model GC40K GC45K-SWB GC55K GC70K

GC35K GC45K GC60K
Item GC40K-STR GC45K-STR GC55K-STR GC70K-STR

Fuel tank 66 (17.4) 80 (21.1) 128 (33.8)

Refill capacities (approximate),

Engine cooling system —

17 (4.5)
0.65 litre (1.4 pt) reserve tank included
Crankcase 4.2 (1.1)
Engine oil Oil filter 0.8 (0.2)
Total 5.0 (1.3)
litre (U.S. gal.)

Transmission 14 (3.7) 15 (4.0)

Differential (P/T) 9.1 (2.4)
Hydraulic tank 45.9 (12.1) 51.6 (13.6) 68.8 (18.2)
Brake fluid reservoir, cc (cu in.) 149 (9.1)
Battery electrolyte specific gravity
1.28
corrected to 20° C (68° F)

◆ Capacity and Truck Weight (Standard Models)

Truck model GC35K GC40K GC40K- GC45K- GC45K GC55K GC55K- GC60K GC70K GC70K-
Item STR SWB/STR STR STR
3,500 4,000 4,000 4,500 4,500 5,500 5,500 6,000 7,000 7,000
Capacity, kg (lb)
(7,000) (8,000) (8,000) (10,000) (10,000) (12,000) (12,000) (13,500) (15,500) (15,500)
Truck weight, kg (lb), approx. 5,200 5,600 5,700 6,500 6,600 7,200 7,400 8,800 9,500 10,000
(without load) (11,500) (12,300) (12,700) (14,300) (14,500) (15,800) (16,200) (19,300) (20,900) (22,000)

NOTICE: Capacities shown apply to trucks with standard (high grip wide) tires and 130 simplex mast.

140 140
 ||||||||||||||||||||||||||||||||||||||||||| TO THE CAT LIFT TRUCK OWNER |||||||||||||||||||||||||||||||||||||||||

◆ The Importance of Genuine Parts

The dealers and the owners are urged to use
ONLY Genuine Parts to maintain lift trucks in
a safe and efficient operating condition.

Safe and efficient operation of your lift truck

PART No.
PCS PART NAME
could be endangered by the use of
inferior parts. In most cases, imitations sold as
Made in
cheap parts invariably could mean short life
and high cost. 104830C

Genuine parts give safe and reliable performance.

! CAUTION
The use of other than genuine parts could
cause damage not covered by your
Cat Lift Trucks warranty.

141 141
TO THE CAT LIFT TRUCK OWNER 142

◆ Instructions for Ordering Parts

When ordering parts, or when asking your Cat

lift dealer to have your truck repaired, be sure
to provide the TRUCK MODEL and SERIAL
NUMBER and the ENGINE MODEL and
SERIAL NUMBER.

Manufacturer’s Name Plate

101522

Each lift truck has a name plate. It tells you the:

Truck serial number.
Truck model designation. 103495

Engine Serial Number

102529
Gasoline and LP-Gas engine models

142 142
TO THE CAT LIFT TRUCK OWNER 143

SERVICE REGISTRATION

Truck model, Serial No. Engine model, Serial No.

Mast model, Serial No. Attachment model, Serial No.

Delivering Name
dealer
Address

Delivery date

Fill out this sheet for your ready reference.

143 143
|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| INDEX||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
A C
Accelerator Pedal .........................................................................................29 Capacities, Truck Weight ...........................................................................140
Accelerator Pedal, Check (Every 10 Service Hrs.) .....................................98 Capacity (Weight and Load Center) ............................................................47
Adding Engine Coolant .....................................................................105–108 Capacity Plate ..............................................................................................48
Adding Engine Oil .............................................................................103–104 Capacity, Changes In ...................................................................................21
Adding Hydraulic Oil ................................................................................107 Capacity, Stay Within...................................................................................24
After Starting Engine ...................................................................................61 Center of Gravity .........................................................................................46
Air Cleaner Warning Light ..........................................................................33 Changing Direction ......................................................................................64
Air Cleaner, Care in Severe Dust and Lint Conditions ...............................81 Changing LP-Gas Tank ...............................................................................54
Air Cleaner, Change Element (Every 1200 Service Hrs.) .........................123 Changing Speed ...........................................................................................64
Air Cleaner, Clean/Inspect (Every 50 Service Hrs.)..................................113 Compartment, Operator’s, Cleanliness of....................................................13
Alternator Not Charging Warning Light......................................................33 Controls, Position Correctly ........................................................................25
Alternator, Drive Belt, Check-Adjust (Every 50 Service Hrs.) .................114 Coolant Information...................................................................................134
Antifreeze Coolant, Recommended ...........................................................137 Coolant, Adding .................................................................................105–106
Anti-Restart Starter Switch ..........................................................................32 Coolant, Adding Water...............................................................................105
Assist Grip ...................................................................................................42 Coolant, Engine Temperature Gauge...........................................................31
Assist Grip, Check (Every 10 Service Hrs.)................................................98 Coolant, Engine, Care of in Cold Weather ..................................................80
Coolant, Engine, Care of in Hot Weather ....................................................81
B Coolant, Engine, Safety While Checking ....................................................12
Back-up Buzzer............................................................................................45 Counterweight, Allowing for Swing Distance.............................................19
Back-up Lights, Check (Every 10 Service Hrs.) .......................................102
Battery, Check Electrolyte Level ...............................................................111 D
Before Moving Lift Truck............................................................................62 Damage or Faulty, Operation Found (Every 10 Service Hrs.) ....................97
Before Starting Engine...........................................................................56–57 Decals, LP-Gas ..............................................................................................4
Brake Fluid Level Warning Light ................................................................33 Decals, Warning .......................................................................................2–10
Brake Fluid, Recommended ..............................................................136, 137 Differential, Change Oil (Every 1200 Service Hrs.) .................................123
Brake Pedal ..................................................................................................29 Differential, Check Oil Level (Every 200 Service Hrs.) ...........................116
Brake Pedal, Check (Every 10 Service Hrs.)...............................................98 Direction Lever ............................................................................................29
Brake Pedal, Lubricate (Every 200 Service Hrs.) .....................................119 Direction of Travel, Always Look In ...........................................................19
Brake, Service, Change Fluid (Every 2400 Service Hrs.).........................130 Disabled Machine, Park Safely....................................................................25
Brakes, Service, Adding Brake Fluid (Every 10 Service Hrs.) .................108 Do-It-Yourself Maintenance ........................................................................92
Brakes, Service, Check (Every 10 Service Hrs.).......................................102 Drawbar Pin .................................................................................................42
Brakes, Service, Check Fluid Level (Every 10 Service Hrs.) ...................108 Dress, Proper................................................................................................11
Driving Interlock Indicator Light.................................................................91
Driving Interlock System .......................................................................33–34

144 144
INDEX (continued) 145

E Forks, Extending Beyond Load ...................................................................17

Empty Lift Truck, Stability of .....................................................................18 Fuel Amount, Check (Every 10 Service Hrs.) ...........................................100
Engine Coolant Adding......................................................................105–106 Fuel Filler.....................................................................................................43
Engine Coolant Level Warning Light ..........................................................33 Fuel Filter, Gasoline Change (1 Month After Delivery and
Engine Coolant Temperature Gauge............................................................31 Every 1200 Service Hrs.) .............................................................115, 124
Engine Coolant, Temperature Gauge Needle Moves Into Red Zone ..........89 Fuel Filter, LP-Gas, Change (1 Month After Delivery and
Engine Crankcase, Check Oil Level (Every 10 Service Hrs.)...................103 Every 1200 Service Hrs.) .....................................................115, 125–126
Engine Hood ................................................................................................44 Fuel Gauge ...................................................................................................31
Engine Oil Pressure Warning Light .............................................................33 Fuel Shut-off Valve ......................................................................................43
Engine Oil, Recommended ................................................................136, 137 Fuels and Oils, Recommended ..................................................................136
Engine, Adding Oil (Every 10 Service Hrs.) .............................................103 Fuels Oils, Care in Cold Weather ................................................................80
Engine, After Starting ..................................................................................61 Fuels Oils, Care in Hot Weather ..................................................................81
Engine, Before Starting................................................................................56 Fuse Box ......................................................................................................31
Engine, Check (Every 10 Service Hrs.).....................................................102 Fuses and Lights ..........................................................................................40
Engine, Check Coolant Level (Every 10 Service Hrs.) .............................105
Engine, Coolant, Change (Every 1200 Service Hrs.) ........................127–129 G
Engine, Gasoline and LP Gas Change Oil and Filter Gasoline Engine ...........................................................................................53
(Every 200 Service Hrs.) ......................................................................118 Gear Oils, Recommended ..................................................................136, 137
Engine, Inspection Points ............................................................................44 Genuine Parts, Importance Of ...................................................................141
Engine, Stalls ...............................................................................................90 Grease, Chassis ..........................................................................................136
Engine, Starting with Jumper Cables...........................................................60 Greases, Recommended.....................................................................136, 137
Engine, Starting, Gasoline ...........................................................................58
Engine, Starting, Gasoline Cold ..................................................................58 H
Engine, Starting, Gasoline Warm.................................................................58 Handling Loads Safely...........................................................................22, 70
Engine, Starting, LP-Gas .............................................................................61 Handling Round Objects..............................................................................75
Engine, Won’t Start......................................................................................59 Healthy, Always Stay on the Job .................................................................13
Exhaust Fumes, Dangers of .........................................................................12 Hood, Engine ...............................................................................................44
Horn Switch .................................................................................................29
F Horn, Check (Every 10 Service Hrs.)........................................................100
Floor Capacity, Be Aware of........................................................................17 Horseplay and Stuntdriving, Refrain From..................................................19
Foreword .........................................................................................................i Hoses, Lines, Tubes .....................................................................................92
Fork Adjustment...........................................................................................41 Hourmeter ....................................................................................................31
Fork Stoppers ...............................................................................................41 How To Use This Manual..............................................................................ii
Forks, Changing ...........................................................................................41 Hydraulic Oils, Recommended..........................................................136, 138
Forks, Checking Stopper Engagement.........................................................17 Hydraulic System, Adding Oil (Every 10 Service Hrs.) ...........................107
Forks, Do Not Abuse .............................................................................22, 23 Hydraulic System, Change Oil (Every 2400 Service Hrs.) .......................130
145 145
INDEX (continued) 146

Hydraulic System, Change Return Oil Filler and Wash Strainer Lift Truck, Shipping.....................................................................................79
(1 Month After Delivery and Every 1200 Service Hrs.)..............115, 122 Lift Truck, Stability................................................................................46–47
Hydraulic System, Check Oil Level (Every 10 Service Hrs.) ...................107 Lift Truck, Stopping.....................................................................................67
Hydraulic Tank, Oil Level/Filler Hole.........................................................43 Lift Truck, Storage .......................................................................................78
Lift Truck, Unloading ............................................................................73–74
I Light Switch.................................................................................................32
Inching .........................................................................................................66 Lights, Check (Every 10 Service Hrs.)........................................................97
Inching Pedal ...............................................................................................29 Lights, When To Use ...................................................................................16
Inching Pedal, Check (Every 10 Service Hrs.)............................................99 Lights, Won’t Come On ...............................................................................40
Index...................................................................................................144–148 Lines, Tubes and Hoses ...............................................................................92
Inspection Precautions .................................................................................93 Load Backrest, Check (Every 10 Service Hrs.)...........................................97
Instrument Panel ..........................................................................................31 Load, Handling Round Objects ...................................................................75
Load, Handling Safely ...........................................................................22, 70
L Load, Inching Into and Lifting.....................................................................71
Leaks, Oil, Fuel or Coolant, Check (Every 10 Service Hrs.)......................97 Load, Stacking Methods ..............................................................................69
Lift Bracket Side Rollers, Lubricate (Every 200 Service Hrs.).................119 Load, Traveling With .............................................................................72, 76
Lift Chains, Adjust .....................................................................................101 Loading, Avoid Off-Center ....................................................................17, 72
Lift Chains, Lubricate–Inspect (Every 200 Service Hrs.) .........................119 Loads, Approaching at Safe Speed ........................................................22, 71
Lift Control Lever ........................................................................................30 Loads, Do Not Allow Others to Hold, on Truck .........................................19
Lift Truck Stability Base..............................................................................47 Loads, Handling.....................................................................................22, 23
Lift Truck, Before Moving...........................................................................62 LP-Gas Equipment, Trouble ........................................................................90
Lift Truck, Break-In New ............................................................................56 LP-Gas Tank Replacement ..............................................................14, 26, 54
Lift Truck, Care of in Cold Weather............................................................80
Lift Truck, Care of in Hot Weather..............................................................81 M
Lift Truck, Care of in Severe Dust or Lint Conditions................................81 Maintenance .........................................................................................92–131
Lift Truck, Damaged, Defective or Unsafe ...........................................13, 15 Maintenance Schedule (1 Month After Delivery) .......................................95
Lift Truck, Do Not Modify ..........................................................................12 Maintenance Schedule (Every 10 Service Hrs.)....................................94, 95
Lift Truck, Inching .......................................................................................66 Maintenance Schedule (Every 1200 Service Hrs.) ......................................96
Lift Truck, Keeping People Clear..........................................................21, 22 Maintenance Schedule (Every 200 Service Hrs.) ........................................95
Lift Truck, Know Your.....................................................................13, 27–46 Maintenance Schedule (Every 2400 Service Hrs.) ......................................93
Lift Truck, Move Safely...............................................................................20 Maintenance Schedule (Every 50 Service Hrs.) ..........................................95
Lift Truck, Operation .............................................................................56–68 Mast and Forks, Check (Every 10 Service Hrs.) ...............................110–111
Lift Truck, Parking (After Stopping) ...........................................................68 Mast Strip Roller Surfaces, Lubricate (Every 200 Service Hrs.) ..............119
Lift Truck, Safety On Grades When Empty ................................................20 Mast Supports, Lubricate (Every 50 Service Hrs.)....................................115
Lift Truck, Safety On Grades When Loaded...............................................20 Model View ..................................................................................................28
Lift Truck, Safety When Passing .................................................................19
146 146
INDEX (continued) 147

N Powershift Transmission, Adding Oil ........................................................117

Name Plate, Manufacturer’s.......................................................................142 Powershift Transmission, Change Oil (Every 1200 Service Hrs.) ............121
Powershift Transmission, Check Oil Level (Every 200 Service Hrs.) ......117
Pre-Start Inspection..............................................................................97–111
O
Pre-Start Inspection Items......................................................................94–95
Oil and Fuel, Care in Cold Weather.............................................................80
Oil and Fuel, Care in Hot Weather ..............................................................81 R
Oil, Fuel or Coolant Leaks, Check (Every 10 Service Hrs.).......................94
Radiator Cover .............................................................................................45
Oil, Hydraulic, Change (Every 2400 Service Hrs.)...................................130
Rear Axle Center Pins, Lubricate (Every 200 Service Hrs.) .....................120
OK Monitor Bulb Check .............................................................................32
Rear View Mirror .........................................................................................45
OK Monitor, Check (Every 10 Service Hrs.) ............................................100
Refueling ................................................................................................53–55
OK Monitor, Warning Lights and Indicators ...............................................33
Refueling, No Smoking During.............................................................11, 43
Operating Controls.......................................................................................29
Reverse, Travel.............................................................................................19
Operating Techniques ......................................................................65, 69–77
Riders, Do Not Allow ............................................................................18, 19
Operation................................................................................................56–68
Operator Be Alert.........................................................................................11
S
Operator, Authorized, Trained .....................................................................11
Operator’s Compartment..............................................................................29 Safe, Know Your Lift Truck Is.....................................................................13
Operator’s Seat, (Adjustment) .....................................................................36 Safety Equipment.........................................................................................41
Overhead Clearance .....................................................................................16 Safety Rules for Lift Truck Operators .....................................................1–26
Overhead Guard, Check (Every 10 Service Hrs.) .......................................98 Safety Rules, LP Gas ...................................................................................26
Safety Rules, Warnings ..........................................................................11–26
Safety, Anti-restart .......................................................................................32
P
Seat Activated Transmission Interlock, Check (Every 10 Service Hrs.) ...112
Pallets, Damaged, Do Not Use ....................................................................23 Seat Belt .................................................................................................37–38
Parking Brake Lever ....................................................................................29 Seat Belt, Check (Every 10 Service Hrs.) ...................................................99
Parking Brake Lever, Check (Every 10 Service Hrs.) .................................99 Seat Belt, How to Fasten, Release ...............................................................38
Parking, In Authorized Areas.......................................................................25 Seat, Adjust Before Operation .........................................................16, 36, 99
Parking, Lift Truck.......................................................................................68 Serial Number and Capacity Plate...............................................................27
Parking, On a Grade.....................................................................................25 Service Data .......................................................................................132–140
Parts To be Changed Periodically ..............................................................131 Service Registration Sheet .........................................................................143
Parts, Ordering Instructions .......................................................................142 Signals and Traffic Rules, Know All ...........................................................19
Pedestrians, Watch Out for at All Times................................................18, 19 Slippery Surface, Stay Away From..............................................................18
People, Unauthorized, Do Not Allow ..........................................................21 Special Situations...................................................................................80–81
Plate, Serial Number, Instruction, and Manufacturer ..................................27 Specifications and Refill Capacities (Standard Models) ...................139–140
Powershift Transmission Oil Temperature Warning Light ..........................89 Speed Selector Switch .................................................................................31
Powershift Transmission Oil, Recommended....................................136, 137 Stability and Center of Gravity..............................................................48–49
147 147
INDEX (continued) 148

Starting Gasoline Engine .............................................................................58 U

Starting LP-Gas Engine ...............................................................................61 Unsafe Lift Truck, Do Not Operate .............................................................13
Steep Slope, Driving On ..............................................................................20 Upgrade, Start Lift Truck Carefully.............................................................20
Steering (Turning)........................................................................................65
Steering Tilt Lever .......................................................................................30 W
Steering Wheel, Check (Every 10 Service Hrs.) .......................................100 Warning Decals, Description .....................................................................5–9
Stop Lights, Check (Every 10 Service Hrs.) .............................................100 Warning Decals, Location..........................................................................2–4
Storage .........................................................................................................78 Wheel Nuts, Check-Tighten (Every 10 Service Hrs.) ...............................109
Wheel Nuts, Retighten (Every 200 Service Hrs.)......................................116
T Working on Grades ................................................................................78–79
Table of Contents.....................................................................................iii–iv
Tail Swing ....................................................................................................65
Tie Rod Ends, Lubricate (Every 200 Service Hrs.)...................................120
Tightening Torque ........................................................................................85
Tilt Control Lever ........................................................................................30
Tilt Cylinder Pins, Lubricate (Every 200 Service Hrs.) ............................120
Tilt Cylinder Socket Bolts, Check (Every 10 Service Hrs.)........................95
Tilt Socket Pins, Lubricate (Every 200 Service Hrs.) ...............................120
Tipover, Avoid On a Grade or Ramp ...........................................................20
Tipover, Avoid, Do’s and Don’t .............................................................49–51
Tipovers, Be Alert for ..................................................................................21
Tipovers, How to Avoid, Survive...........................................................46–52
Tipovers, How to Survive ............................................................................52
Tire, Changing........................................................................................82–88
Tire, Check (Every 10 Service Hrs.)..........................................................109
Tire, Jack Capacities ....................................................................................83
Tire, Jacking Method .............................................................................82–84
Trailer, Driving Onto....................................................................................23
Transmission Oil, Powershift, Recommended...................................136, 137
Transmission, Powershift, Change Oil, etc (Every 1200 Service Hrs.) ....121
Transmission, Powershift, Check Oil Level (Every 200 Service Hrs.) .....117
Traveling on a Grade....................................................................................76
Traveling, See Where You Are Going..........................................................19
Troubleshooting .....................................................................................82–90
Tubes, Lines and Hoses ...............................................................................92
Turning .........................................................................................................65
148 148
 Mitsubishi Caterpillar Forklift America Inc.
2121 W. Sam Houston Parkway N.
Houston, TX 77043-2305

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