TROUBLESHOOTING

 TROUBLESHOOTING
 Stalled Engine
If the engine stalls, hydraulic pressure is lost in the power
steering. This increases your steering effort. In this case, stop
your lift truck in a safe area and restart the engine.

P00116

 If a Tire Blows Out

 If a Tire Blows out During Travel or Operation

R CAUTION
A flat tire tilts the truck, which makes it difficult to turn the steering wheel properly. Operating the lift truck with a flat tire may
cause an accident.

Remedy
(1) Stay calm and firmly hold on to the steering wheel.
(2) Gently release the accelerator pedal to slow down.
(3) Park the lift truck in a safe area.
(4) Replace the punctured tire with a new one.
Note: Contact your authorized Cat lift truck dealer when
requesting to replace tires.

 Starting With Jumper Cables

To start a truck with a "run-down" battery, use a booster battery or jumper cables from the battery of a second truck.

R WARNING
- Batteries give off flammable gas which could explode.
- Keep flames and sparks away from batteries. They could cause gas to explode.
- DO NOT smoke when checking battery electrolyte levels.
- Improper jump start procedures could cause an explosion that could result in injuries. Turn OFF all lights and accessories
on the stalled truck.
- Always connect battery positive (+) to battery positive (+) and battery negative (-) to engine body. Jump only with a
battery source of the same voltage as the stalled truck.
- DO NOT allow jumper cable ends to contact each other or the truck.
- Electrolyte is an acid and could cause injury if it contacts skin or eyes. Always wear eye protection when starting an engine
in the truck with jumper cables.
- BE SURE to connect the cable end 4 to the ENGINE BODY. If it is connected to the negative (-) terminal of the battery, sparks
could ignite the gases.

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R CAUTION
- Connect the jumper cables away from the moving parts in the engine compartment.
- When carrying batteries, provide short circuit prevention to the terminals. If metals come in contact with the terminals, a
short circuit could result.
- DO NOT touch the cable with wet hands. If touched, it may result in an electrical shock.
Note:
- Use 24 volt jumper cables to jump start the truck. This lift truck has a 24 volt starting system. Use only equal voltage for
jump starting. Use of a welder or higher voltage will damage the electrical system.
- You can buy jumper cables from your authorized Cat lift truck dealer.
- Turn OFF the battery switch before the boost connection to prevent damage to electrical components on the stalled lift
truck. Many "dead" batteries can be recharged.

3)
1)
2)
+ –

–
1) +

– +

–
+

E00689
1) “Good” battery
2) Cable end
3) Truck being started

(1) Position the second lift truck, with its engine running,
within jumper cable distance.
(2) Connect the jumper cables in the sequence shown. Do r
not short across the positive (+) and negative (-)
terminals. + – e
(3) After connecting the cables, increase the speed of the –
second lift truck's engine and then start the engine of +
the stalled lift truck that has the "run-down" battery. – +
(4) After the engine starts, disconnect the jumper cables in
–

the reverse sequence. w +

q E00688

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 TROUBLESHOOTING
 If Lights Won't Glow

R CAUTION
- Always replace fuses with fuses of the correct amperage.
- If a fuse burns out immediately after being replaced and you cannot locate the cause, have your authorized Cat lift truck
dealer make a circuit check.
- Always use a fuse of the same wattage.

Code Capacity Circuit Code Capacity Circuit

Head light, Parking light, Tail light, F10 20A Air dryer
F1 15A
Turn signal light F11 10A Spare power supply, Thermoswitch
F2 10A Horn, Glow timer Backup light, Back buzzer, Low air
F3 10A Stop light pressure buzzer, Brake warning
F12 15A
light, Revolving Light, Lining wear
F4 15A DC-DC converter 1 buzzer
F5 15A Working light F13 10A DC-DC converter 1&2, Alternator,
F6 30A DC-DC converter 2 Register, Engine stop timer

F7 30A Heater F14 10A Spare

F8 20A Starter F15 15A Spare

F9 15A Spare power supply F16 20A Spare

F17 30A Spare
 How to Check Fuses and Lights
(1) Remove the fuse cover.

1
P00208
1. Fuse box

(2) Use the puller.

Note: To remove the fuse or insert a replacement fuse, use
the puller located inside the fuse panel lid.

E00458
1. Puller

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(3) Check to see if fuse is blown.

(4) Check to see if light is burned out If there is no problem
with the fuses

E00459

(5) Lights may be defective.

Light Type Capacity

Head light 24V-60W
Working light (Option) 24V-60W
Turn signal light 24V-25W
Front
Clearance light 24V-5W
Tail / Stop light 24V-21W / 5W
Rear Backup light 24V-21W
Turn signal light 24V-21W

(6) Install the fuse cover.

If the Engine Coolant Temperature Gauge Shows RED Zone

R WARNING
- DO NOT add cold water to an overheated engine. This
could cause engine damage. Wait for the engine to
cool, if possible. If not, slowly pour water into the 1
radiator.
- Immediately turn the engine OFF if the fan belt is
broken.

P00199

1. Overheat

R CAUTION
If any of the following liquids are spilled on the floor, clean them up immediately. If not cleaned up, it could result in slipping,
skidding, or environmental pollution:
- Oil or grease
- Coolant
- Diesel fuel
- Brake fluid
- Electrolyte

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 TROUBLESHOOTING

(1) Park the lift truck in a safe area.

(2) Raise the engine hood to ventilate the engine
compartment.
(3) Allow the engine to idle for a while. DO NOT attempt to
turn the engine OFF.
(4) Turn the engine OFF after the engine coolant
temperature gauge shows the WHITE zone.

N00019

(5) Check the following:

- Lack of coolant
- Loose or broken fan belt
- Engine oil level
- Dirt buildup in radiator air passages

If Torque Converter Oil Temperature Warning Icon Glows (Powershift)

(1) Stop the lift truck in a non-traffic area.
(2) Apply the parking brake.
(3) Place the direction lever in NEUTRAL position.
(4) Run the engine at low idle for a while.
(5) After the warning icon has gone OUT, operate the lift
truck again.

P00193

R CAUTION
If the warning icon does not go OUT, or if it constantly glows, contact your authorized Cat lift truck dealer.

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TROUBLESHOOTING
If the Lift Truck Won’t Change Direction
If the operator half rises from the operator seat for more than approximately 2 seconds with the direction lever being placed in
the FORWARD or REVERSE position, an operator presence switch in the operator seat activates the driving interlock system.
Check the following points if the lift truck will not move even after the direction lever is shifted to the FORWARD or REVERSE
position:

The driving interlock indicator icon starts blinking and the lift truck stops moving.

Are you seated?

YES
Stop working and move the lift truck to a safe area. Turn the
engine OFF and contact your authorized Cat lift truck dealer.
NO
Place the direction lever to the NEUTRAL position and sit
securely, with the seat belt fastened.

P00201

The driving interlock indicator icon is OFF but the lift truck fails to move.

Stop working and move the lift truck to a safe area. Turn the
engine OFF and contact your authorized Cat lift truck dealer.

P00200

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 TROUBLESHOOTING
If the Lift Truck Won’t Move
If the operator half rises from the operator seat for more than approximately 2 seconds with the direction lever being placed in
the FORWARD or REVERSE position, an operator presence switch in the operator seat activates the driving interlock system.
Check the following points if the lift truck will not move even after the direction lever is shifted to the FORWARD or REVERSE
position:

The driving interlock indicator icon starts blinking and the lift truck stops moving.

Are you seated?

YES
Stop working and move the lift truck to a safe area. Turn the
engine OFF and contact your authorized Cat lift truck dealer.
NO
Sit securely with the seat belt fastened, and apply the
parking brake. Then release the parking brake.

PA0501

The driving interlock indicator icon is OFF but the lift truck fails to move.

Stop working and move the lift truck to a safe area. Turn the
engine OFF and contact your authorized Cat lift truck dealer.

PA0502

If the Mast Stops Moving

If the operator half rises from the operator seat for more than 2 seconds without the lift or tilt lever being placed in the
NEUTRAL position, an operator presence switch in the operator seat activates the mast interlock system.

Check the following points if the mast will not move even after the lift or tilt lever is shifted to other than the
NEUTRAL position.

Remedy
(1) Sit properly on the operator seat.
(2) Return the lift or tilt lever to the NEUTRAL position.
(3) Operate the lift or tilt lever.

Note: If the mast interlock system remains in a locked

condition after taking the above Steps, contact your
authorized Cat lift truck dealer immediately.

P00028

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TROUBLESHOOTING
 If the Mast and Attachments Malfunction
Push down on the emergency mast stop button (if equipped) to stop the mast and attachments.

R WARNING
- If you see the mast or attachment malfunctioning, push
down on the emergency mast stop button (if
equipped). Contact your authorized Cat lift truck dealer
immediately.
- DO NOT attempt to return the emergency mast stop
button to the OPERATE position for operating the lift
truck before an authorized technician arrives on the
scene.

P00204

P00202

Push down on the emergency mast stop button (if equipped), and then take the following safety measures.

(1) Move the lift truck to a safe area.

(2) Return the direction lever to the NEUTRAL position.
(3) Apply the parking brake.
(4) Turn the key switch to the z (OFF) position.
(5) Attach a "DO NOT OPERATE" or similar warning tag to
the mast or fork of the lift truck in order to let other
people know your lift truck down.
(6) Contact your authorized Cat lift truck dealer
immediately.

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 TROUBLESHOOTING
 Diagnostic Codes and Explanations
Contact your authorized Cat lift truck dealer when the diagnostic code is displayed.

Code Description Code Description

F01 VCM Memory Check Warning F54 Lift Solenoid Leak
F02 VCM Battery Voltage Warning F55 Tilt Forward Solenoid Warning
F03 VCM Communication Warning F57 Tilt Backward Solenoid Warning
F07 MP Communication Warning F59 Tilt Solenoid Leak
F10 Lift Lever Neutral Warning F60 Attachment 1A Solenoid Warning
F11 Tilt Lever Neutral Warning F62 Attachment 1B Solenoid Warning
F12 Attachment 1 Lever Neutral Warning F64 Attachment 1 Solenoid Leak
F13 Attachment 2 Lever Neutral Warning F65 Attachment 2A Solenoid Warning
F14 Attachment 3 Lever Neutral Warning F67 Attachment 2B Solenoid Warning
F16 Shift Lever Warning F69 Attachment 2 Solenoid Warning
F17 Vehicle Speed Warning F70 Attachment 3A Solenoid Warning
F20 Lift Lever Warning F72 Attachment 3B Solenoid Warning
F22 Tilt Lever Warning F73 Hour meter gap
F24 Attachment 1 Lever Warning F74 Attachment 3 Solenoid Leak
F26 Attachment 2 Lever Warning F75 Unload Solenoid Warning
F28 Attachment 3 Lever Warning F79 Unload Solenoid Leak
F29 Joystick Lever Warning F85 Transmission Forward Solenoid Warning
F31 VCM Sensor Voltage Warning F87 Transmission Backward Solenoid Warning
F34 Vehicle Speed Sensor Warning F89 Transmission Solenoid Leak
F41 Output Unit Warning F93 Speed Change Solenoid 1 Warning
F44 Output Unit PWM Voltage Warning F96 EAT Setting Warning
F45 Output Unit Communication Warning
F46 Input Unit Warning P03 VCM Communication Warning
F49 Input Unit Communication Warning P07 MP Communication Warning
F50 Lift Up Solenoid Warning
F52 Lift Down Solenoid Warning

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