CAT DP40K Manual

CAT Gaffeltruck DP40K

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Operation & Maintenance Manual

99730-85141Keep this manual in your lift truck as a ready reference.

GP40K AT29C-00011-20230

AT29C-20231-up

GP40KL AT29C-50011-70230

AT29C-70231-up

GP45K AT29C-80001-89999

AT29C-R0231-up

GP50K AT33B-50001-70230

AT33B-70231-up

DP40K AT19C-00011-20230

AT19C-20231-up

DP40KL AT19C-50001-70230

AT19C-70231-up

DP45K AT19C-80001-89999

AT19C-R0231-up

DP50K AT28B-50001-70230

AT28B-70231-up

The Occupational Safety and Health Administration (OSHA) is now mandating

operator training for all lift truck operators.

SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on

the skill and alertness of the operator. To develop the skill, the operator should:

1. Know the working capabilities and limitations of the lift truck.

2. Know the make-up of the lift truck.

3. Read and understand the safe driving and load handling procedures con-

tained in this manual.

And, most important, a qualified person experienced in lift truck operation

should guide new operators through several driving and load handling opera-

tions before they attempt to operate the lift truck on their own.

It is the responsibility of the employer to make sure the operator can see, hear

and has the physical and mental ability to operate the lift truck safely.

This manual contains information necessary for the operation and “do-it-your-

self” maintenance of standard lift trucks. Optional equipment is sometimes

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. The lift trucks are NOT intended for use on public roads.

FOREWORD

100588A

99730-85141

iiii

The following safety signs and NOTICE are used in this manual to

emphasize important and critical instructions. Be sure to read these precautionary

instructions and all safety related

decals installed on your truck

before you operate it.

Mitsubishi Caterpillar Forklift America Inc. (MCFA) 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 MCFA 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 operation, lubrication, maintenance or repair pro-

cedures 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

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 dealer before starting any job. Cat dealers have the current

information available. Additional manuals are available from your Cat

dealer.

Directional terms:

The directions “left,” “right,” “front” and “rear” are given from the view-

point of the operator facing forward.

101582C

HOW TO USE THIS MANUAL

Indicates a imminently hazardous situation

which, if not avoided, will result in death or

serious injury.

This is the safety alert symbol. It is used to alert you to

potential personal injury hazards. Obey all safety messages

that follow this symbol to avoid possible injury or death.

Indicates a potentially hazardous situation

which, if not avoided, could result in death or

serious injury.

Indicates a potentially hazardous situation

which, if not avoided, may result in minor or

moderate injury, or damage to your machine.

DANGER

WARNING

CAUTION

SAFETY RULES FOR LIFT TRUCK OPERATORS

◆

◆Decals for LP-Gas Only

Fuel decal

Dual Fuel System decal Fuel Gauge

decal

(For L.P. Gas Only)

Maintenance decal

Location decal L.P.G. decal

105365

G/LPG Changeover decal

SAFETY RULES FOR LIFT TRUCK OPERATORS

◆

◆Warning Decals, Description

Located to the left front of the operator’s seat.

Proper operating force: 250 to 290 N (25 to 30

kgf) [55 to 66 lbf].

When leaving the machine (lift truck),

apply the parking brake! The parking

brake is not automatically applied.

102506A

To avoid serious injury, do not carry pas-

sengers. A lift is designed for only one

operator and no riders.

Located to the right front of the operator’s seat.

102511

Located to the right of the operator’s seat on the

engine hood.

103186

Improper operation or maintenance could

result in injury or death. Do not operate

or work on the lift truck unless you are

properly trained.

WARNING

• Parking Brake • Capacity Plate • No Rider

SAFETY RULES FOR LIFT TRUCK OPERATORS

Located to the right side of the operator’s seat

on the engine compartment cover.

FOR SAFETY OBSERVE THE

FOLLOWING WARNINGS

1. Do not operate this truck unless you have

been trained and authorized to do so. Read

all warnings and instructions in the opera-

tor’s manual and on this truck. An

Operation & Maintenance Manual is sup-

plied with this truck or available from your

Cat lift truck dealers.

2. Do not operate this truck until you have

checked its condition. Give special atten-

tion to Tires, Rims, Horns, Light

Battery(s), Controller, Lift and Tilt

Systems including forks or attachments,

chains, cable and limit switches, brakes,

steering mechanism, fuel system, hydraulic

hoses and guards.

3. Operate the truck only from the designated

operating position. Never place any part of

your body into the mast structure, between

the mast and the truck, or outside the truck.

Do not carry passengers.

4. Do not operate the truck without the over-

head guard.

5. Do not handle loads which are higher than

the load backrest or load backrest exten-

sion unless the load is secured so that no

part of it could fall backward.

6. Do not handle unstable or loosely stacked

loads. Use special care when handling

long, high or wide loads to avoid losing the

load, striking bystanders, or tipping the truck.

7. Do not overload the truck. Check capacity

plate for load weight and load center infor-

mation.

8. Start, stop, travel, steer and brake

smoothly. Slow down for turns on uneven

or slippery surfaces that could cause truck

to slide or overturn. Use special care when

traveling without a load as the risk of over-

turning is greater.

9. Elevate forks or other lifting mechanism

only to pick up or stack a load. Lift and

lower with mast vertical or tilted slightly

back—NEVER FORWARD. Watch out for

obstructions, especially overhead.

10. Operate tilting mechanism slowly and

smoothly. Do not tilt forward when ele-

vated except to pick up or deposit a load.

When stacking, use only enough backward

tilt to stabilize load.

11. Travel with the load or lifting mechanism

as low as possible and tilt back. Always

look in the direction of travel. Keep a clear

view, and when load interferes with visi-

bility, travel with the load or lifting mech-

anism trailing (except when climbing

ramps).

12. Use special care when operating on ramp,

travel slowly, and do not angle or turn.

When the truck is loaded, travel with the

load uphill. When the truck is empty, travel

with the lifting mechanism downhill.

13. Observe applicable traffic regulations.

Yield right of way to pedestrians. Slow

down and sound horn at cross aisles and

wherever vision is obstructed.

14. When using forks, move them as far apart

as the load will permit. Before lifting, be

sure the load is centered and the forks are

completely under the load.

15. Do not allow anyone to stand or pass under

the load or lifting mechanism.

16. Do not lift personnel except on a securely

attached, specially designed Work

Platform. Use extreme care when lifting

personnel. Place the mast in the vertical

position, place the truck controls in neutral

and apply the brakes. Lift and lower

smoothly. Be available to operate controls

as long as personnel are on the Work

Platform. Never transport personnel on

forks or Work Platform.

17. Before getting off the truck, put the direc-

tion lever in neutral engaging the lever

lock knob, lower the lifting mechanism

fully, and set the parking brake. If leaving

the truck unattended, shut the power off also.

Only trained and authorized personnel

may operate this lift truck. For safe oper-

ation, read and understand the

Operation and Maintenance Manual fur-

nished with this lift truck and observe the

following warnings:

103187

WARNING

SAFETY RULES FOR LIFT TRUCK OPERATORS

103937

Located on the radiator cap.

Check the coolant level only after the engine has been stopped and the

filler cap is cool enough to touch with your hands.

Remove the filler cap slowly to relieve pressure.

Located inside the top frame member of the overhead guard.

Operation without this device in place may be hazardous. This overhead

guard conforms to ANSI/ITSDF B56.1. This design also passed a verti-

cal impact test of 24000 foot pounds.

102513

• Overhead Guard

Located inside the front frame member of the overhead guard.

The Back-up Buzzer must sound when operating this vehicle in reverse.

103964

Located on the frame of the cooling fan.

To avoid serious injury, stay clear of the moving fan.

103936

• Back-up Buzzer

• Cooling System

WARNING

SAFETY RULES FOR LIFT TRUCK OPERATORS

103185

Located on the mast.

Do not stand or ride on the forks.

Do not stand or ride on a load or pallet

on the forks.

Do not stand or walk under the forks.

102512

Located on the load backrest.

Operation without this device in place

may be hazardous.

DO NOT remove the load backrest exten-

sion.

105183

Located on the mast.

Do not touch, lean on, or reach through

the mast or permit others to do so.

Hands off!

105182

WARNING

105181

7 / ? 6 1 + . / 5 . .

7/ ?6

?6 1+

1+ ./

./ 5.

5. .

105180

104757

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

SAFETY RULES FOR LIFT TRUCK OPERATORS

TIPOVER WARNINGS

1. Side tipover of an unloaded truck can occur

if the combination of speed and a sharp turn

which exceeds the stability of the truck.

2. Side tipover can occur if overloaded, or

loaded within capacity and:

– The load is elevated.

– Turning and/or braking when traveling in

reverse.

– Turning and/or accelerating when travel-

ing forward.

These actions may exceed the stability of

the truck.

Backward tilt and/or off-center positioning of

the load and/or uneven ground conditions will

further aggravate the above conditions.

3. Forward tipover can occur if overloaded or

when loaded within capacity and the load is

elevated in forward tilt, braking in forward

travel, or commencing reverse travel. These

actions may exceed the stability or the

truck.

4. Serious injury or death can occur if the

operator is trapped between the truck and

the ground.

IN CASE OF TIPOVER

1. The operator should stay with the truck if

side or forward tipover occurs. The operator

should hold on firmly to the steering wheel,

brace feet, lean forward and lean away from

the point of impact.

2. If the truck falls off of a loading dock or

ramp, you should try to stay within the con-

fines of the operator’s seat area. Should the

landing area present a more severe hazard,

you may find it prudent to leave the truck.

102514A

Located inside the top frame member of the

overhead guard.

102514B

Located inside the top frame member of the

overhead guard.

Located inside the front frame member of the

overhead guard.

103267A

Tipover can occur if truck is improperly

operated. Injury or death could result.

• Tipover Warnings

DANGER

WARNING

1010

SAFETY RULES FOR LIFT TRUCK OPERATORS

Authorized, trained operator only!

Thoroughly learn how to operate a lift truck

and the safe areas and surfaces to travel before

you drive one.

DO NOT travel on public roads! Dress properly for the job!

DO NOT wear loose clothing or accessories—

flapping cuffs, dangling chains, neck ties,

scarves, or rings—that can catch in moving

parts.

NO smoking while refueling!

DO NOT fuel while the engine is running.

Keep away from flames or spark sources. Turn

off all electrical switches on the truck. Fuel in

a well ventilated area.

Be alert!

Know how to use a first aid kit and a fire extin-

guisher—and where to get prompt assistance.

◆

◆Safety Rules

100989

100605

101003

You may need:

– Safety goggles.

– Ear protectors.

– Hard hat.

100604

100870

WARNING

1111

SAFETY RULES FOR LIFT TRUCK OPERATORS

100610

Know your lift truck and attachments!

Know the operating, inspection and mainte-

nance instructions in the OPERATION &

MAINTENANCE MANUAL.

Know all signals and traffic rules!

Know who is responsible for signaling. Learn

to tell at a glance what the signal means, and

what action you should take.

Avoid being splashed by scalding hot

coolant!

Wait until the engine cools before opening or

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.

Shut down engine before servicing!

DO NOT service a lift truck while engine is

running unless absolutely necessary to do so.

100607 100609

100612

101006

101007

Exhaust fumes could kill you!

If you operate a lift truck in an enclosed area,

make sure there is adequate ventilation.

Unauthorized addition or modification is

prohibited!

DO NOT add to or modify the lift truck unless

authorized in writing by the manufacturer to do

so. Any change to the lift truck could cause

serious injury or property damage.

WARNING

1212

SAFETY RULES FOR LIFT TRUCK OPERATORS

Inspect your lift truck prior to operation!

At the beginning of each shift, fill out a daily

inspection sheet. Check for maintenance prob-

lems and have repairs made before you operate

the truck.

DO NOT remove the overhead guard!

The overhead guard is intended to protect the

lift truck operator from overhead obstructions

and falling objects.

101008 103255

Keep the operator’s compartment clean!

102835

DO NOT operate an unsafe lift truck!

Inspect a lift truck before you operate it to be

sure it is properly maintained and in good

working order.

102517

Always stay healthy on the job!

Be healthy—and NOT under the influence of

drugs or alcohol—when operating the truck.

102520B

Know your lift truck is safe!

DO NOT operate any lift truck that is not safe

to operate.

102522B

WARNING

1313

SAFETY RULES FOR LIFT TRUCK OPERATORS

LP-gas tank replacement!

LP-gases are flammable. Do not attempt to

change LP-gas tanks unless you are trained and

authorized to do so. Be sure to get a trained and

qualified mechanic to change them.

201317A

Alarm must sound when operating this

truck in reverse!

When operating in reverse, ALARM MUST

SOUND.

Failure to maintain a clear view in the direction

of travel could result in injury or death.

103907

For handling frequency transducer, ECU

and ECM!

1. Do not directly expose these equipment to

washing water, rain, oil and every other liq-

uid.

2. Do not apply force, open, modify these

equipment nor operate the truck without

these equipment.

3. Turn key switch OFF. Disconnect battery

cable and then disconnect these equipment

before following operations:

• Removing these equipment from truck

• Factory approved welding

103926

Frequency transducer and ECU for

two speed T/M (Electronic control unit)

ECM

(Controller for engine)

WARNING

1414

SAFETY RULES FOR LIFT TRUCK OPERATORS

DO NOT operate a damaged or defective lift

truck!

A truck will operate effectively and safely

when it is in proper working order.

Be sure the assist grip is properly tightened!

Face the lift truck when mounting and dis-

mounting.

Maintain a three point contact (one foot and

two hands) with the floor and handholds.

Never get on or off a moving lift truck.

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.

101644

101010

Operate only in approved areas!

Certain areas such as those containing haz-

ardous flammable gases, liquid or other com-

bustibles, should be avoided.

101005

Start engine safely!

Start the engine only when securely seated in

the operator’s compartment.

101115C

WARNING

1515

SAFETY RULES FOR LIFT TRUCK OPERATORS

101014A

Adjust the seat before operation!

DO NOT adjust the seat while the lift truck is

in motion. This could cause serious injury.

Make sure your lift truck is in safe operat-

ing condition!

Test the brakes and inching pedal while mov-

ing slowly in a safe area. Make sure the mast

moves up and down smoothly.

Fasten the seat belt properly!

If you DO NOT, it may not restrain you in an

accident.

100976

101114 B

Always check overhead clearance!

Serious accidents may be caused by the mast

and overhead guard hitting pipes, beams or

other overhead obstructions. Watch out for

power lines.

101023

Use lights in dark, dim areas!

Even with lights on, DO NOT assume people

see you and will move out of your way.

100635 101025

Stay within the confines of the truck!

Keep your arms and legs inside the operator’s

compartment.

WARNING

1616

SAFETY RULES FOR LIFT TRUCK OPERATORS

Always be aware of floor capacity!

Make sure the floor will support the weight of

the loaded lift truck.

101027

Stay under the overhead guard!

DO NOT hold on to the overhead guard.

101526

Be careful of forks that extend beyond the

load!

If the forks extend beyond the load, use extra

caution. Make sure the fork tips do not contact

other material.

101036

Avoid off-center loading!

Set the forks as far apart as possible for maxi-

mum support of the pallet or load. Too small a

fork spread can cause instability of the load.

103444

Check fork stoppers for engagement!

If the fork stoppers are not properly engaged,

the forks may shift and cause off-centered or

unstable loads.

Check work areas for high risk!

When working on docks, ramps, platforms and

other high risk areas, use adequate blocks to

reduce the risk of the lift truck from falling off.

102146A101035

20% 20%

60%

WARNING

1717

SAFETY RULES FOR LIFT TRUCK OPERATORS

Position controls correctly for starting!

Make sure the direction lever is in the NEU-

TRAL position, the lock knob is in the NEU-

TRAL position and the parking brake lever is

set properly.

102518

Be aware of the stability of an empty lift

truck!

An empty lift truck will tip over more easily

than a loaded one in a lowered position.

100662

DO NOT allow any riders!

DO NOT allow anyone to ride on the forks or

on any other part of the lift truck—at any time.

If you cannot see where you are going, DO

NOT MOVE!

Travel slowly around corners. Sound the horn

at cross aisles and other areas where you can-

not see clearly or where visibility is restricted.

101015 100626

Stay away from slippery surfaces!

– Loose or slippery materials such as sand,

gravel, ice, mud, etc., on your operating

surfaces could cause a skid or tipover.

Avoid these conditions or slow down.

– Keep your operating surfaces clean and dry

at all times. Wet spots could cause a skid or

tipover.

– 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.

100998

◆

◆Operating Precautions

WARNING

1818

SAFETY RULES FOR LIFT TRUCK OPERATORS

DO NOT engage in stunt driving or horse-

play!

Stunt driving and horseplay is dangerous for

both the lift truck operator and the fellow

workers.

Travel in reverse if forward visibility is

blocked!

For better visibility with large loads, travel in

reverse, but always keep a lookout in the direc-

tion of travel.

101019 101021

DO NOT allow anyone to hold loads! Always look in the direction of travel!

Always be aware of people near your lift truck.

DO NOT proceed until they are aware of you.

101017100873A

DO NOT pass another truck!

DO NOT pass another lift truck traveling in the

same direction at intersections, blind spots or

at other dangerous areas.

101016

Obey all traffic rules and warning signs!

Drive carefully, observe traffic rules and be in

full control of the lift truck at all times.

101022B

WARNING

1919

SAFETY RULES FOR LIFT TRUCK OPERATORS

Travel safely on grades with a loaded lift

truck!

Keep the load upgrade to maintain control

when traveling up or down a grade with a heav-

ily loaded truck.

Be particularly careful when driving up or

down a steep slope!

Use extreme care to reduce the risk of the tips

of forks or the bottom of pallet from touching

the ground.

Travel safely on grades with an empty lift

truck!

Keep the counterweight upgrade when travel-

ing up or down a grade with an empty truck.

101026 101029102519

Start lift truck upgrade carefully!

When starting the lift truck upgrade, be sure to

use the parking brake.

102525B

DO NOT turn on a ramp or grade!

Turning on a ramp or grade can cause a lift

truck, loaded or unloaded, to tip over.

100667

Move your lift truck safely!

Sound the horn and be sure no people or

objects are in your path before moving.

101013

WARNING

2020

SAFETY RULES FOR LIFT TRUCK OPERATORS

Danger! Keep out!

DO NOT allow any unauthorized people in the

work area.

101031

Be careful of changes in capacity!

Optional attachments which change the capac-

ity are sometimes installed. Know the capacity

before operating the truck.

A helper should NOT be near the lift truck!

People should be clear of the lift truck operat-

ing area.

101033

100924

101020

Allow for counterweight swing distance!

When turning in aisles, especially narrow aisles

keep as far away as possible from stock and

racks. Be cautious near people.

◆

◆Working Precautions

101002

Always be alert for tipovers!

Turning sharply with a raised load, even at a

slow speed, may result in a tipover. Realize that

the overhead guard is not designed to provide

total protection in the event of a tipover.

WARNING

2121

Handle only stable loads!

If a load is unstable, it can easily shift and fall

on someone.

101041100652

DO NOT move when someone’s next to

truck!

If someone is standing next to your truck, don’t

move until they are out of the way.

DO NOT speed when approaching loads!

Bring truck to a full stop in front of a load, then

approach carefully.

DO NOT pick up unsecured loads that

extend above the backrest extension height!

100648 101615

DO NOT allow anyone to walk or stand

under raised forks!

101037

Use forks properly!

Fork misuse could cause accidents, serious

injuries and equipment damage.

101034

SAFETY RULES FOR LIFT TRUCK OPERATORS

WARNING

2222

SAFETY RULES FOR LIFT TRUCK OPERATORS

DO NOT abuse your equipment!

DO NOT use the forks to open or close the

doors on a railroad car or to move a car.

DO NOT allow any riders!

DO NOT permit riders on the forks or pallet.

102524B 102523B

Drive onto a trailer carefully!

Make sure the trailer brakes are applied and the

wheels are blocked while loading or unloading.

101040

101039

DO NOT abuse your forks!

Fork misuse could cause accidents, serious

injuries and equipment damage.

DO NOT allow unloading from raised loads!

Failure to follow this rules could cause serious

injury.

101042

DO NOT use damaged pallets!

Make sure pallets and skids are sturdy and in

safe operating conditions.

101775

WARNING

2323

SAFETY RULES FOR LIFT TRUCK OPERATORS

Shift the transmission smoothly!

Avoid sudden shifting while the truck is mov-

ing. This could cause damage to the transmis-

sion.

101787

Stay clear of pinch points!

Keep all parts of your body away from moving

parts such as the mast, carriage and attach-

ments. Do not put any part of your body

between the head guard and the mast. If the

mast moves unexpectedly, you could get

caught between the mast and overhead guard

and a serious accident could occur.

102521B

Use only specialized equipment designed to

safely raise personnel to high work areas!

Do not lift personnel except on a securely

attached, specially designed Work Platform.

Use extreme care when lifting personnel. Place

the mast in the vertical position, place the truck

controls in neutral and apply the parking brake.

Lift and lower smoothly. Be available to oper-

ate controls as long as personnel are on the

Work Platform. Never transport personnel on

forks or Work Platform.

101043

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.

100992

WARNING

2424

SAFETY RULES FOR LIFT TRUCK OPERATORS

102528

Park in authorized areas only!

Park a safe distance from access to fire aisles,

stairways and fire equipment.

DO NOT park near a flammable material stor-

age area.

DO NOT park on a grade!

When you leave your truck, or park it:

– Set the parking brake.

– Put the direction lever in NEUTRAL and

lock knob in NEUTRAL.

– Lower the forks fully to the floor.

– Tilt the mast forward until the forks are

flat.

– Turn the key switch off.

100658A

101044

102527B

Park a disabled machine safely!

– If the lift mechanism is disabled and the

forks cannot be lowered, park the truck in

a non-operating area and attach warning

tags to the forks to alert pedestrians and

traffic.

– Use barriers to keep anyone from standing

or passing under the forks.

– Remove the starter switch key and attach

DO NOT OPERATE or similar warning

tag to the truck.

WARNING

2525

SAFETY RULES FOR LIFT TRUCK OPERATORS

Only trained, authorized personnel should fill

or exchange LP-Gas tanks.

Personnel engaged in filling LP-Gas tanks

should wear protective clothing such as a face

shield, long sleeves and gauntlet gloves.

Do not refuel or store LP-Gas powered lift

trucks near underground entrances, elevator

shafts, or other places where LP-Gas could col-

lect in a pocket and cause potential danger for

an explosion.

Do not leave the lift truck, for even a short time,

near equipment that generates high tempera-

tures. Ovens and furnaces are examples. The

heat may raise the pressure of the fuel and open

the relief valve.

Close the service valve on the tank when LP-

Gas fueled lift trucks are parked overnight or

stored for long periods indoors with the fuel

tank in place.

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.

◆

◆LP-Gas

The careless handling of LP-Gas tanks can

result in a serious accident. To reduce the risk

of damage to tanks, use extreme care when

transporting them.

All defective or damaged LP-Gas tanks must

be removed from service.

Inspect the LP-Gas fuel lines and fittings with

a soap solution after filling the tank or when

looking for leaks.

100717A

The storage and handling of liquid fuels in the

U.S.A. should be in accordance with the NFPA

No. 30, “Flammable and Combustion Code.”

Outside the U.S.A., store and handle in accor-

dance with local regulations.

The lift truck should be refueled only at desig-

nated safe locations. Safe outdoor locations are

preferable to those indoors.

DO NOT completely fill the tank. The fuel

expands when it gets warm and it may over-

flow. This will create a fire hazard.

Only trained, authorized personnel should fill

or exchange LP-Gas tanks.

Do not drop, throw, roll or drag LP-gas tanks.

Do not strike LP-Gas tanks or any associated

parts of the tanks or fuel systems.

Check the LP-Gas tank for secure mounting.

Loose tanks can cause pressure fuel lines to

leak resulting in serious injury.

2626

||||||||||||||||||||||||||||||||||||||||||||||||| KNOW YOUR LIFT TRUCK |||||||||||||||||||||||||||||||||||||||||||||||

◆

◆Serial Number and Capacity Plate

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

102993

103256

Capacity Plate

Engine Serial Number

Diesel engine modelsGasoline and LP-Gas engine models

Manufacturer Name Plate

Lift Truck Serial Number

Name Plate 101522

Instruction Plate 103446

103916

UL Plate

UL Plate 103963

2626

||||||||||||||||||||||||||||||||||||||||||||||||| KNOW YOUR LIFT TRUCK |||||||||||||||||||||||||||||||||||||||||||||||

◆

◆Serial Number and Capacity Plate

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

102993

103256

Capacity Plate

Engine Serial Number

Diesel engine modelsGasoline and LP-Gas engine models

Manufacturer Name Plate

Lift Truck Serial Number

Name Plate 101522

Instruction Plate 103446

103916

UL Plate

UL Plate 103963

2727

KNOW YOUR LIFT TRUCK

◆

◆Model View

103255 103193

Tail and

Stop Light

Turn Signal Light

Backup Light

Rear Combination Light

Engine Hood

Fuel tank

Overhead Guard

Operator’s Seat

Lift Chain

Backrest Extension

Fork

Lift Cylinder

Tilt Cylinder

Front Wheel

Counterweight

Rear Combination Light

Mast

Head Light

Operator’s Seat Belt

Rear Wheel

Instrument Panel

2828

KNOW YOUR LIFT TRUCK

◆

◆Operator’s Compartment

Parking brake lever

Release

Apply

101363

Direction lever

This truck is equipped with a neutral switch. Be sure

to put the transmission in NEUTRAL when starting

the engine.

101619A

Inching pedal By varying the position of this pedal,

the operator can move the truck slowly

for inching while maintaining engine

speed. Full application of the pedal

puts the transmission in neutral and

applies the service brakes.

100037

Accelerator pedal

100039

Horn switch

102592

103259

Forward (F)

Reverse (R)

Released

Clutch

disengaged

Brake

applied

Neutral (N)

Idling

Full throttle

Push to sound horn

Turn signal switch

(optional)

100311

Left turn

Right turn

Brake pedal

100038

Release

Apply

•••

ECU

Attachment control levers

Unlocked

(left)

Locked

(right)

• The knob locks the direction lever in the

NEUTRAL position.

2929

Move the lever in arrow direction to unlock the

steering wheel. Adjust it to accommodate

operators or to make getting on and off the

truck easier.

Push down the lever to lock the steering wheel.

Lifting speed is controlled by the speed of the

engine (the position of the accelerator pedal)

and the position of the control lever.

Lowering speed is controlled by the position of

the control lever regardless of the speed of the

engine.

The lever will return to the NEUTRAL posi-

tion when released.

Tilting speed is controlled by the speed of the

engine (the position of the accelerator pedal)

and the position of the control lever.

The lever will return to the NEUTRAL posi-

tion when released.

The mast will not tilt forward even if the con-

trol lever is moved forward when the engine is

stopped.

100312 100313

103259

KNOW YOUR LIFT TRUCK

• Lift Control Lever • Tilt Control Lever

• Steering Tilt Lever

Always adjust the steering wheel tilt

angle while stopped at a safe place, as

adjustment while driving could lead to

accidents.

Lower

Raise

Forward

Backward

103434

Steering tilt

lever

Unlock

Lock

The mast descends downward if the lift

control lever is moved forward even

though the engine is stopped.

WARNING

3030

KNOW YOUR LIFT TRUCK

◆

◆Instrument Panel

102792

Engine coolant temperature gauge

Fuse box

102386

Hourmeter

104787

Normal

(white)

0.1 hour

(6 minutes)

1 hour

Overheat

(red)

OK monitor

When any warning light (except glow plug

indicator light) glows during operation, stop

the truck and take corrective action.

The gauge needle is normally in the white zone.

If the needle moves into the red zone, set the

topic. Engine coolant temperature gauge

needle moves into red zone.

Starts registering the operating hours of the

engine when the key switch is turned to the l

(ON) position. Periodic maintenance recom-

mendations are based on these engine hours.

Indicates the amount of fuel in the tank when

the key switch is turned to the (ON) position.l

To get an accurate gauge reading, be sure the

truck is level.

1st speed mode/automatic mode selector

switch

This switch was changed and moved to the

overhead guard.

104573

Full

Normal

(white)

Empty

(red)

104788

Fuel gauge

3131

KNOW YOUR LIFT TRUCK

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.

Light switch

Anti-restart starter switch and key

103921

100048A

(OFF)

(ON)

(START)

Applies power to all electrical cir-

cuits except for starter circuit. In

diesel models, power is applied to

heater plugs for 6 seconds and OK

monitor indicator glows.

Applies power to the starter motor to

crank the engine. A switch spring

returns the key switch to the l(ON)

position when the key is released.

Position 2

Has a built-in mechanical lockout that prevents

the key switch from being turned to the

(START) position while the engine is running.

Turn the key switch back to the (OFF) posi-

tion before recranking the engine.

Removes all power from instrument

panel and electrical circuits except

for horn and lights.

position

1 2

Light

Pull

Position 1

Instrument panel light

Tail lights

Clearance lights

Head lights

102391

OFF ON

103524

OK monitor bulb check

The following warning lights should glow

when the key switch is turned to the l(ON)

position.

The lights will go out when the engine is

started; if not, the charging system has a defect.

103922

If the lights fail to glow with the key switch in

the l(ON) position, the bulbs have burnt out.

Consult your Cat lift truck dealer.

Optional

(For LP-Gas model)

Optional

For Diesel model

For Gasoline model

3232

KNOW YOUR LIFT TRUCK

Powershift transmission oil

temperature warning light

(optional)

Glows when the oil temperature is

high and the danger of overheat-

ing is present.

If this light glows, see the topic,

Powershift transmission oil tem-

perature warning light glows.

Brake fluid level warning light

Glows when the fluid level is

lower than the specified level.

Have the brakes checked by your

Cat lift truck dealer.

Engine oil pressure warning light

If this light glows during operation, stop the engine and check the oil level.

Add oil as required.

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.

Heater plug indicator

(DIESEL)

Glows when the key switch is

turned to (ON) position and goesl

out after heating is completed.

Turn the key switch to the

(START) position after the indica-

tor has gone out.

Engine coolant level warning

light (optional)

Glows when the coolant level in

the radiator is too low. If the light

glows, refill the radiator at the

reserve tank.

103239

Air cleaner warning light

(optional)

Glows when the air cleaner ele-

ment is clogged. If the light glows,

clean or replace the element.

Alternator not charging

warning light

Glows when the charging system

is out of operation. If the light

glows, check the alternator drive

belt for slippage or breakage.

LP-Gas residual pressure alarm

light (optional)

Lights when the residual quantity

becomes small.

◆

◆OK Monitor (Warning Lights and Indicators)

CAUTION

ECM warning light/Frequency

Converter warning light

(GASOLINE)

Glows when ECM (engine control

module) or Frequency Converter is

abnormal.

Consult your Cat lift truck dealer.

3333

KNOW YOUR LIFT TRUCK

Automatic mode

(1st speed 2nd speed)

1st speed mode/automatic mode selector

switch (For 5 Ton Model as standard and

others as optional)

Keep speed mode in 1st speed for operat-

ing at the speed-limit area [14 km/h (8.7

mph) at max.], climbing or traction.

1st speed mode

104575

104789

In normal operation your lift truck will drive in

a creep mode when the direction lever is placed

in the forward or reverse position at engine

idling (not depressing the accelerator pedal). If

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

neutral position electrically (the lever itself

remains in the forward or reverse position), and

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

automatically applied the moment the interlock

is activated.

Depending on the condition of the road (grade,

for example), therefore, the lift truck may be

accelerated, instead of being stopped.

◆

◆Driving Interlock System

1. Prior to operating the lift truck, be sure

to check the driving interlock for func-

tion.

2. While driving the lift truck, if you lift

your hips above the seat for over 2 sec-

onds, the driving interlock system will

be activated, the same as in case of

engine idling.

Always drive the lift truck correctly

with safety in mind.

3. 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. Then, return

the direction lever to the neutral posi-

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.

This switch is built in the seat.

104131

• Operator Presence Switch

Operator presence

switch

CAUTION

Neutral indicator light

Glows when the direction lever is placed in

Neutral (N) position.

Driving interlock indicator light

Flickers if the operator leaves the seat with

the direction lever in the forward or reverse

position while the engine is idling.

ECM warning light (GASOLINE)

(IF EQUIPPED)

Glow when ECM (engine control module) is

abnormal.

Consult your Cat lift truck dealer.

3434

KNOW YOUR LIFT TRUCK

The lift truck is provided with a device that pre-

vents the engine from being started when the

direction lever is not in the neutral position.

104016

• Neutral System

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.

CAUTION

3535

KNOW YOUR LIFT TRUCK

◆

◆Operator’s Seat

• Adjustment

Adjust the seat before starting the engine. After

adjusting, jiggle the seat to make sure it is prop-

erly locked. DO NOT adjust the seat while the

truck is in motion.

Move the lever to the left, slide the seat to one

of the seven positions, and release the lever.

100974A 100973

Front to back adjustments:

120 mm (4.7 in.)

Lever

• How to tip the seat forward

This industrial truck is equipped with an

operator restraint system. Should it

become necessary to replace any of the

components including the seat assembly

for any reason, it must only be replaced

with components approved by the manu-

facturer.

102716

To open the engine hood on a truck equipped

with the LPG system, tip the seat forward first

to get clear of the LPG tank.

To tip the seat forward

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 back-

rest.

To reposition the seat

Reposition the seat by pushing the backrest

back and then push the lever to lock.

WARNING

3636

KNOW YOUR LIFT TRUCK

◆

◆Seat Belt

100978

The seat belt will help to restrain you in acci-

dents such as a tipover or mast and attachments

collision. If you are unrestrained in a tipover,

you can fall outside of the operator’s compart-

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

until you hit a solid object.

Wear your seat belt anytime you operate a lift

truck.

If the seat belt is torn, the pulling motion is

interrupted during extension of the belt, or the

belt cannot be inserted into the buckle properly.

Replace the seat belt assembly.

The seat belt shall be examined at the regular

service intervals. It is recommended that it be

replaced if any of the following conditions are

found.

– Cut or frayed strap

– Worn or damaged hardware, including

anchor points

– Buckle or retractor malfunction

– Loose stitching

Also, replace the seat belt assembly if it was

worn during an accident.

100976 100977

Seat belts can “jack-knife” drivers—

the upper body bends tightly at the

waist. If you are pregnant or have suf-

fered an abdominal disease or injury,

consult a doctor before using the seat

belt.

WARNING

DANGER

3737

KNOW YOUR LIFT TRUCK

NOTICE: It is not necessary to adjust the belt

length.

The belt is designed to fit any body

size.

Tug on it to confirm a tight fit.

1. Grip the plate (connector) of the belt and

pull the belt from the retractor. Then insert

the plate into the slot of the buckle until a

snap is heard.

2. Make sure the belt is not twisted.

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

across your hips, not across your abdomen.

Push the button in the buckle to release the belt.

The belt will automatically retract when

released. Hold the plate of the belt and allow

the belt to slowly retract.

100981

100982A

100983

If you fasten the belt across your

abdomen, the belt will dig into your

abdomen in an accident and could cause

serious internal injuries.

To Fasten To Release

Buckle

Plate

WARNING

3838

KNOW YOUR LIFT TRUCK

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.

IMPORTANT

3939

KNOW YOUR LIFT TRUCK

◆

◆Fuses and Lights

To remove the fuse or insert a replacement

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

Lamp type Gasoline Diesel

models (12V) models (24V)

Meter panel lamp 3W (14V) 3W (28V)

Tail/Stop lamp 8W/23W 10W/25W

Headlamp 45W 60W

Turn signal lamp 27W 25W

Back-up lamp 10W 12W

Working lamp (opt) 45W 60W

Lights are suspected

to have burned out.

One light of the circuit fails to light.

All lights of the circuit fail to light.

Check to see if fuse has been blown out.

Check the fuses one by one by

operating the light switch and seeing if

each light comes on.

Check for burned-out or “blown-out”

fuses first.

100846

– Always replace fuses with fuses of the

correct amperage.

– If fuse burns out immediately and you

cannot locate the cause, have your Cat

lift truck dealer make a circuit check.

– Use a replacement light bulb of the

same wattage.

Code Gasoline models Diesel models

Capa Circuit Capa Circuit

city city

10A Direction lever 10A Direction lever

15A Instrument panel 10A Instrument panel

(for monitor and (for monitor and

gauge), backup, gauge), turn

stop and turn signal lights (opt)

signal (opt) lights,

ECU (for T/M

controller,

frequency

transducer)

15A Spare power 10A Spare power

source source

15A Instrument panel 15A Instrument panel

(for panel light), (for panel light),

tail and working head, tail and

(opt) lights working (opt)

lights

15A Head lights 10A Horn

10A ECM for engine 10A Spare fuse

10A Horn 10A Stop lights,

ECU (for T/M

controller)

15A Fuel pump 10A Backup lights

10A Starter 15A Spare fuse

• Lights Won’t Come On

Puller

102535A

100845

101442

CAUTION

4040

KNOW YOUR LIFT TRUCK

◆

◆Fork Stoppers

For load stability, adjust the forks as wide as

possible.

To adjust the fork spread, move the levers or

twist the knob upward and reposition the forks.

Spread the forks to fit the load.

To reduce the risk from serious injury or death

for you and people around you, DO NOT use a

lift truck without safety equipment in proper

operating order.

– Overhead guard

– Load backrest extension

◆

◆Safety Equipment

When adjusting the fork spread, be care-

ful not to pinch your hand between forks

and lift bracket.

– After adjusting the fork spread, restore

the stoppers to the original position to

lock the forks.

– Position each fork the same distance

from the center of the backrest extension.

Remove a fork from the carriage to replace it or

to access other parts of the truck for mainte-

nance. Slide the forks, one at a time, to the

installation/removal notch on the bottom car-

riage bar. Tilt the carriage forward, then lower

it until the hook fork disengages the forks from

the carriage. Use a lifting device to move the

forks away from the truck.

• To Remove

DO NOT try to move a fork without a lift-

ing device. Each fork can weigh in excess

of 45 kg (100 lb.)

• To Install

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

tilted forward, to a point just to the rear of the

forks. Carefully slide the forks, one at a time,

onto the carriage so the top hook of the fork is

placed above the top carriage bar. Raise the car-

riage to engage the top hooks allowing the bot-

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.

102791

➀Carriage Bars

➁Hook Fork

➂Blocks

◆

◆Changing Forks

➀➁

➂

103445

WARNING

CAUTION

4141

KNOW YOUR LIFT TRUCK

◆

◆Drawbar Pin

Use the drawbar pin for:

– Pulling the truck out of a drop-off or ditch.

– Loading the truck on a hauling truck.

1. When hitching a cable to the pin, make

sure the pin is inserted safely.

2. Take up slack slowly—DO NOT jerk. Keep

the cable taut. If the cable is slack, the sud-

den impact of the load can snap it, resulting

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.

Grasp the assist grip with the left hand, the seat

backrest with the right hand, and step up with

the left foot to get on the truck safely.

DO NOT use the drawbar pin for towing

loads.

DO NOT grab the steering wheel or lever.

DO NOT jump on or off the truck.

Precautions for Use of the Drawbar Pin

100864A

◆

◆Assist Grip

101644

Drawbar pin 103242

WARNING

4242

KNOW YOUR LIFT TRUCK

The oil level/filler hole is located on the right

side of the truck inside the engine hood. To

check the oil level, use the dipstick located in

the hole.

The fuel filler is located on the left side of the

truck. The cap can be removed by turning it

counterclockwise.

The fuel shut-off valve is located near the air

cleaner inside the engine hood. In an emer-

gency or when performing maintenance, close

this valve.

Never fill the tank near an open flame or when

the engine is running. When filling, keep the

funnel or fuel hose nozzle in contact with the

tank’s metal. This reduces the risk of an electric

spark igniting the fuel.

After refueling, close the cap tightly and wipe

up spillage.

◆

◆Fuel Filler

Confirm the engine type before filling the

tank with the recommended fuel.

103196

103197 100989 102538

◆

◆Hydraulic Tank Oil Level/Filler Hole ◆

◆

◆Fuel Shut-off Valve

103938

Open

CAUTION

WARNING

9393

TROUBLESHOOTING

If you smell gas or notice something wrong

with LP-Gas equipment during operation,

immediately stop the truck in a safe area, turn

the key switch to the (OFF) position, close

the fuel valve of the LP-Gas tank, and try to

find the cause. (It is advisable to have a test kit

on hand for detecting gas leakage.)

If the internal pressure of the LP-Gas tank

rises too high and causes the relief valve to

open to let out the excess pressure, sprinkle

water over the tank. At the same time, extin-

guish any fire or flame source (such as a pilot

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.

There is a possibility of fire after a collision or

when a truck turns over. If this happens, close

the LP-Gas fuel valve of the LP-Gas tank as

soon as possible.

Use a dry-chemical (powder) or carbon diox-

ide type extinguisher. Never use water. When

possible, however, have large quantities of

water poured over the LP-Gas tank to cool it

down while the fire is being extinguished.

◆

◆Trouble with the LP-Gas Equipment

WARNING

9494

|||||||||||||||||||||||||||||||||||||||||||||||||||||||||| MAINTENANCE |||||||||||||||||||||||||||||||||||||||||||||||||||||||

Taking proper care of your lift truck is a vital

part of the overall planned maintenance pro-

gram.

Your participation in this program will provide

an early warning to help identify potential

maintenance problems.

Do-it-yourself maintenance does not include

repairs. If your truck requires any repairs, con-

sult your Cat lift truck dealer. The dealer’s lift

truck mechanics are well trained and know how

to safely make repairs. Service Manuals are

also available from your Cat lift truck dealer.

Follow these rules to help save you from injury

and to service your truck properly.

◆

◆General

The fuel shut off valve is located near the air

cleaner inside the engine hood. To avoid an

accident, close this valve when performing

maintenance.

– Make sure the service area is safe.

– Park the truck on a level ground with

the forks lowered, parking brake

applied, transmission in NEUTRAL,

the direction lever in NEUTRAL, the

lock knob in NEUTRAL, engine

stopped and the wheels blocked.

– Follow the recommended safety pro-

cedures.

– Use only the right tools for the job.

Lines, Tubes and Hoses

DO NOT bend or strike high pressure

lines. DO NOT install bent or damaged

lines, tubes or hoses.

Repair loose or damaged fuel and oil

lines, tubes or hoses. Leaks can cause

fires. Contact your dealer for repair or

replacement.

Check lines, tubes and hoses carefully.

DO NOT use your bare hands to check

for leaks, use a board or cardboard.

Tighten connections to the recom-

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

wire reinforcing exposed.

– Outer covering ballooning locally.

– Evidence of kinked or crushed hose.

– Metal embedded in the outer cover.

– End fittings displaced.

Make sure all clamps, guards and heat

shields are installed correctly to reduce

the risk of vibration, rubbing against

other parts, and excessive heat during

operation.

103938

Open

If the truck is found to be in need of repair

or in any way unsafe, or contribute to an

unsafe condition, the matter shall be

reported immediately to the designated

authority, and the truck shall not be oper-

ated until it has been restored to safe oper-

ating condition.

WARNING

CAUTION

9595

MAINTENANCE

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.

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

safety. At the beginning of each shift, check

your lift truck to make sure it is in safe operat-

ing condition.

Always inspect your truck under the following

conditions.

◆

◆Inspection Precautions

If it is necessary to make an inspection

while the engine is running, ALWAYS

USE TWO WORKERS—one, the opera-

tor, at the controls and the other check-

ing within visual contact of the operator.

– Avoid mixing lubricants. In some cases

different brands of lubricants are not

compatible with each other and deteri-

orate when mixed. It is best to stick

with the same brand at successive serv-

ice intervals.

– Before refilling, clean filler holes. After

filling, clean up spills.

– Lift truck level

– Mast in vertical position

– Fork tips on ground

– Engine stopped

– Control levers in neutral

– Wheels blocked

WARNING

CAUTION

WARNING

9696

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

Service Hours or Weekly, Whichever Comes First to keep your lift truck

in proper working condition.

For periodic inspection and periodic change of rubber parts, however, rely

on the expert knowledge of the factory-trained servicemen, and the service

facilities at your Cat lift truck dealer’s workshop.

Periodic inspection time intervals

• One month after delivery of a new truck

• Every 200 service hours or monthly,

whichever comes first

• Every 400 service hours or 2 months,

whichever comes first

• Every 600 service hours or 3 months,

whichever comes first

• Every 1200 service hours or 6 months,

whichever comes first

• Every 2400 service hours or 1 year,

whichever comes first

MAINTENANCE

◆

◆Maintenance Schedule

Item Service Page

Accelerator pedal Check 100

Brake pedal Check 100

Inching pedal Check 101

Parking brake lever Check 101

Seat belt Check 101

Seat adjustment Check 101

Horn Check 102

Steering wheel Check 102

movement

Amount of fuel (truck level) Check 102

Stop lights Check 102

OK monitor Check 102

Lift chains Check/adjust 103

Engine Check 104

Service brakes Check 104

Back-up lights Check 104

Engine crankcase Check oil level 105

Engine coolant Check 106

coolant level

Hydraulic oil Check 109

oil level

• Every 10 Service Hours or Daily (Pre-Start),

Whichever Comes First, continued

Item Service Page

Damaged or faulty operation found

the day before Check 99

Oil, fuel or coolant leaks Check 99

Lights Check 99

Load backrest extension Check 99

Tilt cylinder socket bolts Check 100

Overhead guard Check 100

Assist grip Check 100

• Every 10 Service Hours or Daily (Pre-Start),

Whichever Comes First

9797

MAINTENANCE

Item Service Page

Brake fluid Check level 110

Wheel nuts Check 111

Tires and rims Check 111

Mast and forks Check 112

Battery Check electrolyte 113

level

• Every 10 Service Hours or Daily (Pre-start),

Whichever Comes First, continued

Item Service Page

Air cleaner element Clean/inspect 114

Alternator drive belt – Diesel Check/adjust 115

Mast supports Lubricate 116

• Every 50 Service Hours or Weekly, Whichever Comes First

Item Service Page

Hydraulic tank return oil filter Change 116

Engine crankcase – Gasoline and LP-Gas Change filter 116

Fuel filter – Diesel Change 116

Fuel filter – LP-Gas Change **

• One Month After Delivery of a New Truck

Item Service Page

Wheel nuts Retighten 117

Differential Check oil level 117

Powershift transmission Check oil level 118

Alternator drive belt – Gasoline Check/adjust 119

Spark plug Check **

Vaporizer – LP-Gas Check tar **

Piping and piping joints – LP-Gas Check damage/ 119

gas leakage

Engine crankcase – Gasoline and LP-Gas Change oil 120

Engine crankcase – Diesel Change oil 121

and filter

• Every 200 Service Hours or Monthly, Whichever Comes First

The change intervals for engine oil and filter are depend on the percent-

age of sulfur in the diesel fuel. Check the following:

*Whichever comes first

Whenever the engine oil is changed, the filter must be replaced at the

same time with a genuine MCF oil filter.

Sulfur percentage Oil grade spec. Change interval

0 to 0.2 % CF or higher 500 hrs. or 3 months*

0.2 to 0.5 % CF or higher 300 hrs. or 3 months*

Over 0.5 % CF or higher 200 hrs. or 3 months*

NOTICE: For the description of ** marked items, refer to the TB45 gaso-

line engine service manual.

9898

MAINTENANCE

• Every 1200 Service Hours or 6 Months,

Whichever Comes First

Item Service Page

Hydraulic oil Change 136

Brake fluid Change 136

Fuel filter – LP-Gas Change **

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

Item Service Page

Powershift transmission Change oil/ 128

wash strainer

Hydraulic system Change return 129

oil filter/wash

strainer

Differential Change oil 130

Air cleaner element Change 130

element

Fuel filter – Diesel Change 131

Engine coolant – Diesel Change 133

Item Service Page

Engine coolant – Gasoline Change 124

• Every 400 Service Hours or 2 Months, Whichever Comes First

Item Service Page

Mast strip roller surfaces Lubricate 122

Lift bracket side rollers Lubricate 122

Lift chains Lubricate/ 122

inspect

Tilt socket pins Lubricate 122

Brake pedal Lubricate 122

Rear axle center pins Lubricate 123

Tie rod pins Lubricate 123

Universal joint with grease nipple Lubricate 123

• Every 200 Service Hours or Monthly, Whichever Comes First,

continued

Item Service Page

Intake/exhaust valve clearance – Gasoline Adjust **

Injection nozzle – Gasoline and LP-Gas Inspect **

PCV valve and hose – Gasoline Inspect **

LP-Gas filter Clean **

Engine crankcase – Gasoline and LP-Gas Change filter 127

• Every 600 Service Hours or 3 Months, Whichever Comes First

NOTICE: For the description of ** marked items, refer to the TB45 gaso-

line engine service manual.

9999

• Damage or Faulty Operation Found

the Day Before

– Have repairs been made properly?

Check the daily inspection sheet.

Fill out a daily inspection sheet. Remember,

the complete performance of a daily inspection

is the best protection against injury and prop-

erty damage.

Check on the floor for oil, fuel or coolant leaks.

• Lights

– Are all the lights in safe working condi-

tion?

– Are their lenses clean and not defective?

– Do the tail and head lights come ON prop-

erly when you switch them on.

– Is the backrest extension free of distortion,

cracks and other defects? Shake the back-

rest to check for excessive rattle.

102840 101400A

MAINTENANCE

100678A

• Oil, Fuel or Coolant Leaks • Load Backrest Extension

◆

◆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.

WARNING

100100

1. Check the front and rear overhead guard

mounting bolts on each side. Tighten bolts

to 14.5 N•m (1.5 kgf•m) [10.7 lbf•ft].

2. Inspect overhead guard for bent or cracked

sections. Contact your Cat lift truck dealer

if repairs are needed.

Inspect, and if necessary, tighten the screws of

the assist grip.

– Can you depress the accelerator pedal

smoothly without any sign of rubbing?

101049

100699

102553

MAINTENANCE

• Overhead Guard

• Assist Grip

• Accelerator Pedal

• Brake Pedal

– Do you have sufficient pedal travel?

– Is the free-play adjusted properly?

Correct Free Play:

Unit: mm (in.)

• Tilt Cylinder Socket Bolts

– Are the bolts tightened properly?

Use a wrench.

NOTICE: After retightening the bolt, put a

mark across the bolt and tilt cylin-

der socket. This permits you to eas-

ily notice loosening of the bolt.

Tightening Torque for the Bolt

262 ± 13 N•m (27 ± 1.4 kgf•m)

[193 ± 9.6 lbf•ft]

103201

4 ton models 4 to 15 (0.2 to 0.6)

4.5 to 5 ton models 5 to 18 (0.2 to 0.7)

101101

– Is the free play correct?

Correct Free Play

Unit: mm (in.)

– 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]

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] to snap it over center.

– Can you depress the pedals all the way?

NOTICE: See the topic, Adjustment under

Operator’s Seat.

101437

101050

MAINTENANCE

• Inching Pedal

Adjustment

Release Apply

• Parking Brake Lever

• Seat Adjustment

All models 5 (0.2)

• Seat Belt

– Is the seat belt in safe condition?

Replace the belt assembly if the belt is

torn, cut, or if the plate and/or buckle is

defective.

100977

100700

102102

– Does the horn sound properly when you

push the switch?

– Is the free play 15 to 30 mm (0.6 to 1.2

in.)? Check the play at the rim of the

wheel by rotating the wheel in both direc-

tions.

– Is wheel installation loose? Check by

shaking the wheel up and down.

– Is the amount of fuel in the tank enough for

the day’s work?

– Do all stop lights come ON properly when

you depress the brake pedal?

– Do all the warning lamps glow when the

key switch is in the (ON) position?l

NOTICE: When a lamp does not light with

the key switch in the (ON) posi-l

tion, the bulb may be burned out.

Contact your Cat lift truck dealer if

repairs are needed.

102591 102394 103268

103193101726B

MAINTENANCE

• Horn

• Stop Lights• Steering Wheel

• OK Monitor• Amount of Fuel (Truck level)

103103

1. Check the lift chains for wear. Use the fol-

lowing chart to determine if it is still in

usable condition.

Lift Chain Elongation Limit:(/20 links)

2. Lift the forks high enough to put their full

weight on the carriage and chains.

3. Check to be sure the lift chains have equal

tension.

4. If the chains are loose or the tension is not

equal, have the chains adjusted.

1. Loosen the locknut and the nut ① ②. Then

turn the nut to adjust tension.③

2. Hold the nut and tighten the nut ③ ② to

torque A. Hold the nut ③and tighten the

locknut ① to torque B.

Tightening Torque:

Unit: N•m (kgf•m) [lbf•ft]

102009 102709

102708

MAINTENANCE

• Lift Chains

Check and Adjust

– Check the lift chains periodically and

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

chains can cause accidents. If some-

thing is wrong with the chains, con-

sult your Cat lift truck dealer for

repair or replacement.

– DO NOT put your foot under the

fork.

4 ton models

4.5 to 5 ton models

518 mm (20.4 in.)

648 mm (25.5 in.)

➂

➀

➁

To Adjust

4 ton A 103 (10.5 ) [76 ]

models B 147 (15 ) [108 ]

4.5 to 5 A 139 (14.2 ) [103 ]

ton models B 176 (18 ) [130 ]

+36

+49

−14

−2

−19

+36

+49

−14

−2

−19

WARNING

104104

– Is exhaust smoke normal?

– Listen for abnormal noise or excessive

vibration.

– Do the brakes apply and stop the truck

properly—without dragging, chattering or

squealing?

When you move the direction lever into

REVERSE position:

– Do all back-up lights come ON?

– Does the back-up buzzer sound?

MAINTENANCE

• Engine

Exhaust fumes can kill you! If it is neces-

sary 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

of all emergency devices (such as fire

extinguisher, first aid kit, etc.) and how to

use them.

• Back-up Lights

100712

103193

• Service Brakes

WARNING

105105

MAINTENANCE

103919

101304 103924

101670

103918

101669

Park the lift truck with the forks lowered, park-

ing brake applied, transmission in NEUTRAL,

engine stopped and the wheels blocked. The

engine must be cooled down.

1. Raise the hood.

2. Remove the dipstick and wipe it clean, then

insert it all the way.

4. Close and secure the hood.

1. Remove the oil filler cap.

• Engine Crankcase

Check Oil Level

Hot oil and components could cause seri-

ous injury. Do not allow hot oil or com-

ponents to contact your skin.

3. Maintain the correct level range on the dip

stick.

Adding Engine Oil

– Perform the work on level ground.

– Clean the filler hole to prevent dirt

from dropping into the engine.

– DO NOT overfill.

– Clean up spillage.

Correct level range

Gasoline

Diesel

Gasoline

Diesel Gasoline

Diesel

WARNING

CAUTION

106106

MAINTENANCE

103929

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

the correct range on the dipstick.

4. Close and tighten the filler cap.2. Add engine oil as required.

For engine oil, see the topic,

Recommended Fuels and Oils.

101671

Gasoline

Diesel

103919

101304

Correct level range

Gasoline

Diesel

107107

The lift truck must be level, the forks lowered,

the parking brake applied, the transmission in

NEUTRAL, engine stopped and the wheels

blocked. The engine must be cooled down.

1. Raise the hood.

2. Maintain the coolant level between the

FULL and LOW marks on the reserve

tank.

3. Close and secure the hood.

101465

MAINTENANCE

• Engine Coolant

Check Coolant Level

At operating temperature, the engine

coolant is hot and under pressure.

Steam could cause injuries. DO NOT let

it contact your skin and eyes.

To avoid having scalding coolant or steam

blow out of the radiator, do not remove

the radiator cap unless the engine is cold.

Muffle the cap in a thick cloth and turn it

slowly to release all pressure before

removing the cap.

Correct

level

range

Keep fire away from undiluted antifreeze

as it is FLAMMABLE.

DO NOT add water only. This dilutes the

antifreeze/summer coolant protection and

adversely affects the engine. Be sure to pre-

mix antifreeze/summer coolant with tap

water (soft water). See the topic, Engine

Cooling System Capacity under

Specifications.

If coolant has to be added frequently, have

your Cat lift truck dealer check the cooling

system.

– Antifreeze/summer coolant (ASC) con-

tains rust inhibitors. It is not necessary

to add other chemicals.

– Recommended concentration range of

ASC is 30% to 60% by volume. ASC

of less than 30% concentration does not

provide sufficient corrosion protection.

Concentrations over 60% adversely

affect freeze protection and heat trans-

fer rates.

– Avoid mixing different brands of

coolant.

– Select an ASC suitable for use in

engines using aluminum alloy parts.

– Select an ASC which contains silicate

of less than 0.2% by weight.

Adding Coolant

WARNING

CAUTION

108108

1. Remove the reserve tank cap and add

coolant to the FULL mark.

2. When adding coolant, maintain the same

concentration of antifreeze solution.

Antifreeze solution is TOXIC. In case of con-

tact with your skin, FLUSH IMMEDIATELY

WITH WATER. Have your Cat lift truck

dealer discard antifreeze solution drained from

the engine.

101299A

MAINTENANCE

NOTICE: The engine cooling system is pro-

tected to –30°C (22°F) with 50%

concentration of antifreeze/summer

coolant (ASC) when shipped from

the factory.

3. Put the reserve tank cap back on.

100899

WARNING

109109

MAINTENANCE

100695A

100698

100815A

1. Operate the lift truck for a few minutes to

warm the oil.

2. Park the lift truck on a level surface, with

the forks lowered, mast tilted back, parking

brake applied, transmission in NEUTRAL,

engine stopped and the wheels blocked.

3. Remove the hydraulic tank filler cap by

turning it counterclockwise.

5. Put the hydraulic tank filler cap back on.

6. Check for oil leaks.

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.

5. Close and secure the hood.

1. Remove the hydraulic tank filler cap.

2. Add oil to the hydraulic tank.

For Hydraulic Oil, see the topic,

Recommended Fuel and Oils.

• Hydraulic Oil

Check Oil Level

Hot oil and components could cause

serious injury. Do not allow hot oil or

components to contact your skin.

Remove the hydraulic tank filler cap

only after the engine has been stopped

and the cap is cool enough to remove

with your hands.

Remove the hydraulic tank filler cap

slowly to relieve pressure.

4. Add oil needed to raise it to the correct

level range on the dipstick.

Adding Hydraulic Oil

When adding hydraulic oil:

– Perform the work on level ground.

– Clean the filler hole to prevent dirt

from dropping into the tank.

– DO NOT overfill.

– Clean up spillage.

100814

Correct level range

WARNING

CAUTION

110110

Park the lift truck with the forks lowered, park-

ing brake applied, transmission in NEUTRAL,

the engine stopped and the wheels blocked.

1. Check the brake fluid level at the reservoir.

2. Maintain the brake fluid level between the

MAX and MIN marks on the reservoir.

Adding Brake Fluid

1. Remove the reservoir cap.

2. Add brake fluid to the reservoir.

3. Put the reservoir cap back on.

103244

MAINTENANCE

• Brake Fluid

Check Level

If the brake fluid in the reservoir

decreases rapidly, the brake system is

leaking.

Have your Cat lift truck dealer check the

system.

Before refilling the reservoirs, clean the

ports to reduce the risk of dirt from getting

inside the reservoirs.

Correct

level

range

WARNING

CAUTION

111111

4 ton models 403 (41.1) [297]

Front

4.5 to 5 551 (56.2) [406]

ton models

Rear 4 to 5 377 (38.5) [278]

ton models

– 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.

– Are the wheel nuts tightened properly?

Use a torque wrench.

Tightening Torque

MAINTENANCE

101048

100681A

• Wheel Nuts

Check – Tighten, when required

• Tires and Rims

Check

– Is the tread area thickness more than serv-

ice limit?

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

cracks?

Make sure the replacement tire is of the

same size, type and load range.

Limit:

5 mm

(0.2 in.)

Unit: N•m (kgf•m) [lbf•ft]

WARNING

112112

– Does the mast move up and down smoothly

when you operate the lift control lever?

– Does the mast tilt forward and back

smoothly when you operate the tilt control

lever?

– Are there any oil leaks from the cylinders

and hydraulic lines?

– Are the stoppers properly engaged?

– Are the forks free of distortion and cracks?

Are the welds of the hangers free of

cracks?

If the truck is being used to carry maximum

capacity loads, the forks should be checked

daily.

1. Carefully inspect the forks for cracks.

Special attention should be given to the

heel section A, all weld areas and mount-

ing brackets B.

Forks with cracks should be removed from

service.

“Wet Test” magnetic particle inspection is gen-

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.

2. Check the difference in height of one fork

tip to the other when mounted on the fork

carrier. A difference in fork tip height can

result in uneven support of the load and

cause problems when entering loads.

The maximum allowable difference in fork tip

elevation C is 5 mm (0.2 in.) for pallet forks.

Replace one or both forks when the difference

in fork tip height exceeds the maximum allow-

able difference.

101064 101628 101629

MAINTENANCE

• Mast and Forks

Check

103444

113113

3. Check the fork blade D. The fork should

be withdrawn from service if the thickness

is reduced to less than the tolerant thick-

ness.

Fork blade length may also be reduced by

wear, especially on tapered forks and platens.

Remove the forks from service when the blade

length is no longer adequate for the intended

loads.

Unit: mm (in.)

1. If the electrolyte level is low, remove the

filler caps and add distilled water to the

cells. Before removing the caps, clean the

top of the battery.

2. After adding the water, tighten the caps

securely.

101630 101403

MAINTENANCE

• Battery

Check Electrolyte Level

Tolerant thickness Std. Limit

4 ton models 50 (2.0) 43 (1.7)

4.5 ton model 50 (2.0) 46 (1.8)

5 ton models 60 (2.4) 48 (1.9)

Correct level range

If acid gets in your eyes, FLUSH THEM

IMMEDIATELY WITH LARGE

AMOUNTS OF WATER AND SEE A

DOCTOR AT ONCE.

If distilled water has to be often added, have

your Cat lift truck dealer check the battery.

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

20°C (68°F)

1.260 to 1.280 Fully charged

1.220 to 1.260 Three-fourths charged (to be

recharged)

Below 1.220 Completely discharged (to be

recharged and retested)

WARNING

CAUTION

114114

MAINTENANCE

101318

101197

101198

101199

NOTICE:

Never service the air cleaner with the engine

running.

Do not clean the elements by striking them

against another object.

Always inspect the element before and after

cleaning. Use a light inside the element.

Do not use elements with damaged pleats, gas-

kets or seals.

Park the lift truck on a level surface, with the

forks lowered, the parking brake applied, the

transmission in NEUTRAL, engine stopped

and the wheels blocked.

2. Remove the dust pan by releasing the

latches at three places.

3. Unscrew the wing nut, and remove the ele-

ment by pulling it.

4. Remove the cover from the dust pan, and

clean the inside of the pan by removing

dust.

5. Clean the inside of the air cleaner housing.

7. Insert a light inside a clean, dry element

and check. Discard the element if tears or

rips are found.

8. Put the element back in place.

9. Reinstall the dust cap.

10. Close the hood.

6. Direct air inside the element along the

length of the pleats, and lightly tap it.

• Air Cleaner Element

Clean and Inspect

When using compressed air for cleaning,

wear an approved face shield and pro-

tective clothing.

Use a maximum air pressure of 2

kgf/cm 2(30 psi) for cleaning purposes.

Install the dust pan with its arrow mark up.

1. Raise the hood.

100901

Dust pan

Wing nut

Element

Cover

◆

◆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.

CAUTION

WARNING

115115

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, engine stopped

and the wheels blocked.

1. Raise the hood.

2. Push the belt downward with about 98 N

(10 kgf) [22 lbf] pressure midway between

the pulleys as shown.

NOTICE: If the deflection is out of the correct

range, readjust the belt.

Also, check the belt to make sure

that it is not worn, frayed, or has

separated piles.

3. Loosen the alternator bracket bolts (indi-

cated by the black arrows), and move the

alternator out or in.

4. Close and secure the hood.

101417

100696

MAINTENANCE

• Alternator Drive Belt – Diesel

Check and Adjust

– After stopping the engine, check and

adjust the rotating part.

– After adjusting the belt, tighten the

bracket bolt securely.

– If the belt is too tight, unnecessary

stresses are placed on the alternator

bearing and belt. Such stresses will

shorten the service life of both.

– Keep the belt free of oil and grease to

reduce the risk of slipping.

Deflection

Deflection 11 to 13 mm

(0.4 to 0.5 in.)

CAUTION

116116

102771A

Lubricate 1 fitting on each support for a total of

2 fittings.

• Mast Supports

Lubricate

MAINTENANCE

– Filter should be changed.

See Hydraulic System, Change Return Oil

Filter in the Every 1200 Service Hours.

• Hydraulic Tank Return Oil Filter

Change

◆

◆One Month After Delivery of a New Truck

You must read and understand the warnings and instructions contained in this manual before performing

any operation or maintenance procedure.

– Filter should be changed.

See Fuel Filter – Diesel, Change in the Every

1200 Service Hours.

• Fuel Filter – Diesel

Change

– Filter should be changed.

See Engine Crankcase Gasoline and–

LP-Gas, Change Filter in the Every 600

Service Hours.

• Engine Crankcase – Gasoline and

LP-Gas

Change filter

117117

Park the lift truck on a level surface, parking

brake applied, transmission in NEUTRAL,

engine stopped and the wheels blocked.

1. Raise the lift bracket high enough to gain

access to the level/fill plug.

2. Use blocking under the inner mast to

secure the lift bracket in this position.

– Nuts should be retightened.

See Wheel Nuts, Check – Tighten, when

required.

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

cant level to the bottom of the plug brake

operating.

4. Clean the level/fill plug and put it back in

place.

5. Remove the blocking. Lower the lift

bracket.

Adding Oil

See the topic, Differential, Change Oil under

Every 1200 Service Hours or 6 Months,

Whichever Comes First.

102565

MAINTENANCE

• Differential

Check Oil Level

• Wheel Nuts

Retighten

202983

◆

◆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.

118118 118

MAINTENANCE

103275

101631

102566

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, engine

stopped and the wheels blocked.

3. Remove the floor plate. 5. Maintain the correct level range indicated

on the dipstick.

Adding Oil

See the topic, Powershift Transmission,

Change the Oil under Every 1200 Service

Hours or 6 Months, Whichever Comes First.

• Powershift Transmission

Check Oil Level

Hot oil and components could cause

injury. Do not allow hot oil or compo-

nents to contact your skin.

4. Remove the dipstick. Check the oil level.

Correct level range

WARNING

119119

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, engine stopped

and the wheels blocked.

1. Raise the hood.

2. Push the belt downward with about 98 N

(10 kgf) [22 lbf] pressure midway between

the pulleys as shown.

NOTICE: If the deflection is out of the correct

range, readjust the belt.

Also, check the belt to make sure

that it is not worn, frayed, or has

separated piles.

3. Loosen the alternator bracket bolts (indi-

cated by the black arrows), and move the

alternator out or in.

4. Close and secure the hood.

101417

100696

• Alternator Drive Belt – Gasoline

Check and Adjust

– After stopping the engine, check and

adjust the rotating part.

– After adjusting the belt, tighten the

bracket bolt securely.

– If the belt is too tight, unnecessary

stresses are placed on the alternator

bearing and belt. Such stresses will

shorten the service life of both.

– Keep the belt free of oil and grease to

reduce the risk of slipping.

Deflection

Deflection 13 to 15 mm

(0.5 to 0.6 in.)

– Inspect damage to piping and piping joints.

– Inspect gas leakage from them.

• Piping and Piping joints – LP-Gas

Check Damage and Gas Leakage

CAUTION

120120

MAINTENANCE

103931

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, engine stopped

and the wheels blocked.

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.

5. Fill the crankcase. See Refill Capacities

and Lubrication Specifications charts.

9. Close and secure the hood.

6. Start the engine and allow the oil to fill the

filter and passages.

7. Check for oil leaks.

8. Stop the engine and measure the oil level.

Maintain the correct level range on the dip-

stick.

• Engine Crankcase – Gasoline and LP-Gas

Change Oil

Hot oil and components could cause

serious injury. Do not allow hot oil or

components to contact skin.

103924

103918

103919

Correct level range

WARNING

121121

MAINTENANCE

101675

101669

101670

101304

101674

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, engine

stopped and the wheels blocked.

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. 8. Fill the crankcase. See Refill Capacities

and Lubrication Specifications charts.

12. Close and secure the hood.

10. Check for oil leaks.

11. Stop the engine and measure the oil level.

Maintain the correct level range on the dip-

stick.

9. Start the engine and allow the oil to fill the

filter and passages.

• Engine Crankcase – Diesel

Change Oil and Filter

Hot oil and components could cause

serious injury. Do not allow hot oil or

components to contact skin. 7. Apply a small amount of clean engine oil to

the oil filter element gasket. Install the new

filter element.

5. Remove and discard the oil filter element.

6. Wipe the sealing surface of the oil filter

element mounting base.

Correct level range

Whenever the engine oil is changed, the filter must be replaced at the same time with a genuine MCF oil

filter.

WARNING

122122

MAINTENANCE

102570

102571

Lubricate 1 fitting on each side of the inner

mast for a total of 2 fittings.

Lubricate 1 fitting on each side roller for a total

of 2 fittings.

Lubricate each chain on the left and right of the

mast.

• Mast Strip Roller Surfaces

Lubricate

• Lift Bracket Side Rollers

Lubricate

• Lift Chains

Lubricate and Inspect

1. Brush a film of engine oil onto the chain

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

links for wear, loose pins or cracked leaves.

Lubricate 1 fitting.

• Brake Pedal

Lubricate

102713 103202

Lubricate 1 fitting on each pin for a total of 2

fittings.

• Tilt Socket Pins

Lubricate

103458

123123

MAINTENANCE

103247

• Tie Rod Pins

Lubricate

Lubricate 1 fitting on each pin for a total of 4

fittings.

Lubricate 1 fitting on each pin for a total of 2

fittings.

• Rear Axle Center Pins

Lubricate

102576 103933

Lubricate 2 fittings.

• Universal Joint – with Grease Nipple

Lubricate

124124

MAINTENANCE

◆

◆Every 400 Service Hours or 2 Months, Whichever Comes First

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

See the topic, Engine Coolant, Check Level

under Every 10 Service Hours or Daily,

whichever comes first.

1. Loosen the radiator cover retaining knob.

Lift and remove the radiator cover.

2. Turn the radiator filler cap slowly to

relieve the pressure, then remove the cap.

103214

103210

• Engine Coolant – Gasoline

Change

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-

ing brake applied, transmission in NEU-

TRAL, engine stopped and the wheels

blocked.

Check the coolant level only after the

engine has been stopped and the filler cap

is cool enough to touch with your bare

hand.

Remove the filler cap slowly to relieve

pressure.

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

engine, consult your Cat lift truck dealer.

Antifreeze solution is TOXIC. In case of con-

tact with your skin, FLUSH IMMEDIATELY

WITH WATER. Have your Cat lift truck

dealer discard antifreeze solution drained from

the engine.

100899

WARNING

125125

MAINTENANCE

3. Open radiator drain valve. Allow the

coolant to drain.

5. Close the radiator drain valve.

6. Fill the cooling system with 1 kg (2 lb)

sodium bisulfate per 40 liters (10 gallons)

of water. Most commercial cooling system

cleaners can be used.

7. Start and run the engine for 30 minutes.

8. Stop the engine and drain the cleaning

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)

sodium carbonate per 40 liters (10 gallons)

of water.

11. Start and run the engine for 10 minutes.

12. Stop the engine and drain the neutralizing

solution.

13. Flush the system with clean water until

draining water is clear.

20. Put the radiator filler cap back on.

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.

101641A

101465A

4. Drain the reserve tank.

14. Close the drain valve.

15. Mix a coolant solution of water and

antifreeze.

16. Fill the cooling system. See Refill

Capacities. To avoid air locks, add the

coolant slowly.

103216

103200

126126

MAINTENANCE

21. Remove the reserve tank filler cap.

22. Keep the coolant level at the FULL line on

the reserve tank.

23. Put the reserve tank filler cap back on.

101299

101465A

127127

MAINTENANCE

◆

◆Every 600 Service Hours or 3 Months, Whichever Comes First

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

103930

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, engine stopped

and the wheels blocked.

3. Raise the hood.

4. Remove and discard the oil filter element.

5. Wipe the sealing surface of the oil filter

element mounting base.

6. Apply a small amount of clean engine oil

to the oil filter element gasket. Install the

new filter element.

7. Fill the crankcase if required. See Refill

Capacities and Lubrication Specifications

charts.

11. Close and secure the hood.

10. Stop the engine and measure the oil level.

Maintain the correct level range on the dip-

stick.

• Engine Crankcase – Gasoline and LP-Gas

Change Filter

Hot oil and components could cause

serious injury. Do not allow hot oil or

components to contact skin.

Crankshaft pulley side

103918

103919

Correct level range

103924

8. Start the engine and allow the oil to fill the

filter and passages.

9. Check for oil leaks.

WARNING

128128

MAINTENANCE

102577

101631

Park the lift truck on a level surface with the

forks lowered, parking brake applied, transmis-

sion in NEUTRAL, engine stopped and the

wheels blocked.

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

plug back in place.

3. Remove the floor plate.

4. Remove the filler cap ➂. Fill the transmission

with oil. See Refill Capacities. Put the filler

cap ➂ back in place.

5. Start the engine.

6. Run the engine at low idle.

7. Stop the engine.

8. Remove the dipstick . Check the oil level.➃

9. Add oil, if needed, to reach the correct

level range on the dipstick ➃.

10. Check for oil leaks at the strainer and drain

plug.

11. Put the floor plate back in place.

◆

◆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

Hot oil and components could cause

serious injury. Do not allow hot oil or

components to contact your skin.

1. Remove the drain plug . Allow the oil to➀

drain. Remove the cover ➁, the O-ring seal

and the strainer.

Correct level range

➁

➀

➂

103275

➃

WARNING

129129

MAINTENANCE

100695A

100698

103212

Park the lift truck with the forks lowered on a

level surface, parking brake applied, transmis-

sion in NEUTRAL, engine stopped and the

wheels blocked.

1. Raise the hood.

2. Remove the battery and tank cover.

4. Remove the gasket and strainer ➀.

5. Remove the gasket and return oil filter ➁.

Discard the filter element.

6. Clean the filter parts and replace the seal

and gasket, if necessary. Install a new filter

element.

7. Put the filter body assembly back in place

and tighten the retaining bolts.

13. Put the dipstick and filler cap back in place.

14. Check for oil leaks.

15. Close and secure the hood.

• Hydraulic System

Change Return Oil Filter and Wash Strainer

Hot oil components can cause personal

injury. Do not allow hot oil or compo-

nents to contact your skin.

At operating temperature, the hydraulic

tank is hot and can be under pressure.

3. Remove the hose.

Correct level range

8. Wash the strainer in clean, nonflammable

solvent.

9. Inspect the gasket and replace it, if neces-

sary.

10. Put the strainer, gasket, cover and battery

back in place.

11. Remove the filler cap. Check the oil level.

12. Add oil, if needed, to reach the correct

level range on the dipstick.

103461

➀

➁

103462

WARNING

130130

Park the lift truck on a level surface, parking

brake applied, transmission in NEUTRAL,

forks lowered, lubricant warm, engine stopped

and the wheels blocked.

1. Raise the lift bracket high enough to gain

access to the level/fill plug ➁.

2. Use blocking under inner mast to secure

the lift bracket in this position.

3. Remove the drain plug ➀ and the level/fill

plug .➁

4. Allow the oil to drain. Clean and reinstall

the drain plug.

5. Fill with oil to the bottom of the level/fill

hole.

6. Put the level/fill plug back in place.

7. Remove blocking. Lower the lift bracket.

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 Element, Clean

and Inspect Every 50 Hours orunder

Weekly, whichever comes first.

Cat Lift Trucks strongly recommends that the

air cleaner element be changed if it is dirty. If

you attempt to clean the element, handle it

carefully.

Recommended change intervals

102580

202983

MAINTENANCE

• Differential

Change Oil

➀

➁

• Air Cleaner Element

Change

Normal conditions

Severe dust or

lint conditions

Every 1200 service hours

or 6 months,

whichever comes first

Every 200 service hours

or monthly,

whichever comes first

131131

MAINTENANCE

101682A

101743

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, engine

stopped and the wheels blocked.

1. Raise the hood.

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

the truck. Remove the filter.

3. Use filter wrench to remove filter element.

4. Clean sealing surface of filter base.

5. Apply a light coat of engine oil to the gas-

ket of the new filter element.

• Fuel Filter – Diesel

Change

Fuel leaked or spilled onto hot surfaces

or electrical components can cause a fire.

Clean up any spillage of fuel. Know the

location of all emergency devices (such as

fire extinguishers, first aid kits, etc.) and

how to use them.

Disconnect the battery when changing

fuel filters.

101681A

6. Install the new filter element by hand until

the gasket contacts the filter base.

7. Start the engine and check for fuel leaks.

8. Stop the engine.

9. Close and secure the hood.

WARNING

132132

MAINTENANCE

101338A

NOTICE: If the engine runs out of fuel, it can-

not be started even if the fuel tank is

filled. In such a case, prime the fuel

system as follows:

1. Loosen the air vent plug on the fuel fil-➀

ter about 1.5 turns with a wrench.

2. Unlock priming pump plunger ➁by turn-

ing it counterclockwise. Operate the prim-

ing pump until the fuel flows free of bub-

bles from the vent.

3. Tighten air vent plug ➀.

How to Prime the Diesel Fuel System

– Make sure no fuel leaks from the air

vent plug.

– Clean up spillage.

CAUTION

133133

See the topic, Engine Coolant, Check Level

under Every 10 Service Hours or Daily,

whichever comes first.

Antifreeze solution is TOXIC. In case of con-

tact with your skin, FLUSH IMMEDIATELY

WITH WATER. Have your Cat lift truck

dealer discard antifreeze solution drained from

the engine.

1. Loosen the radiator cover retaining knob.

Lift and remove the radiator cover.

2. Turn the radiator filler cap slowly to

relieve the pressure, then remove the cap.

103214

103210

MAINTENANCE

• Engine Coolant – Diesel

Change

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-

ing brake applied, transmission in NEU-

TRAL, engine stopped and the wheels

blocked.

Check the coolant level only after the

engine has been stopped and the filler cap

is cool enough to touch with your bare

hand.

Remove the filler cap slowly to relieve

pressure.

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

engine, consult your Cat lift truck dealer.

100899

407181

For diesel engine model, also remove the

engine block drain plug.

WARNING

134134

3. Open radiator drain valve. Allow the

coolant to drain.

5. Close the radiator drain valve.

6. Fill the cooling system with 1 kg (2 lb)

sodium bisulfate per 40 liters (10 gallons)

of water. Most commercial cooling system

cleaners can be used.

7. Start and run the engine for 30 minutes.

8. Stop the engine and drain the cleaning

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)

sodium carbonate per 40 liters (10 gallons)

of water.

11. Start and run the engine for 10 minutes.

12. Stop the engine and drain the neutralizing

solution.

13. Flush the system with clean water until

draining water is clear.

20. Put the radiator filler cap back on.

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.

101641A

101465A

MAINTENANCE

4. Drain the reserve tank.

14. Close the drain valve.

15. Mix a coolant solution of water and

antifreeze.

16. Fill the cooling system. See Refill

Capacities. To avoid air locks, add the

coolant slowly.

103216

103200

135135

21. Remove the reserve tank filler cap.

22. Keep the coolant level at the FULL line on

the reserve tank.

23. Put the reserve tank filler cap back on.

101299

101465A

MAINTENANCE

136136

MAINTENANCE

102586 100698

100695A 103246

100814

Park the lift truck with the forks lowered on a

level surface parking brake applied, transmis-

sion in NEUTRAL, engine stopped and the

wheels blocked.

1. Operate the lift truck to warm the oil.

2. Park the lift truck with forks lowered, park-

ing brake applied, transmission in NEU-

TRAL, and engine stopped.

3. Remove the filler cap.

5. Fill the hydraulic tank. See Refill

Capacities. Put the filler cap back on.

6. Start the engine and operate the hydraulic

controls and the steering system through a

few cycles to fill the filters and lines.

7. Retract all hydraulic cylinders and stop the

engine.

8. Remove the filler cap and the dipstick.

Keep the oil level at the HIGH mark on the

dipstick.

NOTICE: When changing fluid consult with

your Cat lift truck dealer.

◆

◆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

Hot oil and components could cause

serious injury. Do not allow hot oil or

components to contact your skin.

The engine has been stopped and the

filler cap is cool enough to remove with

your bare hand.

Remove the filler cap slowly to relieve

pressure.

4. Remove the hydraulic tank drain plug.

Allow the oil to drain. Clean and put the

plug back in place.

• Brake Fluid

Change

9. Put the dipstick and the filler cap back in

place.

Correct level range

WARNING

137137

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 diffi-

cult to determine visually whether or not they

are still in good condition. Changing at proper

intervals will reduce the risk of injury to the

operator and damage to the truck.

NOTICE: Periodic changes of these parts are not covered by Warranty.

MAINTENANCE

◆

◆Parts to be Changed Periodically

Ref.

No. Parts to be changed Interval

1LP-Gas repair kit 2400 service hours or 1 year,

(Converter and fuel lock filter) whichever comes first

2Cups and dust seals of the 2400 service hours or 1 year,

wheel cylinders whichever comes first

3Cup and dust seal of the 2400 service hours or 1 year,

master cylinder whichever comes first

4 Power steering hoses 4800 service hours or 2 years,

whichever comes first

5Fuel hoses 4800 to 9600 service hours or 2 to 4

(Include LP-Gas) years, whichever comes first

6Inner 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

8Hydraulic hoses on and 2400 to 4800 service hours or 1 to 2

around mast years, whichever comes first

103253

138138

||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| SERVICE DATA ||||||||||||||||||||||||||||||||||||||||||||||||||||||||

◆

◆Fuel Information

• Gasoline (Gas) Specification

Use only fuel recommended in this section.

Your lift truck must use unleaded gasoline only.

Oxygenated Gasoline

Some gasoline sold at service stations contains oxygenates such as ethanol, methanol, and MTBE (Methyl

Tertiary Butyl Ether), although it 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.

138138

||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| SERVICE DATA ||||||||||||||||||||||||||||||||||||||||||||||||||||||||

◆

◆Fuel Information

• Gasoline (Gas) Specification

Use only fuel recommended in this section.

Your lift truck must use unleaded gasoline only.

Oxygenated Gasoline

Some gasoline sold at service stations contains oxygenates such as ethanol, methanol, and MTBE (Methyl

Tertiary Butyl Ether), although it 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.

139139

SERVICE DATA

– Types of Fuel

The preferred fuels provide maximum engine

service life and performance. They are distil-

late fuels. They are commonly called diesel

fuel, furnace oil, gas oil or kerosene (for cold

weather operation).

Mitsubishi Caterpillar Forklift America Inc.

strongly encourages the use of fuels that meet

the Preferred Fuels specification.

– Fuel Sulfur Content

The percentage of sulfur in the fuel will affect

the engine oil recommendations. Fuel sulfur is

chemically changed during combustion to

form both sulfurous and sulfuric acid. These

acids chemically attack metal surfaces and

cause corrosive wear.

Any API classification performance of oil

should have sufficient TBN for fuels with less

than 0.5% sulfur. For fuels with 0.5% to 1.5%

sulfur by weight, engine oil must have a TBN

of 20 times the percentage of fuel sulfur as

measured by the ASTM (American Society of

Testing Materials) D-2896 method. (ASTM D-

2896 can normally be found at your local tech-

nological society, library or college.)

• Diesel Fuel 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.

• Liquefied Petroleum (LP-Gas)

Specifications

140140

SERVICE DATA

NOTICE:

Mitsubishi Caterpillar Forklift America Inc.

recommends that the coolant mix contain 50%

commercially available automotive antifreeze,

and 50% water.

To reduce the risk of damage to your engine,

never add coolant to an overheated engine.

Allow the engine to cool first.

Dowtherm 209 full-fill coolant will lower the

water pump cavitation temperature and cooling

boiling point. These lowered temperatures will

cause overheating at a lower ambient tempera-

ture than an ethylene glycol and water mix. If

Dowtherm is used, follow the instructions pro-

vided and use only the inhibitor package rec-

ommended by the supplier.

If the lift truck is to be stored in, or shipped to,

an area with freezing temperatures, the cooling

system must be protected to the lowest

expected outside (ambient) temperature.

The engine cooling system is protected with a

commercially available automotive antifreeze

when shipped from the factory.

In cold weather, check the specific gravity of

the coolant frequently to ensure adequate pro-

tection.

◆

◆Coolant Information

Clean the cooling system if it is contaminated,

the engine overheats or foaming is observed in

the radiator.

Old coolant should be drained, the system

cleaned and new coolant added – as recom-

mended – using a commercially available auto-

motive antifreeze.

Filling at over 20 liters (5 U.S. gallons) per

minute can cause air pockets in the cooling

system.

After draining and refilling the cooling system,

run the engine with the radiator cap off. Run it

until the coolant reaches its normal operating

temperatures and the coolant level stabilizes.

Add coolant as necessary to fill the system to

the proper level.

Operate with a thermostat in the cooling sys-

tem all year-round. Cooling system problems

can arise without a thermostat.

• Coolant Water

Hard water, or water with high levels of cal-

cium and magnesium ions, encourages the for-

mation of insoluble chemical compounds by

combining with cooling system additives such

as silicates and phosphates.

The tendency of silicates and phosphates to

precipitate out-of-solution increases with

increasing water hardness. Hard water, or

water with high levels of calcium and magne-

sium ions, encourages the formation of insolu-

ble chemicals, especially after a number of

heating and cooling cycles.

Mitsubishi Caterpillar Forklift America Inc.

prefers the use of distilled water or deionized

water to reduce the potential and severity of

chemical insolubility.

Acceptable Water

Water content Limits ppm

Chlorides (Cl) 50 maximum

Sulfates (SO4) 50 maximum

Total hardness 80mg/l

Total solids 250 maximum

pH 6.0 to 8.0

ppm = parts per million

Using water that meets the minimum accept-

able water requirement may not prevent

dropout of these chemical compounds com-

pletely but should control the dropout rate at

acceptable levels.

141141

SERVICE DATA

NOTICE:

Mitsubishi Caterpillar Forklift America Inc.

recommends that the coolant mix contain 50%

commercially available automotive antifreeze,

or equivalent, and acceptable water to maintain

an adequate water pump cavitation 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.

• Antifreeze

Make Proper Antifreeze Additions.

Do not add pure (100%) antifreeze to the cool-

ing system. Add antifreeze mixed with water

using the same freeze protection ratio that is in

your cooling system.

142142

-45 (-49) -39 (-38) -30 (-22) -25 (-13) -20 (-4) -15 (5) -10 (14)

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 in this section.Specifications

Antifreeze solution Ambient temperature, °C (°F)

Concentration (%)

SERVICE DATA

◆

◆Recommended Fuels and Oils

-30 -20 -10 0 10 20 30

(-22) (-4) (14) (32) (50) (68) (86)

SAE10W SAE30

SAE90SAE80W

SAE10W-30

Recommendation for ambient temperatures °C (°F)

Fuel Consult your local Cat lift truck dealer

Consult your local Cat lift truck dealer

F.M.V.S.S. No. 116–DOT3 or DOT4 (SAE J1703)

NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295

NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340

API service classification SJ, min.

API service classification CD, min.

Engine oil

Dexron II

ISO VG32

Transmission oil

Hydraulic oil

Brake fluid

Grease

Wheel bearings

Chassis

Gear oil API service classification

multipurpose type GL-4 or GL-5

Fuel or oil Recommendation

Gasoline models

Diesel models

143143

SERVICE DATA

Manufacturer

Mobil

Shell

Exxon

Castrol

Specifications

Viscosity

Mobil 1 10W-30

Shell Fleet 10W-30

XD-3 10W-30

Castrol GTX 10W-30

SAE10W-30

API service classification SJ

Manufacturer

Mobil

Shell

Exxon

Castrol

Specifications

Viscosity

—

API service classification GL-4 or GL-5

Shell Donax TC

Exxtrans

Castrol Dexron ®III/Mercon ®

Mobil ATF

SAE80W SAE90

Mobilube HD 80W-90 Mobilux EP 1 Mobilux EP 2

Shell Spirax HD 80W-90 Retinax HD NLGI 1

Ronex Extra Duty 1

Retinax HD NLGI 2

Ronex Extra Duty 2

Castrol Hypoy 80W-90

Gear Oil GX80W-90

Castrol EPL1 Castrol EPL2

Consistency 310 - 340 Consistency 265 - 295

NLGI No. 1 NLGI No. 2

Manufacturer

Mobil

Shell

Exxon

Castrol

SAE10W

Specifications

Viscosity

Mobil Delvac 1210 Mobil Delvac 1230

Shell Rotella T 10W

XD-3 10W

Shell Rotella T 30

XD-3 30

Castrol Syntec 10W-30

SAE30

API service classification CD or MIL-L-2104E equivalents

SAEJ1703

—

Shell Advance Brake Fluid

Brake Fluid DOT-3

Castrol GT LMA Brake Fluid

Mobil Universal Brake Fluid

Dexron

Full Force

USI Chemical

Marcus

Peak

• Engine Oils (Gasoline)

Below oils are reference only.

• Engine Oils (Diesel)

• Gear Oils

• Transmission Oils

• Brake Fluids/

Clutch Oil

• Antifreeze/Summer

Coolant

• Greases

144144

SERVICE DATA

Manufacturer

Mobil

Shell

Exxon

Castrol

Specifications

Viscosity

Nuto H32

Castrol Hyspin AWH-M32

Tellus T-32

Mobiltrans HD 10W

ISO VG32

—

NOTICE:

Brands of oil are subject to change without notice. When you buy oil, check

specification. (For example: API service classification CD, SAE10W)

• Hydraulic oils

145145

◆

◆Specifications and Refill Capacities (Standard Models)

GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K

Item

Alternator drive belt deflection - when pushed 13 to 15 11 to 13

with 98 N (10 kgf) [22 lbf] pressure, mm (in.) (0.5 to 0.6) (0.4 to 0.5)

Spark plugs Gap, mm (in.) 1.24 (0.049) —

Type – NGK BPR4ES —

Engine idling speed, rpm 650 to 700

Steering wheel free-play - when measured 15 to 30

at rim with engine idling, mm (in.) (0.6 to 1.2)

Inching pedal free play, mm (in.) 5 (0.2)

Brake pedal free-play, mm (in.) 4 to 15 (0.2 to 0.6) 5 to 18 (0.2 to 0.7) 4 to 15 (0.2 to 0.6) 5 to 18 (0.2 to 0.7)

Parking brake lever effort, N (kgf) [lbf] 250 to 290 (25 to 30) [55 to 66]

Single 8.25 - 15 - 300 - 15 - 8.25 - 15 - 300 - 15 -

Front 14 PR(I) 20 PR(I) 14 PR(I) 20 PR(I)

Tire size Dual 7.50 - 16 - 12 PR(I)

Rear 7.00 - 12 - 12 PR(I)

Tire pressure, Front single 800 (8.0) [114]

kPa (kgf/cm2) [psi] Front dual 700 (7.0) [100]

(Pneumatic) Rear 700 (7.0) [100] 850 (8.5) [120] 700 (7.0) [100] 850 (8.5) [120]

Tightening torque for Front 403 (41.1) [297] 551 (56.2) [406] 403 (41.1) [297] 551 (56.2) [406]

wheel nuts, N•m (kgf•m) [lbf•ft] Rear 377 (38.5) [278]

Lift chain elongation limit, 518 (20.4) 648 (25.5) 518 (20.4) 648 (25.5)

mm (in.)/20 links

Truck model

SERVICE DATA

146146

SERVICE DATA

GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K

Item

Fuel tank 115 (30)

Engine cooling system — 11.2 (3.0) 14.7 (3.9)

0.65 litre (1.4 pt) reserve tank included

Crankcase 7.3 (1.9) 11 (2.9)

Engine oil Oil filter 0.3 (0.08) 1 (0.3)

Total 7.6 (2.0) 12 (3.2)

Transmission 14 (3.7) 15 (4.0) 14 (3.7) 15 (4.0)

Differential (P/T) 9.1 (2.4)

Hydraulic tank 64.5 (17.0)

Brake fluid reservoir, cc (cu in.) 150 (9.2)

Battery electrolyte specific gravity 1.28

corrected to 20° C (68° F)

Truck model

Refill capacities (approximate),

litre (U.S. gal.)

GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K

Item

Capacity, kg (lb) 600 mm (24 in.) —4000 (9000) 4500 (10000) 5000 (11000) —4000 (9000) 4500 (10000) 5000 (11000)

500 mm (24 in.) 4000 (8000) — — — 4000 (8000) — — —

Truck weight, Single drive tires 5570 (12300) 5970 (13150) 6530 (14400) 7050 (15500) 5710 (12600) 6120 (13500) 6680 (14750) 7160 (15800)

unloaded kg (lb) Dual drive tires 5700 (12550) 6050 (13350) 6610 (14550) 7130 (15700) 5900 (13000) 6250 (13750) 6820 (15050) 7320 (16150)

Truck model

◆

◆Capacity and Truck Weight (Standard Models)

147147

||||||||||||||||||||||||||||||||||||||||||| 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

could be endangered by the use of

inferior parts. In most cases, imitations sold as

cheap parts invariably could mean short life

and high cost.

PART No.

PART NAME

PCS

Made in

104830C

Genuine parts give safe and reliable

performance.

The use of other than genuine parts could

cause damage not covered by your

Cat lift trucks warranty.

CAUTION

148148

When ordering parts, or when asking your lift

truck dealer to have your truck repaired, be

sure to provide the TRUCK SERIAL NUM-

BER and the ENGINE SERIAL NUMBER.

Manufacturer’s Name Plate

TO THE CAT LIFT TRUCK OWNER

◆

◆Instructions for Ordering Parts

102993

103266

Engine Serial Number

Diesel engine modelsGasoline and LP-Gas engine models

101522

103916

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

Truck serial number.

Truck model designation.

149149

Name

Address

Delivery date

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

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

TO THE CAT LIFT TRUCK OWNER

Delivering

dealer

Fill out this sheet for your ready reference.

SERVICE REGISTRATION

150150

◆

◆Transfer of Ownership Report for Mitsubishi Caterpillar Forklift America Inc. Customers Only

DATE

TRANSFER REPORT

TRANSFER OF OWNERSHIP REPORT

DISTRIBUTED BY: MODEL SERIAL NUMBER HOUR METER

TRANSFERRED FROM

DEALER / CUSTOMER NAME ADDRESS

CITY / TOWN COUNTY STATE ZIP COUNTRY

TRANSFERRED TO

CUSTOMER NAME ADDRESS

CITY / TOWN COUNTY STATE ZIP COUNTRY

CUSTOMER’S PRINCIPAL BUSINESS CUSTOMER CONTACT

(AREA CODE) TELEPHONE NUMBER (AREA CODE) TELEFAX NUMBER

( ) ( )

Mitsubishi Caterpillar Forklift America Inc.

2121 W. Sam Houston Parkway N.

Houston, TX 77043-2305

Fax: (713) 365-1414

Attn: Marketing Services

Copies distributed to:

❑Dealer Sales Department

❑Dealer Service Department/Warranty

❑MCFA Marketing Services [FAX (713) 65-1414]3

CUSTOMER’S SIGNATURE DATE

151151

|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| INDEX||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||

Accelerator Pedal .........................................................................................28

Accelerator Pedal, Check (Every 10 Service Hrs.) ...................................100

Adding Engine Coolant .....................................................................107–108

Adding Engine Oil .............................................................................105–106

Adding Hydraulic Oil ................................................................................109

After Starting Engine ...................................................................................61

Air Cleaner Warning Light ..........................................................................32

Air Cleaner, Care in Severe Dust and Lint Conditions ...............................81

Air Cleaner, Change Element (Every 1200 Service Hrs.).........................130

Air Cleaner, Clean/Inspect (Every 50 Service Hrs.)..................................114

Alternator Not Charging Warning Light......................................................32

Alternator, Drive Belt – Diesel, Check-Adjust (Every 50 Service Hrs.)...115

Alternator, Drive Belt – Gasoline, Check-Adjust

(Every 200 Service Hrs.)......................................................................119

Antifreeze Coolant, Recommended...........................................................143

Anti-Restart Starter Switch..........................................................................31

Assist Grip ...................................................................................................41

Assist Grip, Check (Every 10 Service Hrs.)..............................................100

Back-up Buzzer............................................................................................43

Back-up Lights, Check (Every 10 Service Hrs.) .......................................104

Battery, Check Electrolyte Level ...............................................................113

Before Moving Lift Truck............................................................................62

Before Starting Engine...........................................................................54–56

Brake Fluid Level Warning Light ................................................................32

Brake Fluid, Recommended...............................................................142–143

Brake Pedal ..................................................................................................28

Brake Pedal, Check (Every 10 Service Hrs.).............................................100

Brake Pedal, Lubricate (Every 200 Service Hrs.) .....................................122

Brake, Service, Change Fluid (Every 2400 Service Hrs.).........................136

Brakes, Service, Adding Brake Fluid (Every 10 Service Hrs.) .................110

Brakes, Service, Check (Every 10 Service Hrs.) .......................................113

Brakes, Service, Check Fluid Level (Every 10 Service Hrs.) ...................110

Capacities, Truck Weight ...........................................................................146

Capacity Chart .............................................................................................45

Capacity, (Weight and Load Center)............................................................45

Capacity, Changes In ...................................................................................20

Capacity, Stay Within...................................................................................23

Center of Gravity .........................................................................................44

Changing Direction......................................................................................64

Changing LP-Gas Tank ...............................................................................52

Changing Speed ...........................................................................................64

Compartment, Operator’s, Cleanliness of....................................................12

Controls, Position Correctly ........................................................................24

Coolant Information...................................................................................140

Coolant, Adding Water...............................................................................107

Coolant, Adding .................................................................................107–108

Coolant, Engine Temperature Gauge ...........................................................30

Coolant, Engine, Care of in Cold Weather ..................................................80

Coolant, Engine, Care of in Hot Weather ....................................................81

Coolant, Engine, Safety While Checking ....................................................11

Counterweight, Allowing for Swing Distance.............................................18

Damage or Faulty, Operation Found (Every 10 Service Hrs.) ....................99

Decals, LP-Gas ..............................................................................................4

Decals, Warning .........................................................................................2–9

Diesel Engine ...............................................................................................51

Differential, Change Oil (Every 1200 Service Hrs.) .................................130

Differential, Check Oil Level (Every 200 Service Hrs.) ...........................117

Direction Lever ............................................................................................28

Direction of Travel, Always Look In...........................................................18

Disabled Machine, Park Safely....................................................................24

Do-It-Yourself Maintenance ........................................................................94

Drawbar Pin .................................................................................................41

Dress, Proper................................................................................................10

Driving Interlock Indicator Light.................................................................92

Driving Interlock System.......................................................................33–34

Dual Fuel Type, Gasoline/LP-Gas ...............................................................55

152152

ECM Warning Light.....................................................................................32

Empty Lift Truck, Stability of .....................................................................17

Engine Coolant Adding......................................................................107–108

Engine Coolant Level Warning Light ..........................................................32

Engine Coolant Temperature Gauge............................................................30

Engine Coolant, Temperature Gauge Needle Moves Into Red Zone ..........91

Engine Crankcase, Check Oil Level (Every 10 Service Hrs.)...................105

Engine Hood ................................................................................................43

Engine Oil Pressure Warning Light .............................................................32

Engine Oil, Recommended ................................................................142–143

Engine, Adding Oil (Every 10 Service Hrs.).............................................105

Engine, After Starting ..................................................................................61

Engine, Before Starting................................................................................54

Engine, Check (Every 10 Service Hrs.).....................................................104

Engine, Check Coolant Level (Every 10 Service Hrs.).............................107

Engine, Coolant, Change (Every 1200 Service Hrs.)........................133–135

Engine, Diesel, Change Oil and Filter (Every 200 Service Hrs.)..............121

Engine, Gasoline and LP Gas Change Oil (Every 200 Service Hrs.) .......120

Engine, Inspection Points ............................................................................43

Engine, Stalls ...............................................................................................90

Engine, Starting with Jumper Cables...........................................................60

Engine, Starting, Diesel ...............................................................................58

Engine, Starting, Gasoline ...........................................................................57

Engine, Starting, LP-Gas .............................................................................61

Engine, Won’t Start......................................................................................59

Equipment for Risk Reduction ....................................................................40

Exhaust Fumes, Dangers of .........................................................................11

Floor Capacity, Be Aware of........................................................................16

Foreword .........................................................................................................i

Fork Adjustment...........................................................................................40

Fork Stoppers ...............................................................................................40

Forks, Changing ...........................................................................................40

Forks, Checking Stopper Engagement.........................................................16

Forks, Do Not Abuse .............................................................................21, 22

Forks, Extending Beyond Load ...................................................................16

Fuel Amount, Check (Every 10 Service Hrs.)...........................................102

Fuel Filler.....................................................................................................42

Fuel Filter, Diesel Change (1 Month After Delivery and

Every 1200 Service Hrs.) .............................................................116, 131

Fuel Gauge ...................................................................................................30

Fuel Shut-off Valve ......................................................................................42

Fuels and Oils, Recommended ..................................................................142

Fuels Oils, Care in Cold Weather ................................................................80

Fuels Oils, Care in Hot Weather ..................................................................81

Fuse Box ......................................................................................................30

Fuses and Lights ..........................................................................................39

Gasoline Engine ...........................................................................................51

Gear Oils, Recommended ..................................................................142–143

Genuine Parts, Importance Of ...................................................................147

Grease, Chassis ..........................................................................................142

Greases, Recommended.....................................................................142–143

Handling Loads Safely...........................................................................21, 70

Healthy, Always Stay on the Job .................................................................12

Hood, Engine ...............................................................................................43

Horn Switch .................................................................................................28

Horn, Check (Every 10 Service Hrs.)........................................................102

Horseplay and Stuntdriving, Refrain From..................................................18

Hoses, Lines, Tubes .....................................................................................94

Hourmeter ....................................................................................................30

How To Use This Manual..............................................................................ii

Hydraulic Oils, Recommended..........................................................132, 144

Hydraulic System, Adding Oil (Every 10 Service Hrs.) ...........................109

Hydraulic System, Change Oil (Every 2400 Service Hrs.).......................136

Hydraulic System, Change Return Oil Filler and Wash Strainer

(1 Month After Delivery and Every 1200 Service Hrs.) ..............116, 129

Hydraulic System, Check Oil Level (Every 10 Service Hrs.)...................109

Hydraulic Tank, Oil Level/Filler Hole.........................................................42

INDEX (continued)

153153

Inching Pedal ...............................................................................................28

Inching Pedal, Check (Every 10 Service Hrs.)..........................................101

Inching .........................................................................................................66

Index...................................................................................................151–155

Inspection Precautions .................................................................................95

Instrument Panel ..........................................................................................30

Interlock System, Driving......................................................................33–34

Leaks, Oil, Fuel or Coolant, Check (Every 10 Service Hrs.)......................99

Lift Bracket Side Rollers, Lubricate (Every 200 Service Hrs.).................122

Lift Chains, Adjust .....................................................................................103

Lift Chains, Lubricate–Inspect (Every 200 Service Hrs.) .........................122

Lift Control Lever ........................................................................................29

Lift Truck Stability Base..............................................................................45

Lift Truck, Before Moving...........................................................................62

Lift Truck, Break-In New ............................................................................54

Lift Truck, Care of in Cold Weather............................................................80

Lift Truck, Care of in Hot Weather..............................................................81

Lift Truck, Care of in Severe Dust or Lint Conditions................................81

Lift Truck, Damaged, Defective or Unsafe ...........................................12, 14

Lift Truck, Do Not Modify ..........................................................................11

Lift Truck, Inching.......................................................................................66

Lift Truck, Keeping People Clear..........................................................20, 21

Lift Truck, Know Your.....................................................................12, 26–43

Lift Truck, Move Safely...............................................................................19

Lift Truck, Operation .............................................................................54–68

Lift Truck, Parking (After Stopping) ...........................................................68

Lift Truck, Safety On Grades When Empty ................................................19

Lift Truck, Safety On Grades When Loaded...............................................19

Lift Truck, Safety When Passing .................................................................18

Lift Truck, Shipping.....................................................................................79

Lift Truck, Stability................................................................................44–45

Lift Truck, Stopping.....................................................................................67

Lift Truck, Storage.......................................................................................78

Lift Truck, Unloading ............................................................................73–74

Light Switch.................................................................................................31

Lights, Check (Every 10 Service Hrs.)........................................................99

Lights, When To Use ...................................................................................15

Lights, Won’t Come On...............................................................................39

Lines, Tubes and Hoses ...............................................................................94

Load Backrest, Check (Every 10 Service Hrs.)...........................................99

Load, Handling Safely ...........................................................................21, 70

Load, Inching Into and Lifting.....................................................................71

Load, Stacking Methods ..............................................................................69

Load, Traveling With .............................................................................72, 74

Loading, Avoid Off-Center ....................................................................16, 72

Loads, Approaching at Safe Speed........................................................21, 71

Loads, Do Not Allow Others to Hold, on Truck .........................................18

Loads, Handling.....................................................................................21, 22

LP-Gas Equipment, Trouble ........................................................................93

LP-Gas Tank Replacement ..............................................................13, 25, 52

Maintenance Schedule (1 Month After Delivery) .......................................97

Maintenance Schedule (Every 10 Service Hrs.)....................................96, 97

Maintenance Schedule (Every 1200 Service Hrs.) ......................................98

Maintenance Schedule (Every 200 Service Hrs.) ........................................97

Maintenance Schedule (Every 2400 Service Hrs.) ......................................98

Maintenance Schedule (Every 400 Service Hrs.) ........................................98

Maintenance Schedule (Every 50 Service Hrs.) ..........................................97

Maintenance Schedule (Every 600 Service Hrs.) ........................................98

Maintenance .........................................................................................94–137

Mast and Forks, Check (Every 10 Service Hrs.) ...............................112–113

Mast Strip Roller Surfaces, Lubricate (Every 200 Service Hrs.) ..............122

Mast Supports, Lubricate (Every 50 Service Hrs.)....................................116

Model View ..................................................................................................27

Name Plate, Manufacturer’s.......................................................................148

Neutral System.............................................................................................33

INDEX (continued)

154154

Oil and Fuel, Care in Cold Weather.............................................................80

Oil and Fuel, Care in Hot Weather ..............................................................81

Oil, Fuel or Coolant Leaks, Check (Every 10 Service Hrs.).......................99

Oil, Hydraulic, Change (Every 2400 Service Hrs.)...................................136

OK Monitor Bulb Check .............................................................................31

OK Monitor, Check (Every 10 Service Hrs.) ............................................102

OK Monitor, Warning Lights and Indicators...............................................32

Operating Controls.......................................................................................28

Operating Techniques ......................................................................65, 69–77

Operation................................................................................................54–68

Operator Be Alert.........................................................................................10

Operator Presence Switch............................................................................33

Operator, Authorized, Trained .....................................................................10

Operator’s Compartment..............................................................................28

Operator’s Seat, (Adjustment) .....................................................................35

Overhead Clearance .....................................................................................15

Overhead Guard, Check (Every 10 Service Hrs.) .....................................100

Pallets, Damaged, Do Not Use ....................................................................22

Parking Brake Lever ....................................................................................28

Parking Brake Lever, Check (Every 10 Service Hrs.)...............................101

Parking, Lift Truck.......................................................................................68

Parking, In Authorized Areas.......................................................................24

Parking, On a Grade.....................................................................................24

Parts To be Changed Periodically ..............................................................137

Parts, Ordering Instructions .......................................................................148

Pedestrians, Watch Out for at All Times................................................17, 18

People, Unauthorized, Do Not Allow ..........................................................20

Plate, Serial Number, Instruction, and Manufacturer ..................................26

Powershift Transmission Oil Temperature Warning Light ..........................91

Powershift Transmission Oil, Recommended....................................142, 143

Powershift Transmission, Adding Oil........................................................118

Powershift Transmission, Change Oil (Every 1200 Service Hrs.) ............128

Powershift Transmission, Check Oil Level (Every 200 Service Hrs.) ......118

Pre-Start Inspection Items......................................................................96–97

Pre-Start Inspection..............................................................................99–113

Rear Axle Center Pins, Lubricate (Every 200 Service Hrs.) .....................123

Refueling................................................................................................51–53

Refueling, No Smoking During.............................................................10, 42

Reverse, Travel.............................................................................................18

Riders, Do Not Allow ............................................................................17, 18

Safe, Know Your Lift Truck Is.....................................................................12

Safety Rules for Lift Truck Operators .....................................................1–25

Safety Rules, LP Gas ...................................................................................25

Safety Rules, Warnings..........................................................................10–25

Safety, Ant-restart.........................................................................................31

Seat Belt.................................................................................................36–37

Seat Belt, Check (Every 10 Service Hrs.) .................................................101

Seat Belt, How to Fasten, Release...............................................................37

Seat, Adjust Before Operation.......................................................15, 35, 101

Serial Number and Capacity Plate...............................................................26

Service Data .......................................................................................138–146

Service Registration Sheet .........................................................................149

Signals and Traffic Rules, Know All ...........................................................18

Slippery Surface, Stay Away From..............................................................17

Special Situations...................................................................................81–82

Specifications and Refill Capacities (Standard Models) ...................145–146

Speed Selector Switch .................................................................................30

Stability and Center of Gravity..............................................................44–45

Starting Diesel Engine .................................................................................58

Starting Gasoline Engine .............................................................................57

Starting LP-Gas Engine ...............................................................................61

Steep Slope, Driving On ..............................................................................19

Steering (Turning) ........................................................................................65

Steering Tilt Lever .......................................................................................29

Steering Wheel, Check (Every 10 Service Hrs.) .......................................102

INDEX (continued)

155155

Stop Lights, Check (Every 10 Service Hrs.) .............................................102

Storage .........................................................................................................78

Table of Contents.....................................................................................iii–iv

Tail Swing ....................................................................................................65

Tightening Torque ........................................................................................84

Tilt Control Lever ........................................................................................29

Tilt Cylinder Socket Bolts, Check (Every 10 Service Hrs.)......................100

Tilt Socket Pins, Lubricate (Every 200 Service Hrs.) ...............................122

Tipover, Avoid On a Grade or Ramp ...........................................................19

Tipover, Avoid, Do’s and Don’t.............................................................47–49

Tipovers, Be Alert for ..................................................................................20

Tipovers, How to Avoid, Survive...........................................................44–50

Tipovers, How to Survive ............................................................................50

Tire, Changing........................................................................................82–90

Tire, Check (Every 10 Service Hrs.)..........................................................111

Tire, Jack Capacities ....................................................................................83

Tire, Jacking Method .............................................................................82–84

Trailer, Driving Onto....................................................................................22

Transmission Oil, Powershift, Recommended...................................142, 143

Transmission, Powershift, Change Oil, etc (Every 1200 Service Hrs.) ....128

Transmission, Powershift, Check Oil Level (Every 200 Service Hrs.) .....118

Traveling on a Grade....................................................................................76

Traveling, See Where You Are Going..........................................................18

Troubleshooting .....................................................................................82–93

Tubes, Lines and Hoses ...............................................................................94

Turning .........................................................................................................65

Unsafe Lift Truck, Do Not Operate .............................................................12

Upgrade, Start Lift Truck Carefully.............................................................19

Warning Decals, Description .....................................................................5–9

Warning Decals, Location..........................................................................2–4

Wheel Nuts, Check-Tighten (Every 10 Service Hrs.) ...............................111

Wheel Nuts, Retighten (Every 200 Service Hrs.)......................................117

Working on Grades ................................................................................75–76

INDEX (continued)

Produkt Specifikationer

Mærke:	CAT
Kategori:	Gaffeltruck
Model:	DP40K

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