99730-86120 GC35K Omm 2013-05e1 Cat

Operation & Maintenance Manual
GC35K AT87B-00001-09999
GC40K AT87B-00001-09999
GC40K STR AT87B-00001-09999
GC45K SWB AT87B-00001-09999
GC45K STR AT87B-00001-09999
GC55K AT88B-00001-09999
GC55K STR AT88B-00001-09999
GC60K AT89B-00001-09999
GC70K AT89B-00001-09999
GC70K STR AT89B-00001-09999
Keep this manual in your lift truck as a ready reference 99730-86120

FOREWORD
FOREWORD
The Occupational Safety and Health Administration (OSHA) prohibits employees under the age of 18 years old from operating
lift trucks, and 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 read this manual to understand the following points:
(1) Working capabilities and limitations of the lift truck
(2) Make-up of the lift truck
(3) Safe driving and load handling procedures
It is the employer's responsibility to make sure the operator can see, hear and has the physical and mental ability to operate the
lift truck safely.
It is also important that a qualified person experienced in lift truck operation should guide new operators through several
driving and load handling operations before they attempt to operate the lift truck on their own.
Note: - If you resell a lift truck, be sure to attach the original

Operation & Maintenance Manual to the lift truck. In
- This manual contains information necessary for the some countries, strict regulations do not allow
operation and "Do-it-yourself" maintenance of imported lift trucks for resale. For resale information,
standard lift trucks. contact your authorized Cat® lift truck dealer.
- Optional equipment is sometimes installed; it can - If a lift truck is resold from another country, an
change some operating characteristics described in this Operation & Maintenance Manual attached to the lift
manual. Before operating such a lift truck, make sure truck may not meet your country's rules and
the necessary instructions are available and regulations. For manual information, contact your
understood. authorized Cat® lift truck dealer.
- Lift truck operator training is provided through your - If your lift truck has an attachment, refer to the
authorized Cat® lift truck dealer. attachment supplier for the proper attachment
They will be glad to help you and answer any questions operating instructions.
you may have about operating your new lift truck. Lift
trucks are NOT intended for use on public roads.
i
FOREWORD
How to Use This Manual
The following safety signs and NOTE are used in this manual to emphasize important and critical instructions:
R 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.
Be sure to read these precautionary instructions and all safety related decals installed on your lift truck before you operate it.
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious
R DANGER injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious
R WARNING injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided,
R CAUTION
could result in minor or moderate injury.
Note: Note indicates important matters and useful information on operation and maintenance.
Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot DIRECTIONAL TERMS:

anticipate every possible circumstance that might involve a
The directions "Left", "Right", "Front", and "Rear" are given
potential hazard. The warnings in this publication and on
from the viewpoint of the operator facing forward.
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 that it does not pose a safety hazard to
yourself and others. You should also ensure the product will
not be damaged or made unsafe by the operation,
lubrication, maintenance, or repair procedures you choose.
All information, specifications, and illustrations in this
manual are based on the latest data available at the time of
publication. The specifications, 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 authorized Cat® lift truck dealer before starting any job.
Additional manuals are available from your authorized Cat®
lift truck dealer.
ii
FOREWORD
 Truck Models Covered in This Manual
Truck model Class Serial number

GC35K 3.5 ton class
GC40K 4.0 ton class
GC45K STR AT87B-00001-up
GC45K SWB 4.5 ton class
GC45K STR
GC55K
5.5 ton class AT88B-00001-up
GC55K STR
GC60K 6.0 ton class
GC70K AT89B-00001-up
7.0 ton class
GC70K STR
iii
TABLE OF CONTENTS
1. SAFETY RULES FOR LIFT TRUCK OPERATORS ....................... 1-1 Driving Interlock System ..................................................... 2-16
General ............................................................................... 1-1  Driving Interlock System Functions ................................................. 2-16
Location of Decals and Plate ................................................. 1-2 Neutral System................................................................... 2-17
Description of Danger, Warning, and Caution Decals .............. 1-4  Neutral System Functions ............................................................... 2-17
 Fasten Seat Belt Decal ...................................................................... 1-4 Operator Seat..................................................................... 2-18

 Survive in a Tipover Decal ................................................................. 1-4  Seat Adjustment ............................................................................. 2-18
 Overhead Guard Decal ...................................................................... 1-5  Forward and Back Adjustment ........................................................ 2-18
 LPG Fuel Cylinder Replacement Procedure Decal .............................. 1-5  Lumbar Support Adjustment .......................................................... 2-18
 Safety Maintenance Procedure Decal ............................................... 1-6  Adjustment of Suspension .............................................................. 2-19
 Parking Brake Adjustment Decal ...................................................... 1-7  How to Tip the Operator Seat Forward ............................................ 2-19
 No Access With Engine Running Decal .............................................. 1-7  Operator Presence Switch ............................................................... 2-19
 Radiator Cap Decal ........................................................................... 1-7 Seat Belt ............................................................................ 2-20

 No One Under / On Forks and No One Between Mast and Engine Hood....................................................................... 2-22
Chassis Decal .................................................................................... 1-8  Hood Latch ...................................................................................... 2-23
 Pinch Point Decal .............................................................................. 1-8 Assist Grip .......................................................................... 2-23

 Load Backrest Extension Decal .......................................................... 1-8 Drawbar Pin ....................................................................... 2-24
 Capacity Plate ................................................................................... 1-9  Radiator Cover ................................................................................ 2-24
 Operation Warning Decal ................................................................. 1-9  Back-up Buzzer ............................................................................... 2-24
 No Riders Warning Decal ................................................................ 1-10
 Backup Alarm Decal ........................................................................ 1-10

3. HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE ............. 3-1
 Operator Restraint System Decal .................................................... 1-10
Know What Lift Truck Stability Is ........................................... 3-1
 Engine Coolant Decal ...................................................................... 1-11
Center of Gravity (CG)............................................................ 3-1
 No Contamination Permissible Decal .............................................. 1-11
Stability and Center of Gravity (Top View).............................. 3-1
 Precautions for Handling ECU Decal ................................................ 1-11
Lift Truck Stability Base......................................................... 3-2
 Inspection/Lubrication Chart Decal ................................................. 1-12
Capacity (Weight and Load Center)........................................ 3-2
 Designated Tire Type Decal ............................................................. 1-12
Capacity Plate...................................................................... 3-3
Safety Rules....................................................................... 1-13  Sample ............................................................................................. 3-3
Operating Precautions........................................................ 1-23 Do’s and Dont’s to Avoid Tipover ............................................ 3-4
Working Precautions .......................................................... 1-28 How to Survive in a Tipover................................................... 3-9
LP-Gas................................................................................ 1-35
4. REFUELING ..................................................................... 4-1
2. KNOW YOUR LIFT TRUCK .................................................. 2-1 LP-Gas Equipped .................................................................. 4-1
Serial Number and Capacity Plate ......................................... 2-1  For Standard LP-Gas Tank ................................................................. 4-2
Model View.......................................................................... 2-2  For Optional LP-Gas Tank .................................................................. 4-3
Driving Switches and Controls............................................... 2-3

5. OPERATION .................................................................... 5-1
 Key Switch ........................................................................................ 2-5
New Lift Truck Break-in ........................................................ 5-1
 Turn Signal (If Equipped) / Light Switch ........................................... 2-6
Before Starting Engine......................................................... 5-1
 Direction Lever ................................................................................. 2-6
Starting Engine ................................................................... 5-3
 Parking Brake Lever .......................................................................... 2-7
 LP-Gas Engine Model ....................................................................... 5-3
 Horn ................................................................................................. 2-7
Engine Won't Start................................................................ 5-3
 Electronic Transmission Control Unit (E.C.U.) .................................... 2-7
After Starting Engine ........................................................... 5-3
 Accelerator Pedal .............................................................................. 2-8
Before Moving Lift Truck ...................................................... 5-4
 Brake Pedal ...................................................................................... 2-8
Lift Truck Operation ............................................................. 5-5
 Inching Pedal ................................................................................... 2-8
 Changing Speed ................................................................................ 5-6
 Steering Column Tilt Lever ............................................................... 2-9
 Changing Direction ........................................................................... 5-6
 Rear View Mirror (If Equipped) ......................................................... 2-9
 Operating Techniques ....................................................................... 5-7
 Foot Direction Control (Option) ........................................................ 2-9
 Steering (Turning) ........................................................................... 5-7
 Lift Lever ........................................................................................ 2-10
 Inching ............................................................................................. 5-8
 Tilt Lever ......................................................................................... 2-10
Stopping Lift Truck............................................................... 5-9
 Attachment Lever ........................................................................... 2-10
Parking Lift Truck (After Stopping)......................................... 5-9
 Mast Vertical Switch (Option) ......................................................... 2-11
Switch Box ......................................................................... 2-12
Meter Panel ....................................................................... 2-13
 Warning Icons and Indicator Lights ................................................ 2-13
 Warning Icons and Indicators ......................................................... 2-14

Mast Interlock System......................................................... 2-15
 Mast Interlock System Functions .................................................... 2-15
TOC-1
TABLE OF CONTENTS
6. OPERATING TECHNIQUES ................................................. 6-1 11. MAINTENANCE ..............................................................11-1
Stacking Methods ................................................................ 6-1 General...............................................................................11-1
 Stacking Different Size Loads ............................................................ 6-1 Inspection Precautions ........................................................11-2
 Stacking Small Identical Loads ......................................................... 6-1 Maintenance Schedule ........................................................11-3
 Stacking Large Identical Loads .......................................................... 6-1  Every 10 Service Hours or Daily (Prestart), Whichever Comes First ..11-3
Handling Loads Safely.......................................................... 6-2  Every 50 Service Hours or Weekly, Whichever Comes First ..............11-4
 Adjusting Fork Spread ...................................................................... 6-3  One Month (30 Days) or 200 Service Hours After Delivery of a
Before Operating the Lift Truck ............................................. 6-4  New Lift Truck, Whichever Comes First ...........................................11-4
Blinking of the Mast Interlock Indicator Icons ........................ 6-5  Every 200 Service Hours or Monthly, Whichever Comes First ...........11-5
Lifting the Load.................................................................... 6-6  Every 1200 Service Hours or 6 Months, Whichever Comes First .......11-6
Traveling With the Load........................................................ 6-8  Every 2400 Service Hours or 12 Months, Whichever Comes First .....11-6
Unloading.......................................................................... 6-10 Every 10 Service Hours or Daily (Prestart),
Working on Grades............................................................. 6-13 Whichever Comes First.........................................................11-8
 Normal Travel Position ................................................................... 6-13  Faulty Operation Found the Day Before ...........................................11-8
 Traveling on a Grade ....................................................................... 6-13  Brake Pedal .....................................................................................11-8
 Stopping on a Grade ....................................................................... 6-14  Parking Brake Lever ........................................................................11-9

Starting on a Grade (Engine Stalls on a Grade) ..................... 6-14  Brake Fluid Level .............................................................................11-9
 Engine Coolant ..............................................................................11-10

7. STORING THE LIFT TRUCK ................................................. 7-1  Battery ..........................................................................................11-11
End of Each Shift Storage...................................................... 7-1  Electric Wires ................................................................................11-12
Long Term Storage............................................................... 7-1  Horn ..............................................................................................11-12
 Storage Within Three Months ........................................................... 7-1  Icons of Meter Panel ......................................................................11-12
 Storage Exceeding Three Months ...................................................... 7-2  Head Lights and Working Lights ...................................................11-12
 Backup Lights ................................................................................11-13

8. TRANSPORTATION HINTS ................................................. 8-1
 Stop Lights ....................................................................................11-13
Lift Truck Loading and Shipping ............................................ 8-1
 Turn Signal Lights (If Equipped) ....................................................11-13
Lift Truck Lifting and Tie Down Information ........................... 8-1
 Driving Interlock System ...............................................................11-14
9. SPECIAL SITUATIONS ...................................................... 9-1  Mast Interlock System ...................................................................11-15
Care in Cold Weather ............................................................ 9-1  Engine (Exhaust, Noise, and Vibration) .........................................11-15
 Engine Crankcase ..........................................................................11-16

 Lubrication Oils ................................................................................. 9-1
 Assist Grip .....................................................................................11-17
 Battery .............................................................................................. 9-1
 Overhead Guard ............................................................................11-17
 Engine Coolant ................................................................................. 9-1
Care in Hot Weather ............................................................. 9-2  Operator Seat ................................................................................11-18
 Seat Belt ........................................................................................11-18

 Lubrication Oils ................................................................................. 9-2
 Rear View Mirror (If Equipped) ......................................................11-18
 Battery .............................................................................................. 9-2
 Amount of Fuel (Lift truck level) ...................................................11-18
 Engine Coolant ................................................................................. 9-2
Severe Dust or Lint Conditions .............................................. 9-3  Hydraulic Oil ..................................................................................11-19
 Lift Chains .....................................................................................11-20
 Air Cleaner Element .......................................................................... 9-3
 Tilt Cylinder Socket Bolts ...............................................................11-21
 Engine Oil and Engine Oil Filter ........................................................ 9-3
 Mast and Forks ..............................................................................11-21
 Hydraulic Oil ..................................................................................... 9-3
 Hydraulic Tank Return Filter ............................................................. 9-3  Load Backrest Extension ................................................................11-23
 Steering Wheel .............................................................................11-23
10. TROUBLESHOOTING ...................................................... 10-1  Accelerator Pedal ..........................................................................11-23
Stalled Engine.................................................................... 10-1  Inching Pedal ................................................................................11-24
 Before Starting the Engine Again .................................................... 10-1  Wheel Nuts ...................................................................................11-24
If the Water Temperature Warning Icon Glows ..................... 10-1  Tires and Rims ...............................................................................11-24
If Torque Converter Oil Temperature Warning Icon Glows...... 10-2  Oil Leaks and Damage of Piping ....................................................11-25
Starting With Jumper Cables ............................................... 10-3  Oil, Fuel, or Coolant Leaks .............................................................11-25
If Lights Won't Glow ........................................................... 10-4 Every 50 Service Hours or Weekly, Whichever Comes First.....11-25
 How to Check Fuses and Lights ....................................................... 10-5  Alternator Drive Belt .....................................................................11-25
Trouble with the LP-Gas Equipment..................................... 10-6  Air Cleaner Element ......................................................................11-27
If the Lift Truck Won’t Change Direction ............................... 10-7  Mast Supports ...............................................................................11-29
If the Lift Truck Won’t Move ................................................ 10-8  Bolts and Nuts ...............................................................................11-29
If the Mast Stops Moving..................................................... 10-9 One Month (30 days) or 200 Service Hours after Delivery of a
New Lift Truck, Whichever Comes First................................11-29
 Fuel Filter .....................................................................................11-29
 Hydraulic Tank Return Oil Filter .....................................................11-29
TOC-2
TABLE OF CONTENTS
Every 200 Service Hours or Monthly, Whichever Comes First. 11-29
 Brake Pedal .................................................................................. 11-29
 Engine Crankcase ......................................................................... 11-30
 Lift Chains ..................................................................................... 11-31
 Lift Bracket Side Rollers ................................................................ 11-31
 Mast Strip Roller Surfaces ............................................................. 11-32

 Tilt Socket Pins ............................................................................. 11-32
 Tilt Cylinder Pins ........................................................................... 11-32
 Rear Axle Center Pins .................................................................... 11-32
 Tie Rod Ends ................................................................................. 11-33
 Differential Oil .............................................................................. 11-33
 Transmission Oil ........................................................................... 11-34

Every 1200 Service Hours or 6 Months,
Whichever Comes First ...................................................... 11-35
 Fuel Filter ..................................................................................... 11-35
 Fuel Filter Tier II ........................................................................... 11-37
 Hydraulic System .......................................................................... 11-38
 Air Cleaner Element ...................................................................... 11-39

Every 2400 Service Hours or 12 Months,
Whichever Comes First ...................................................... 11-40
 Brake Fluid ................................................................................... 11-40
 Hydraulic Oil ................................................................................. 11-40
 Transmission Oil ........................................................................... 11-42
 Differential Oil .............................................................................. 11-43
 Engine Coolant ............................................................................. 11-44

Parts to Be Replaced Periodically....................................... 11-47
 Safety Critical Parts ...................................................................... 11-47
12. SERVICE DATA ............................................................... 12-1

Fuel Information ................................................................ 12-1
 LP-Gas Specifications ...................................................................... 12-1
Coolant Information ........................................................... 12-1
 Coolant Water ................................................................................ 12-1
 Antifreeze Solution ......................................................................... 12-2

Recommended Fuels and Oils .............................................. 12-2
Specifications ..................................................................... 12-3
Capacities and Lift Truck Weight .......................................... 12-4
13. TO THE CAT LIFT TRUCK OWNER ...................................... 13-1

The Importance of Genuine Parts......................................... 13-1
Proper Disposal of Your Lift Truck ........................................ 13-1
Instructions for Ordering Parts ............................................ 13-2
Service Registration............................................................ 13-3
Transfer of Ownership Report for Cat Lift Trucks
Customers Only................................................................... 13-4
TOC-3
SAFETY RULES FOR LIFT TRUCK OPERATORS
 SAFETY RULES FOR LIFT TRUCK OPERATORS
 General
The safety rules and regulations in this section are Continuing improvement and advancement of product
representative of some, but not all rules and regulations design may have caused changes to your lift truck, which
that apply to lift trucks. Rules are paraphrased without are not included in this publication. Whenever a question
representation that they have been reproduced verbatim. arises regarding your lift truck, or this publication, please
consult your authorized Cat® lift truck dealer for the latest
Your lift truck was manufactured in accordance with the
available information.
National Fire Protection Association (NFPA) No. 505 and the
American National Standards Institute, Inc. / Industrial Truck All lift truck users should be familiar with their Local,
Standards Development Foundation (ANSI/ITSDF) B56.1, Regional, and National regulations. United States users
Safety Standard for Low and High Lift Trucks. Operate this should be familiar with the Occupational Safety and Health
lift truck in accordance with local regulations. Administration (OSHA), and ANSI/ITSDF B56.1, Safety
Standard for Low and High Lift Trucks.
See www.itsdf.org web site for more information on the
B56.1 Safety Standards for Low Lift and High Lift Trucks. See www.osha.gov web site for more information on
Regulations (Standards -- 29 CFR) Powered industrial trucks -
The most effective way of reducing the risk of serious
- 1910.178.
injuries, or even death, to you and others, is for you to know
how to operate the lift truck properly. Drive alertly and You should also be familiar with areas of use of different
avoid maneuvers or conditions that could cause accidents. types of lift trucks as specified in the National Fire Protection
Association (NFPA) 505.
Be professional.
Do not operate a lift truck if it is in need of maintenance,
repair or appears to be unsafe in any way. Report all unsafe
conditions immediately to your supervisor, then contact
your authorized Cat® lift truck dealer.
Do not attempt any adjustments or repairs unless you are
trained and authorized to do so.
1-1
 Location of Decals and Plate
- There are several specific decals on your lift truck. Their exact location and description of the potential hazard are reviewed
in this manual. Refer to attachment manufactures documentation for attachment decals. Please take the time to
familiarize yourself with these decals.
- Make sure you can read all decals. If you cannot, clean, or replace them. Use a cloth and soap and water to clean them.
- You must replace a decal if it is damaged, missing, or cannot be read. If a decal is on a part that is changed, make sure a
new decal is placed on the new part. Contact your authorized Cat® lift truck dealer for new decals.
1 16 2
4
32,000
3 5
14 15
9#40+0)
13
IMPROPER OPERATION OR
MAINTENANCE COULD RESULT
IN INJURY OR DEATH
MODEL: MAX MAST: VERTICAL

FORK
SERIAL NO: HEIGHT
mm
ATTACH 1:
ATTACH 2:
TRUCK WEIGHT A-LOAD CENTER

in
B-OFFSET
A
CAPACITY
B 9#40+0)
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7
±５％
kg lbs
mm in mm in kg lbs 㧭㧼㧼㧸㨅‫ޓ‬㧼㧭㧾㧷㧵㧺㧳‫ޓ‬㧮㧾㧭㧷㧱
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#&,756.'8'41224#6+0)
MEETS DESIGN SPECIFICATIONS OF ANSI/ITSDF B56.1
ＥＮＧＬＩＳＨ９３０８３−０７８０１ (14%'2412'4.;
㧼㧾㧻㧼㧱㧾‫ޓ‬㧻㧼㧱㧾㧭㨀㧵㧺㧳‫ޓ‬㧲㧻㧾㧯㧱㧚
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12 -01$
10
8
11
D00833
DANGER (8) No Access With Engine Running Decal

(9) Radiator Cap Decal
(1) Fasten Seat Belt Decal
(10) No One Under/On Forks and No One Between Mast and
(2) Survive in a Tipover Decal Chassis Decal
WARNING (11) Pinch Point Decal
(3) Survive in a Tipover Decal (12) Load Backrest Extension Decal
(4) Overhead Guard Decal (13) Capacity Plate
(5) LPG Fuel Cylinder Replacement Procedure Decal (14) Operating Warning Decal
(6) Safety Maintenance Procedure Decal (15) Backup Alarm Decal
(7) Parking Brake Adjustment Decal (16) No Riders Warning Decal
1-2
LUBRICATION AND MAINTENANCE CHART BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW
CHECK CHANGE LUBRICATE
EVERY 10HR,OR DAILY OIL,FLUID MULTIPURPOSE-TYPE GREASE
ENGINE OIL LEVEL --- FILTER ENGINE OIL
COOLANT LEVEL EVERY 50HR,OR WEEKLY
HYDRAULIC OIL LEVEL EVERY 200HR,OR MONTHLY
ENGINE OIL MAST SUPPORT BUSHINGS
BRAKE FLUID LEVEL (EACH SIDE)
STEERING WHEEL --- ENGINE OIL FILTER
EVERY 200HR,OR MONTHLY
5
TIRES
WHEEL HUB NUTS,RIMS
MAST,FORKS
BATTERY ELECTROLYTE LEVEL
EVERY 1200HR,OR 6MONTHS
POWER SHIFT TRANSMISSION
OIL
FINAL REDUCTION &
LIFT CHAINS(EACH SIDE)
MAST & LIFT BRACKET SIDE
ROLLERS(EACH SIDE)
MAST STRIPS SURFACES
%#76+10 1
6
DIFFERENTIAL OIL (EACH SIDE) 㨀㨔㨕㨟‫ޓ‬㨕㨚㨐㨡㨟㨠㨞㨕㨍㨘‫ޓ‬㨠㨞㨡㨏㨗‫ޓ‬㨕㨟‫ޓ‬㨑㨝㨡㨕㨜㨜㨑㨐‫ޓ‬㨣㨕㨠㨔
EVERY 50HR,OR WEEKLY --- HYDRAULIC TANK OIL FILTER TILT SOCKET PINS(EACH SIDE) 㨍㨚‫ޓ‬㨛㨜㨑㨞㨍㨠㨛㨞‫ޓ‬㨞㨑㨟㨠㨞㨍㨕㨚㨠‫ޓ‬㨟㨥㨟㨠㨑㨙㧚㧿㨔㨛㨡㨘㨐
CLEAN AIR CLEANER ELEMENT --- POWER SHIFT TRANSMISSION TILT CYLINDER PINS(EACH SIDE) 㨕㨠‫ޓ‬㨎㨑㨏㨛㨙㨑‫ޓ‬㨚㨑㨏㨑㨟㨟㨍㨞㨥‫ޓ‬㨠㨛‫ޓ‬㨞㨑㨜㨘㨍㨏㨑‫ޓ‬㨍㨚㨥‫ޓ‬㨛㨒
BOLTS,NUTS OIL FILTER 㨠㨔㨑‫ޓ‬㨏㨛㨙㨜㨛㨚㨑㨚㨠㨟㧘㨕㨚㨏㨘㨡㨐㨕㨚㨓‫ޓ‬㨠㨔㨑‫ޓ‬㨟㨑㨍㨠
--- FUEL FILTER ELEMENT UNIVERSAL JOINT(2FITTINGS) 㨍㨟㨟㨑㨙㨎㨘㨥㧘㨒㨛㨞‫ޓ‬㨍㨚㨥‫ޓ‬㨞㨑㨍㨟㨛㨚㧘㨕㨠‫ޓ‬㨙㨡㨟㨠‫ޓ‬㨛㨚㨘㨥
FAN BELT
ALTERNATOR DRIVE BELT --- AIR CLEANER ELEMENT BRAKE PEDAL 㨎㨑‫ޓ‬㨞㨑㨜㨘㨍㨏㨑㨐‫ޓ‬㨣㨕㨠㨔‫ޓ‬㨏㨛㨙㨜㨛㨚㨑㨚㨠㨟‫ޓ‬㨍㨜㨜㨞㨛㨢㨑㨐
㨎㨥‫ޓ‬㨠㨔㨑‫ޓ‬㨙㨍㨚㨡㨒㨍㨏㨠㨡㨞㨑㨞㧚
EVERY 200HR,OR MONTHLY EVERY 2400HR,OR 1YEAR WATER PUMP
FINAL REDUCTION & HYDRAULIC OIL REAR AXLE SUPPORTS
(FRONT & REAR)
DIFFERENTIAL OIL LEVEL BRAKE FLUID
TIE ROD PINS(4FITTINGS)
OIL LEVEL
ＮＯＴＥ：ＲＥＤＵＣＥＳＥＲＶＩＣＩＮＧＩＮＴＥＲＶＡＬＳＩＮＤＵＳＴＹＯＲＳＥＶＥＲＥＲＣＯＮＤＩＴＩＯＮＳ，ＲＥＦＥＲＴＯＯＰＥＲＡＴＩＯＮＭＡＮＵＡＬ．
10
㧯㧭㧼㧭㧯㧵㨀㨅‫ޓ‬㧿㧼㧱㧯㧵㧲㧵㧱㧰‫ޓ‬㧲㧻㧾‫ޓ‬㨀㧴㧱‫ޓ‬㨀㧾㨁㧯㧷‫ޓ‬㧾㧱㧽㨁㧵㧾㧱㧿
㨀㧵㧾㧱㧿‫ޓ‬㧭㨁㨀㧴㧻㧾㧵㨆㧱㧰‫ޓ‬㧮㨅‫ޓ‬㨀㧴㧱‫ޓ‬㧹㧭㧺㨁㧲㧭㧯㨀㨁㧾㧱㧾
9
7
AS TO FIRE HAZARD ONLY
TYPE ＬＰ
R
INDUSTRIAL TRUCK
No. 2
AU2187
8 6
MODEL SERIAL No.
㨀㧵㧾㧱‫ޓ‬㧼㧾㧱㧿㧿㨁㧾㧱‫ޓ‬㧲㧾㧾㧱 psi
3
deg.
in.
HOUSTON,USA
ＥＮＧＬＩＳＨ９３０８３−０８６０１
4
D00834C
CAUTION OTHERS
(1) Operator Restraint System Decal (5) Inspection / Lubrication Chart Decal
(2) Engine Coolant Decal (6) Hook Decal for Hoisting Point
(3) No Contamination Permissible Decal (7) LPG Fuel Decal
(4) Precautions for Handling E.C.U. Decal (8) Manufacturer Name Plate
(9) UL Plate
(10) Designated Tire Type Decal
1-3
 Description of Danger, Warning, and Caution Decals
 Fasten Seat Belt Decal
R DANGER
Tipover will occur if lift truck is improperly operated. Injury
or death will result.
D00835
 Survive in a Tipover Decal
R DANGER
TIPOVER CAN OCCUR IF TRUCK IS IMPROPERLY OPERATED.
INJURY OR DEATH COULD RESULT.
D00836
R WARNING
FOR SAFETY NOTICE FOLLOWING WARNINGS
(1) Lateral tipover can occur when unloaded if the
combination of speed and sharpness of turn produces
an overturning moment which exceeds the stability of
the lift truck.
(2) Lateral tipover can occur if overloaded or loaded within
capacity and the load is elevated and if turning and/or
braking when traveling rearward or if turning and/or
accelerating when traveling forward produces an
overturning moment which exceeds the stability of the
lift truck.
- Rearward tilt and/or off-center positioning of the load D00837
and/or uneven ground conditions will further
aggravate the above conditions.
(3) Longitudinal tipover can occur if overloaded or when loaded within capacity of the load is elevated if forward tilt, braking
in forward travel, or commencing rearward travel produces an overturning moment which exceeds the stability of the lift
truck.
(4) Serious injury or death can occur to the operator if he/she is trapped between the lift truck and the ground.
IN CASE OF TIPOVER
(1) The operator should stay with lift truck if lateral or longitudinal 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) The operator should stay with the lift truck if it falls off a loading dock or ramp. There are other situations where the
environment of landing area presents a severe hazard. In those incidents, it may be prudent for the operator to leave the
lift truck.
1-4
 Overhead Guard Decal
R WARNING
Operation without this device in place may be hazardous.
32,000
D00849
 LPG Fuel Cylinder Replacement Procedure Decal
R WARNING
LPG FUEL CYLINDER REPLACEMENT PROCEDURE
LPG FUEL IS HIGHLY FLAMMABLE
(1) NO SMOKING. DO NOT replace fuel cylinder in areas
that have a source of fuel ignition.
(2) Close cylinder fuel supply valve and run engine until it
stops prior to disconnecting the fuel hose from the
tank.
(3) Replace the fuel cylinder. BE SURE that the fuel supply
valve is closed and that the size and type are per the
cylinder description plate. Securely mount and position
with locating pin through positioning hole in collar. D00723
Cylinder must not extend outside the plan profile of the
lift truck.
(4) Connect fuel hose. Open valve slowly so the hose and
tank pressure can equalize or the excess flow check
valve may slug. Should leakage occur, close valve and
have qualified personnel make repairs.
(5) Use fuel manufactured to the National Gas Processors
Association “HD-5” specification
1-5
 Safety Maintenance Procedure Decal
R WARNING
RECOMMENDED SAFETY MAINTENANCE PROCEDURE
FOR LP GAS FUELED LIFT TRUCKS
(1) LP-Gas is a combustible fuel that is heavier than air.
Escaping gas may accumulate in low areas which could
cause a fire or explosion.
(2) The fuel cylinder must be mounted so that it does not
extend outside the plan profile of the lift truck and must
be properly positioned with the locating pin through
positioning hole in collar.
(3) The fuel supply valve must be turned OFF when the lift
truck is not in service.
D00850
(4) Cast fittings must not be used in the LP-Gas system.
(5) All pipe threaded fittings must be installed using an (9) The complete LP-Gas system must be inspected
approved sealing compound. periodically. Check all hoses for wear, connections for
(6) Fuel lines must be supported by clamps to minimize leaks, and all parts for damage.
chafing and wear. Note: Fuel hoses have a limited expectancy. They must be
(7) The LP-Gas solenoid valve must be wired to an checked for cracking and drying due to age. Hoses
automatic shut off switch (oil pressure or vacuum) to with visible signs of age must be replaced. Use only
prevent leakage of gas in the event the ignition is on Underwriters Laboratories or Factory Mutual Listed
without the engine running.
LP-Gas hose assemblies where pressure fuel lines are
(8) Check the propane solenoid or vacuum shutoff valve required.
for leakage as follows:
- Turn cylinder fuel supply valve OFF. Start and run (10) Contact the manufacturer for detailed service
engine until it stops. information.
- Install a 0 to 30 PSI pressure gauge to the primary test Note: The above information is provided as a guide. Consult
port of the regulator. National Fire Protection Association pamphlet 58.
NFPA 505 and local governmental safety regulations
- Turn cylinder fuel supply valve ON. The pressure gauge
for the safe storage and handling of liquefied
must be repaired or replaced. An odor is added to LP-
Gas to help detect leaks. If gas odor is detected the petroleum gases.
cylinder fuel supply valve and engine must be turned SERVICE WORK SHOULD BE PERFORMED BY
OFF. Remove all sources of ignition, and ventilate the QUALIFIED PERSONNEL ONLY
area. Make all of the necessary repairs before turning
the fuel supply ON.
1-6
 Parking Brake Adjustment Decal
R WARNING
- When leaving the lift truck, apply parking brake!
Parking brake is not automatically applied.
- Adjust parking brake lever operating force properly.
:$51,1*
㹕㹆㹃㹌ࠉ㹊㹃㸿㹔㹇㹌㹅ࠉ㹋㸿㹁㹆㹇㹌㹃
㸿㹎㹎㹊㹗ࠉ㹎㸿㹐㹉㹇㹌㹅ࠉ㹀㹐㸿㹉㹃
㹎㸿㹐㹉㹇㹌㹅ࠉ㹀㹐㸿㹉㹃ࠉ㹇㹑ࠉ㹌㹍㹒
㸿㹓㹒㹍㹋㸿㹒㹇㹁㸿㹊㹊㹗ࠉ㸿㹎㹎㹊㹇㹃㹂
$'-867/(9(52335$7,1*
)25&(3523(5/<
㹎㹐㹍㹎㹃㹐ࠉ㹍㹎㹃㹐㸿㹒㹇㹌㹅ࠉ㹄㹍㹐㹁㹃㸬
ࠉࠉࠉࠉࠉࠉࠉ㸰㸳㹼㸱㸮㹩㹥
ࠉࠉࠉࠉࠉࠉࠉ㸳㸳㹼㸴㸴㸯㹠㹱
.12%
D00851
Operating Force
245 to 294 N (25 to 30 kgf) [55 to 66 lbf]
 No Access With Engine Running Decal
R WARNING
To avoid serious injury, stay clear of the moving fan.
D00843
 Radiator Cap Decal
R WARNING
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.
D00842
1-7
 No One Under / On Forks and No One Between Mast and Chassis Decal
R WARNING
- DO NOT stand or walk under the forks.
- DO NOT stand or ride on the forks.
- DO NOT stand or ride on a load or pallet on the forks.
- DO NOT place any part of your body between the mast
and the lift truck chassis.
DA0010
91A83-01700
 Pinch Point Decal
R WARNING
Moving Mast—Crush Points.
Keep All Body Parts Clear of Mast.
D00361
 Load Backrest Extension Decal
R WARNING
OPERATION WITHOUT THIS DEVICE IN PLACE MAY BE
HAZARDOUS
D00852
1-8
 Capacity Plate
R WARNING
Improper operation or maintenance could result in
injury or death
Capacity specified for the lift truck requires tires authorized
by the manufacturer.
D00717
 Operation Warning Decal
R WARNING
For safety observe the following warnings
(1) DO NOT operate this lift truck unless you have been
trained and authorized to do so. Read all warnings and
instructions in operator manual and on this lift truck.
Operation & Maintenance Manual is supplied with this
lift truck or available from our lift truck dealers.
(2) DO NOT operate this lift truck until you have checked its
condition. Give special attention to Tires, Rims, Horn,
Lights, 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. D00853
(3) Operate the lift truck only from designated operating (11) Travel with load or lifting mechanism as low as possible
position. DO NOT place any part of your body into the and tilted back. Always look in direction of travel. Keep
mast structure, between the mast and the lift truck, or a clear view, and when load interferes with visibility,
outside the lift truck. DO NOT carry passengers. travel with load or lifting mechanism trailing (except
(4) DO NOT operate the lift truck without the overhead when climbing ramps).
guard, unless conditions prevent use of the overhead (12) Use special care when operating on ramps. Travel
guard. Use special care if operation without overhead slowly, and do not angle or turn. When lift truck is
guard is required. loaded, travel with load uphill. When lift truck is empty,
(5) DO NOT handle loads which are higher than the load travel with lifting mechanism downhill.
backrest or load backrest extension unless load is (13) Observe applicable traffic regulations. Yield right of
secured so that no part of it could fall backward. way to pedestrians. Slow down and sound horn at cross
(6) DO NOT handle unstable or loosely stacked loads. Use aisles and wherever vision is obstructed.
special care when handling long, high, or wide loads to (14) When using forks, space forks as far apart as load will
avoid losing the load, striking bystanders, or tipping the permit. Before lifting, BE SURE that load is centered and
lift truck. forks are completely under load.
(7) DO NOT overload the lift truck. Check capacity plate for (15) DO NOT allow anyone to stand or pass under load or
load weight and load center information. lifting mechanism.
(8) Start, stop, travel, steer, and brake smoothly. Slow (16) DO NOT lift personnel except on a securely attached
down for turns and on uneven or slippery surfaces that specially designed Work Platform. Use extreme care
could cause lift truck to slide or overturn. Use special when lifting personnel. Place mast in vertical position,
care when traveling without load as the risk of overturn place operating control levers in NEUTRAL and apply
is greater. brakes. Lift and lower smoothly. Be available to operate
(9) Elevate forks or other lifting mechanism only to pick up controls as long as personnel are on the Work Platform.
or stack a load. Lift and lower with mast vertical or tilted DO NOT transport personnel on forks or Work Platform.
slightly back. NEVER FORWARD. Watch out for (17) Before getting off lift truck, neutralize direction lever,
obstructions, especially overhead. fully lower lifting mechanism and apply parking brake.
(10) Operate tilting mechanism slowly and smoothly. DO When leaving lift truck unattended, also shut off power.
NOT tilt FORWARD when elevated except to pick up or
deposit a load. When stacking, use only enough
backward tilt to stabilize load.
1-9
 No Riders Warning Decal
R WARNING
To avoid serious injury, DO NOT carry passengers. This lift
truck is designed for only one operator and no riders.
D00839
 Backup Alarm Decal
R WARNING
This vehicle is equipped with a backup alarm.
Alarm must sound!
When operating this lift truck in REVERSE. Failure to
maintain a clear view in the direction of travel could result in
injury or death. The operator is responsible for the safe
operation of this lift truck.
D00838
 Operator Restraint System Decal
R CAUTION
This industrial lift 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 manufacturer.
D00714
1-10
 Engine Coolant Decal
R CAUTION
(1) DO NOT remove radiator filler cap except when
changing coolant.
(2) DO NOT remove radiator filler cap when coolant is hot.
(3) Check coolant level and refill at reserve tank.
(4) Maintain coolant level between FULL and LOW marks
on reserve tank when coolant is cold.
Note: Coolant level above FULL mark on reserve tank is not
abnormal when coolant is hot.
REFILLING
(1) Remove radiator filler cap (pressure valve) and refill up
to top of filler neck. D00734
(2) After refilling, tighten radiator filler cap (pressure valve)

securely.
(3) Remove reserve tank filler cap and refill up to FULL
mark on reserve tank.
(4) After refilling, tighten reserve tank filler cap securely.
 No Contamination Permissible Decal
R CAUTION
Clean outer surface of solenoid valve before removing for
repairs to avoid contamination. No contamination
permissible.
D00844
 Precautions for Handling ECU Decal
R CAUTION
Precautions for handling Electronic Control Unit
(ECU)
(1) DO NOT directly expose ECU to washing water, rain, oil,
and every other liquid.
(2) DO NOT apply force, open, modify ECU, nor operate the
lift truck without ECU.
(3) Turn the key switch OFF, disconnect battery cable and
then disconnect ECU, before following operations:
- Removing ECU from lift truck
- Welding for modification of lift truck
D00845
1-11
 Inspection/Lubrication Chart Decal
Be sure to perform service items quoted below.
LUBRICATION AND MAINTENANCE CHART BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW
CHECK CHANGE LUBRICATE
EVERY 10HR,OR DAILY OIL,FLUID MULTIPURPOSE-TYPE GREASE
Note: Reduce servicing intervals in dusty or severer ENGINE OIL LEVEL --- FILTER ENGINE OIL
COOLANT LEVEL EVERY 50HR,OR WEEKLY
HYDRAULIC OIL LEVEL EVERY 200HR,OR MONTHLY
ENGINE OIL MAST SUPPORT BUSHINGS
BRAKE FLUID LEVEL (EACH SIDE)
STEERING WHEEL --- ENGINE OIL FILTER
TIRES EVERY 200HR,OR MONTHLY
WHEEL HUB NUTS,RIMS EVERY 1200HR,OR 6MONTHS LIFT CHAINS(EACH SIDE)
MAST,FORKS POWER SHIFT TRANSMISSION MAST & LIFT BRACKET SIDE
conditions, refer to operation manual. BATTERY ELECTROLYTE LEVEL OIL ROLLERS(EACH SIDE)
FINAL REDUCTION & MAST STRIPS SURFACES
DIFFERENTIAL OIL (EACH SIDE)
EVERY 50HR,OR WEEKLY --- HYDRAULIC TANK OIL FILTER TILT SOCKET PINS(EACH SIDE)
CLEAN AIR CLEANER ELEMENT --- POWER SHIFT TRANSMISSION TILT CYLINDER PINS(EACH SIDE)
BOLTS,NUTS OIL FILTER
--- FUEL FILTER ELEMENT UNIVERSAL JOINT(2FITTINGS)
FAN BELT
ALTERNATOR DRIVE BELT --- AIR CLEANER ELEMENT BRAKE PEDAL
EVERY 200HR,OR MONTHLY EVERY 2400HR,OR 1YEAR WATER PUMP

FINAL REDUCTION & HYDRAULIC OIL REAR AXLE SUPPORTS
(FRONT & REAR)
DIFFERENTIAL OIL LEVEL BRAKE FLUID
TIE ROD PINS(4FITTINGS)
OIL LEVEL
ＮＯＴＥ：ＲＥＤＵＣＥＳＥＲＶＩＣＩＮＧＩＮＴＥＲＶＡＬＳＩＮＤＵＳＴＹＯＲＳＥＶＥＲＥＲＣＯＮＤＩＴＩＯＮＳ，ＲＥＦＥＲＴＯＯＰＥＲＡＴＩＯＮＭＡＮＵＡＬ．
D00854
 Designated Tire Type Decal

Capacity specified for the truck requires tires authorized by
the manufacturer.
㹁㸿㹎㸿㹁㹇㹒㹗ࠉ㹑㹎㹃㹁㹇㹄㹇㹃㹂ࠉ㹄㹍㹐ࠉ㹒㹆㹃ࠉ㹒㹐㹓㹁㹉ࠉ㹐㹃㹏㹓㹇㹐㹃㹑
㹒㹇㹐㹃㹑ࠉ㸿㹓㹒㹆㹍㹐㹇㹘㹃㹂ࠉ㹀㹗ࠉ㹒㹆㹃ࠉ㹋㸿㹌㹓㹄㸿㹁㹒㹓㹐㹃㹐
D00855
1-12
 Safety Rules
R WARNING
Authorized and trained operators only!
DO NOT operate this lift truck unless you have a certificate
for operating this type of lift truck and have the ability to
operate the lift truck safely.
1)
CERTIFICATE
D00369
1) CERTIFICATE
R WARNING
Lift trucks are NOT intended for use on public roads.
D00370
R WARNING
Dress properly for the job!
Follow your employer guidelines for protective equipment.
DO NOT wear loose clothing or accessories (flapping cuffs,
dangling chains, necktie, scarves, or rings) that could catch
in moving parts.
Wear personal protective equipment appropriate for the
conditions of your work places.
D00651
R WARNING
Operate the lift truck safely within in the rules and
regulations of your employer.
D00726
1-13
R WARNING
Always be alert!
Know your employer guidelines and how to het prompt
assistance if involves in an accident.
D00279
R WARNING
No smoking while refueling!
DO NOT fill the fuel tank while the engine is running or the
operator is on the lift truck. Keep away from flames or spark
sources. Turn OFF all electrical switches on the lift truck.
Pump fuel in a well-ventilated area.
D00680
R WARNING
Know your lift truck is safe!
DO NOT operate any lift truck that is not safe to operate.
D00288L
R WARNING
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 must
take.
D00280A
1-14
R WARNING
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 changes
approved by the manufacturer requires a new capacity
plate and decals after modification.
D00681
R WARNING
Know the lift truck and attachments!
Read and understand the operating, inspection, and
maintenance instructions in the Operation & Maintenance
Manual and the decals on the lift truck.
D00682
R WARNING
Avoid being splashed by scalding hot coolant!
Wait until the engine cools before opening or loosening the
radiator cap. Stand to the side, protect your face, and slowly
loosen cap.
D00285
R WARNING
Turn OFF the key switch before servicing!
DO NOT service this lift truck while engine is running unless
absolutely necessary.
Contact your authorized Cat® lift truck dealer if needed.
D00283
1-15
R WARNING
Exhaust fumes could kill you!
Some of the systems from carbon monoxide poisoning are
headaches, flu like systems, food poisoning like symptoms,
fatigue or weakness. If you feel any of these symptoms,
leave the area and consult a doctor.
D00281
R WARNING
Inspect the lift truck prior to operation!
At the beginning of each shift, fill out a daily inspection
sheet. Defects when found must be immediately reported
and corrected before operating the lift truck, or the lift truck
must be taken out of service.
D00284L
R WARNING
DO NOT operate an unsafe lift truck!
If the lift truck has a "DO NOT OPERATE" or similar warning
tag, the lift truck must not be operated until it has been
restored to safe operating conditions. Inspect the lift truck T
NO TE
before you operate it. DO ERA
OP 1)
D00372
1. DO NOT OPERATE
R WARNING
LP-Gases are flammable!
DO NOT attempt to exchange or refill a LP-Gas tank unless
you are trained and authorized to do so.
D00376
1-16
R CAUTION
When handling Engine Control Module (ECM) and
Electric transmission control unit (ECU)!
1
(1) DO NOT directly expose the ECM or ECU to washing
water, rain, oil, and every other liquid.
(2) DO NOT apply force, open, and modify these
2
equipment nor operate the lift truck without the ECM
or ECU.
(3) Turn the key switch OFF. Disconnect battery cable and
then disconnect the ECM or ECU before following
operations:
- Removing these equipment from the lift truck D00828
- Factory approved welding
1. Electric transmission control 2. Engine control module (ECM)
unit (ECU)
R WARNING
DO NOT operate the lift truck if you are pregnant or have
suffered an abdominal disease or injury.
D00725
R WARNING
DO NOT remove the overhead guard!
The overhead guard is intended to offer protection from the
impact of small packages, boxes, bagged material, etc.,
representative of the job application, but not to withstand
the impact of a falling capacity load.
D00559
R WARNING
DO NOT operate the lift truck under the influence of
drugs or alcohol!
Always stay healthy on the job. Operators of lift trucks must
be qualified as to visual, auditory, physical, and mental
ability to operate the lift truck safely.
D00282A
1-17
R WARNING
Keep the operator compartment clean!
Keep your hands and shoes, as well as the floor and controls
(steering wheel, levers, and pedals) clean and free of grease,
mud and other materials. A slip could cause an accident.
D00846
R WARNING
The back-up alarm must activate when traveling in
reverse!
Make sure the back-up alarm is in working order. The horn
can also be used to alert other lift trucks or pedestrians
when traveling in reverse. Always look in the direction of
travel.
D00829L
R WARNING
Operate only in approved areas!
Certain areas such as those containing hazardous
flammable gases, liquid, or other combustibles require a
Safety Rated lift truck. If your lift truck is not Safety Rated,
the area must be avoided.
D00293A
R WARNING
Sit in the operator seat when starting the engine!
Start the engine only when seated in the normal operating
position.
D00377A
1-18
R WARNING
DO NOT operate a damaged or defective lift truck!
If the lift truck is damaged, take it out of service until it has
been restored to a safe operating condition. Park it in a non-
operating area and remove the key. Attach a "DO NOT
OPERATE" or similar warning tag to the lift truck.
Contact your authorized Cat® lift truck dealer for repairs.
D00378A
R WARNING
Face the lift truck when getting on and off!
Maintain a three point contact (one foot and two hands)
with the foot step, the assist grip, and the seat backrest.
- DO NOT get on or off the moving lift truck.
- DO NOT jump on or off the lift truck.
- DO NOT use the operating control levers or steering
wheel as assist grips when entering or leaving the
operator compartment.
- DO NOT get on or off the right side of the lift truck.
D00305L
R WARNING
Adjust the operator seat before operating the lift
truck!
DO NOT adjust the operator seat while the lift truck is in
motion.
D00053
R WARNING
Always check overhead clearance!
Serious accidents and damages could be caused by the
mast and overhead guard hitting pipes, beams, or other
overhead obstructions. Watch out for power lines.
D00683
1-19
R WARNING
Use lights in dark, dim areas!
Even with lights ON, DO NOT assume people see you and
will move out of your way.
D00296
R WARNING
When operating the lift truck, BE SURE to fasten the
seat belt!
If not, the operator could be thrown out of the lift truck or
crushed under the lift truck.
D00863
R WARNING
Stay within the confines of the lift truck!
Keep your hands and feet inside the operator compartment.
DO NOT put any part of the body outside the operator
compartment of the lift truck.
D00381L
R WARNING
Always be aware of floor capacity!
Make sure the floor will support the weight of the loaded lift
truck.
D00294A
1-20
R WARNING
Avoid off-center loading!
Set the forks as far apart as possible for maximum support of
the pallet or load. Too small of a fork spread could cause
instability of the load. DO NOT pick up an off-center load.
D00303
R WARNING
Stay under the overhead guard!
DO NOT hold on to the overhead guard.
D00380
R WARNING
Check fork locking pins for engagement! 1) 1)
If the fork locking pins are not properly engaged, or in good
repair, the forks could shift and cause off-center or unstable
loads.
D00382
1) OK
R WARNING
Be careful of forks that extend beyond the load!
If the forks extend beyond the load, use extra caution. Make
sure the forktips do not contact other material.
D00340
1-21
R WARNING
Check work places 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.
D00297A
R WARNING
Slow down for wet and 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 a
greater stopping distance on wet surfaces.
- Apply brakes earlier on slippery surfaces than on dry
surfaces. DO NOT drive into a flooded area. D00423
R WARNING
Make sure your lift truck is in safe operating
condition!
Test the brakes and inching pedal while moving slowly in a
safe area. Make sure the mast moves up and down
smoothly.
Q00557
1-22
 Operating Precautions
R WARNING
DO NOT allow anyone to hold loads.
D00307A
R WARNING
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.
D00685
R WARNING
Position lever correctly before turning the key switch
ON!
Make sure the direction lever is in the NEUTRAL position and
apply the parking brake.
D00830
R WARNING
Make sure that no one is around the lift truck before
starting!
Sound the horn and make sure that no one is around the lift
truck.
J00169L
1-23
R WARNING
Slow down where vision is obstructed!
- If you sound the horn, people may not even notice. Pay
attention to movements of people around you.
- The operator is required to slow down and activate the
horn at cross aisles and other locations where vision is
obstructed.
D00316A
R WARNING
DO NOT pass another lift truck!
DO NOT pass another lift truck traveling in the same
direction at intersections, blind spots, or at other dangerous
locations.
D00315
R WARNING
DO NOT engage in stunt driving or horseplay!
Stunt driving and horseplay is hazardous for both the lift
truck operator and fellow workers.
D00309A
R WARNING
Be careful when turning with a load!
- When operating with a load, the load or tip of the forks
are hard to see.
- If operated carelessly, the load or forks could collide
with nearby objects.
- When making turns while operating in REVERSE with a
load, always pay attention to the position of the load.
If not, the load could collide with nearby objects.
D00727
1-24
R WARNING
DO NOT speed when making turns!
Drive slowly when making turns to avoid a tipover.
D00190
R WARNING
Obey all traffic regulations and warning signs,
including authorized facility speed limits!
A safe distance must be maintained approximately three lift
truck lengths from the lift truck ahead, and the lift truck
must be kept under control at all times. Use special care
when traveling without a load as the risk of tipover is
greater.
D00308A
R WARNING
Always look in the direction of travel!
Always be aware of people near your lift truck. DO NOT
move until they are at a safe distance and are aware of you.
D00311L
R WARNING
Travel in REVERSE if forward visibility is blocked!
For better visibility with large loads, travel in REVERSE, but
always keep a lookout in the direction of travel.
D00312L
1-25
R WARNING
Travel safely on grades with a loaded lift truck!
When ascending or descending grades in excess of 5%,
loaded lift trucks must be driven with the load upgrade.
D00321L
R WARNING
Travel safely on grades with an empty lift truck!
Unloaded lift trucks must be operated on all grades with the
forks downgrade.
When descending grades, use service brake and engine
brake.
D00319L
R WARNING
Be particularly careful when driving up or down a
steep slope!
Use extreme care to reduce the risk of forktips or the bottom
of the pallet from touching the ground.
D00317L
R WARNING
Starting the lift truck on an upgrade carefully!
When starting the lift truck on an upgrade, BE SURE to use
the parking brake.
D00320L
1-26
R WARNING
Slow down at the top of upgrades!
Travel slowly near the top of upgrades as the visibility is
limited.
D00318L
R WARNING
Be careful of tail swing when turning while operating
with load end leading!
Make sure that personnel stand clear of the rear swing area
before making turns.
D00791
R WARNING
DO NOT operate the lift truck with a load under windy
conditions!
Lift truck operation under windy conditions could worsen
the following situations:
- Fall of a load from the forks
- Tipover of the lift truck
BE SURE to operate the lift truck after the wind dies down.
D00724L
R WARNING
Be careful when you operate the parking brake lever
during driving!
2
1
D00831
1. Apply (Push) 2. Release (Pull)
1-27
 Working Precautions
R WARNING
Keep out!
- DO NOT allow any unauthorized persons in the work
area where the lift truck is operated.
- Personnel must stand clear of the lift truck operating
area. Keep a safe distance.
D00688
R WARNING
Be careful of changes in capacity!
- Know the capacity when attachments are used. Extra
care must be taken in securing, manipulating,
positioning, and transporting the load. Operate lift
trucks equipped with attachments as partially loaded
lift truck when not handling loads.
- When using an attachment, BE SURE to read the
attachment instructions manual and attachment
warning labels carefully and understand its function
fully before using it.
D00334A
R WARNING
Watch out for pedestrians at all times!
Yield the right-of-way to pedestrians at all times.
D00384L
R WARNING
Use the proper attachment!
When lifting a load, use the proper attachment designed for
the load. DO NOT operate at high speeds.
D00336
1-28
R WARNING
DO NOT speed when approaching loads!
Approaching loads at high speed is dangerous. Also, it may
damage loads.
Approach the load carefully at slow speeds.
D00332
R WARNING
Ensure the load is not too high!
DO NOT pick up unsecured loads that extend above the
load backrest extension height.
D00341A
R WARNING
DO NOT move when someone is next to the lift truck!
If someone is standing next to the lift truck, DO NOT move
until they are a safe distance away. DO NOT assume that
people are aware of you and will move out of your way.
D00385
R WARNING
Handle only stable and safely arranged loads!
If a load is unstable, it could easily shift and fall on someone.
D00331L
1-29
R WARNING
Stay clear of pinch points!
Keep all parts of your body away from moving parts such as
the mast, carriage, and attachments. DO NOT place any part
of your body between the overhead 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.
D00862
R WARNING
DO NOT allow unloading from raised loads!
Failure to follow these rules could cause serious injury.
D00333
R WARNING
Inspect a trailer before entering!
- The brakes on the highway trucks or trailers must be
applied, and wheel chocks or other positive mechanical
means must be used to prevent unintentional
movement of highway trucks and trailers.
- DO NOT travel along the edge of the dock. The lift truck
may fall off the dock.
- Before starting work, check the allowable load of
gangplank, and if it does not have enough strength to
withstand the weight of the lift truck carrying a load, do
D00343
not use it.
- When entering a trailer, use outriggers so that trailer
will not sink.
- Travel slowly on dock plate when getting in or out of
trailers or rail cars.
- Ask the driver of the trailer not to move the trailer until
the work is completed.
- Use any anchoring equipment available in the dock to
secure the trailer or rail car, and also secure the
gangplank to prevent it from falling off.
- Obey the instructions of the supervisor when working
as a team.
R WARNING
Fork positioner operation!
- DO NOT operate the fork positioner while carrying loads.
- DO NOT handle off-center loads.
1-30
R WARNING
Side shift operation!
When picking up loads by side shifting, BE SURE to position
the load in the center.
DO NOT side shift while traveling with loads.
D00402
R WARNING
DO NOT raise or lower a load while side shifted, as it is
dangerous.
DO NOT side shift the forks with the load raised higher than
150 cm (59 in.) unless safety is assured by the load stack or
carrier deck just below the forks.
D00403
R WARNING
DO NOT use damaged pallets!
Make sure pallets and skids are sturdy and in safe condition.
D00335A
R WARNING
DO NOT abuse forks!
Fork misuse could cause accidents, serious injuries, damage
to the lift truck, and damage to the load.
D00339A
1-31
R WARNING
DO NOT use lift truck improperly!
DO NOT use the lift truck for opening or closing railroad car
doors, unless the lift truck utilizes an attachment specifically
designed for opening and closing railroad car doors.
D00342L
R CAUTION
Operate the direction lever smoothly!
Avoid sudden changing of traveling direction. This may
cause damage to the transmission.
D00386L
R WARNING
Always stay within the capacity!
Read the capacity plate to make sure a load is within the
capacity of the lift truck before you handle the load.
F00081L
R WARNING
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
storage area.
D00345
1-32
R WARNING
Watch out for personnel!
DO NOT allow anyone to walk or stand under raised forks.
D00690
R WARNING
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 operating control levers in
the NEUTRAL position, and apply the parking brake. Lift and
lower smoothly. Have a trained operator in position to
control the lift truck as long as personnel are on the work
platform. DO NOT transport personnel on forks or work
platform.
D00691
R WARNING
Park disabled lift truck safely!
DO NOT park on a grade.
D00347A
R WARNING
Park the disabled lift truck safely!
- If the lift mechanism is disabled and the forks cannot be
lowered, park the lift truck in a non-operating area.
- Use barriers to keep anyone from standing or passing
under the forks.
- Remove the key and attach "DO NOT OPERATE" or
similar warning tag to the lift truck. 1)
- Contact your authorized Cat lift truck dealer.
D00389A
1) DO NOT OPERATE
1-33
R WARNING
When you leave or park the lift truck:
- Park the lift truck on level ground.
- Apply the parking brake.
- Place the direction lever in the NEUTRAL position.
- Lower the forks fully to the floor or ground.
- Tilt the mast forward until the forktips touch the floor or
ground.
- Turn the key switch to the z (OFF) position.
- Remove the key from the key switch. D00832
1-34
LP-Gas
Only trained and authorized personnel must fill or replace
LP-Gas tanks. Personnel engaged in filling LP-Gas tanks
must wear protective equipment 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 collect 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 temperatures. Ovens and D00388
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 The lift truck must be fueled only at designated safe
trucks are parked overnight or stored for long periods locations. Safe outdoor locations are preferable to indoor
indoors with the fuel tank in place. Close the valves on locations. Do not completely fill the tank. The fuel expands
empty tanks. when it gets warm and it may overflow. This will create a fire
hazard.
Inspect LP-Gas tanks before filling and before reuse. Look
for damage to the valve, liquid gauge, fittings, and hand Check the LP-Gas tank for secure mounting. Loose tanks
wheels. Check for dents, scrapes, or other damage to the could cause pressure fuel lines to leak resulting in serious
pressure vessel and for dirt or debris in the openings. injury.
Defective or damaged LP-Gas tanks must be removed from The storage and handling of liquid fuels in the U.S.A. must
service. Check the LP-Gas fuel lines and fittings with a soap be in accordance with the NFPA No. 30, "Flammable and
solution after filling the tank or when looking for leaks. Combustion Code". Outside the U.S.A., store and handle in
accordance with local regulations.
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. Careless handling of LP-Gas tanks could result in a
serious accident. To reduce the risk of damage to the tanks,
use extreme care when transporting them.
1-35
KNOW YOUR LIFT TRUCK
 KNOW YOUR LIFT TRUCK
 Serial Number and Capacity Plate
For quick reference, record your lift serial numbers in the spaces provided on 13-3 "Service Registration" of 13-1 "TO THE CAT
LIFT TRUCK OWNER".
2
1 IMPROPER OPERATION OR
IN INJURY OR DEATH

FORK
SERIAL NO: HEIGHT
AS TO FIRE HAZARD ONLY mm
ATTACH 1:
in
TYPE ＬＰ ATTACH 2: A B
TRUCK WEIGHT A-LOAD CENTER B-OFFSET CAPACITY

R
INDUSTRIAL TRUCK ±５％ mm in mm in kg lbs
No. kg lbs
AU2187 MEETS DESIGN SPECIFICATIONS OF ANSI/ITSDF B56.1

ＥＮＧＬＩＳＨ９３０８３−０７８０１
4
3
MODEL SERIAL No.
㹒㹇㹐㹃ࠉ㹎㹐㹃㹑㹑㹓㹐㹃ࠉ㹄㹐㹐㹃 psi
deg.
in.
HOUSTON,USA
ＥＮＧＬＩＳＨ９３０８３−０８６０１
E00951C
1. UL Plate 3. Engine Serial Number

2. Capacity Plate 4. Manufacturer Name Plate
2-1
 Model View
6 9
5
10
4
11
3 12
2
13
1
14
18
15 17
19
16
E00925
1. Fork 11. Seat belt

2. Load backrest extension 12. Engine hood
3. Meter panel 13. Rear wheel
4. Lift cylinder 14. Fuel tank
5. Mast 15. Tilt cylinder
6. Head light 16. Front wheel
7. Overhead guard 17. Rear combination light
8. Counterweight 18. Stop light
9. Operator seat 19. Backup light
10. Rear combination light
2-2
 Driving Switches and Controls
1 2 3
8 7 6 5
E00926
1. Direction lever 6. Brake pedal

2. Parking brake lever 7. Inching pedal
3. Horn 8. Foot direction control (Option)
4. Switch box 9. Electronic transmission control unit (ECU)
5. Accelerator pedal
2-3
1 2
5 4
E00927
1. Steering tilt lever 4. Tilt lever

2. Lift lever 5. Mast vertical switch (Option)
3. Attachment control lever
Note: For details of operation, see 5-1 "OPERATION".
2-4
 Key Switch
The key switch has as a built-in mechanical lockout that
prevents the key switch from being turned to the Z(START) 1)
position while the engine is running. Turn the key switch 2)
back to the z(OFF) position before starting the engine.
3)
1 E00936
1. Key 2) UON
1) z OFF 3) Z START
R CAUTION
DO NOT crank the engine for more than 10 seconds at any one time. This may cause damage to the starter and run down the
battery.
Position Definition
OFF
z The key switch in the z (OFF) position removes power from meter panel and electrical circuits except for
horn and lights.
ON
U
The key switch in the U (ON) position applies power to all electrical circuits except for starter circuit.
START
Z The key switch in the Z (START) position applies power to the starter motor to crank the engine. A switch
spring returns the key switch to the U (ON) position when the key is released.
2-5
 Turn Signal (If Equipped) / Light Switch
- When turning to the right or to the left, operate the turn
signal switch in the direction of the arrow as shown in
the illustration on the right. The turn signal switch 1
automatically returns when the steering wheel is
returned, but it can also be turned manually. 3
- When the light switch is placed to the Y position,
the meter panel light, tail lights, and clearance lights
illuminate. When the light switch is placed to the H
position, head lights also illuminate in addition to the 2 4
above lights.
E00343
1. Head light (Position 2) 3. Left turn
2. Clearance light (Position 1) 4. Right turn
Position
Lights
1 2
Meter panel lights B B
Tail lights B B
Clearance lights B B
Head lights B
Note: The lights may be turned ON by placing the light switch in position 1 or 2 regardless of the key switch position. Turn OFF
the lights when the lift truck is not being operated to prevent the battery from discharging.
 Direction Lever
This truck is equipped with a neutral switch. Be sure to put
the transmission in NEUTRAL when starting the engine.
Note: The knob locks the direction lever in the NEUTRAL
1
position.
3
J00240
1. FORWARD (F) 3. REVERSE (R)
2. NEUTRAL (N)
R WARNING
- Lock the direction lever before starting the engine.
- Lock the direction lever when parking the lift truck — or before servicing, adjusting or repairing it.
2-6
 Parking Brake Lever
Pull the parking brake lever to apply. Push the parking
brake lever to release. 2
E00929
1. Apply 2. Release
 Horn
Push the horn to activate.
E00930
 Electronic Transmission Control Unit (E.C.U.)
E00938
R CAUTION
When handling Electric transmission control unit (ECU)!
- DO NOT directly expose ECU to water, rain, oil, or any other liquid.
- DO NOT apply force, open, or modify this equipment or operate the lift truck without the ECU.
2-7
 Accelerator Pedal
Depress the accelerator pedal to travel.
E00932
1. Idling 2. Full throttle
 Brake Pedal
Depress the brake pedal to apply the service brake.
1
E00933
1. Release 2. Apply
 Inching Pedal
The operator can move the lift truck slowly by pressing the
inching pedal. Use of inching pedal lowers the traveling 1
speed while maintaining engine speed.
Full application of the inching pedal shifts the transmission 2
in NEUTRAL and applies the service brake.
3
E00437
1. Released 3. Brake applied
2. Clutch disengaged
2-8
 Steering Column Tilt Lever
The steering column position can be adjusted with the
steering column tilt lever to the operators' desired driving
position.
1
Adjustment of steering column position
(1) Unlock the steering column tilt lever.
1)
Lock
(2) Hold the steering column and adjust it to the
appropriate position.
(3) After adjustment, lock the steering column tilt lever.
2)
E00844
1. Steering column tilt lever 1) Lock
2) Unlock
R WARNING
- Always adjust the steering column tilt angle while stopped at a safe place, as adjustment while driving could lead to
accidents.
- Make sure that the steering column is firmly secured.
 Rear View Mirror (If Equipped)
R WARNING
Always adjust the rear view mirror before starting at a safe
place, as adjustment while driving could lead to accidents. 1
E00939
1. Rear view mirror
 Foot Direction Control (Option)

With this option, the forward-reverse lever is replaced by a
directional control that is part of the accelerator pedal.
Depress the left side of the control to go forward; depress
the right side to go in reverse. Speed is increased by further
depressing the control. Toggle the neutral switch located on
the steering column between neutral or drive for operation.
E00931
2-9
 Lift Lever
Lift speed is controlled by the engine speed (the depressed
position of the accelerator pedal) and the position of the lift 1
lever. Lowering speed is controlled only by the position of 1
the lift lever regardless of the engine speed. The lever will
return to the NEUTRAL position when released.
2
2
E00103
1. LOWER 2. RAISE
Equipped with mast interlock system

If the operator leaves the operator seat for approximately 2 seconds while the key switch is in the U (ON) position, regardless of
whether the engine is running or not, the mast will not lift or lower if the lift lever is operated. This is not a failure, but the
interlock system is activated.
If the operator sits on the operator seat while the key switch is in the U (ON) position with engine stopped, the mast can be
lowered.
 Tilt Lever
Tilt speed is controlled by the engine speed (the depressed
position of the accelerator pedal) and the position of the tilt 1
lever. The lever will return to the NEUTRAL position when 1
released.
2 2
E00104
1. FORWARD 2. BACKWARD

whether the engine is running or not, the mast will not tilt even if the tilt lever is operated. This is not a failure, but the mast
If the operator sits on the operator seat while the key switch is in the U (ON) position, regardless of whether the engine is
running or not, the mast can be tilted forward or backward.
 Attachment Lever
Attachment speed is controlled by the engine speed ( the depressed position of the accelerator pedal) and the position of
the attachment lever. The lever will return to the NEUTRAL position when released.
whether the engine is running or not, the mast will not tilt even if the tilt lever is operated. This is not a failure, but the mast
If the operator sits on the operator seat while the key switch is in the U (ON) position, regardless of whether the engine is
running or not, the mast can be tilted forward or backward.
2-10
 Mast Vertical Switch (Option)
When the mast is placed at a tilt-back position without load,
place the tilt lever FORWARD while pressing the switch. The
mast stops at a vertical position.
1
E00935
1. Switch
2-11
Switch Box
1
4
1)
5
2
6
3 2)
2)
7
E00937
1. First speed mode/automatic mode selector switch 5. Mast interlock indicator icon
(Only for 6 to 7 ton model) 6. Clogged air cleaner element indicator icon
2. Driving interlock indicator icon, Neutral indicator icon 7. Torque converter oil temperature warning icon
3. ECM warning icon 1) Automatic mode (First speed, Second speed)
4. LPG empty indicator icon 2) First speed mode
1. First speed mode/automatic mode selector switch 3. ECM warning icon

(Only for 6 to 7 ton) Glows when engine control module (ECM) is abnormal.
- First speed mode is for jobs requiring low travel speed Consult your authorized lift truck dealer.
and greater drawbar pull. Travel speed is 0 to 13.3 km/
h (0 to 8.3 mph) 4. LPG empty indicator icon
- Automatic mode shifts transmission up and down This warning icon glows when LPG is empty.
automatically. First speed is 0 to 9.5 km/h (0 to 5.9 5. Mast interlock indicator icon
mph). Second speed is 9.5 to 22.8 km/h (5.9 to 14.2
This warning icon blinks when the operator is not In the
mph)
normal operating position in the operator seat for 2
First speed mode for operating at the speed-limit area (14 seconds. The mast will not move even if the lift, tilt and/or
km/h [8.7 mph] at maximum), climbing or towing a lift attachment levers are operated. This warning icon goes
truck. OUT if the lift, tilt and/or attachment levers are placed in
2. Driving interlock indicator icon/Neutral indicator the NEUTRAL position and the operator sits in the operator
icon seat properly.
Blinks if the operator leaves the seat with the direction 6. Clogged air cleaner element indicator icon
lever in the FORWARD or REVERSE position while the Glows when air cleaner element is clogged.
engine is idling. Glows when the direction lever is placed in
NEUTRAL (N) position. 7. Torque converter oil temperature warning icon
This warning icon glows when the oil temperature is high
and the danger of overheating is present.
2-12
Meter Panel
R CAUTION
When any warning icon in the meter panel glows or blinks, stop the lift truck and take corrective action.
Meter panel consists of warning icons, LCD (Liquid Crystal Display) screen, and hour meter.
E00953
1. Warning icons
2. Hour meter
 Warning Icons and Indicator Lights

When the key switch is turned to the U (ON) position, warning icons and indicator lights will glow.
* * *
E00954
Note: Warning icon marked * will not glow.
2-13
 Warning Icons and Indicators
1 2 3 4
E00952
1. Brake fluid warning icon 3. Engine oil pressure warning icon
2. Battery charge warning icon 4. Water temperature warning icon
1. Brake fluid warning icon 3. Engine oil pressure warning icon

- This warning icon glows when the fluid level is lower If this light glows during operation, stop the engine and
than the specified level. check the oil level. Add oil as required.
2. Battery charge warning icon 4.Water temperature warning icon
- This warning icon glows when the charging system is If this light glows during operation, stop the lift truck, and
not functioning properly. check engine coolant level.
- First, check the battery voltage. If the battery is fine, For details, refer to 11-19 "Engine Coolant".
check the alternator drive belt for slippage or breakage. If this warning icon glows even when engine coolant level is
correct, contact your authorized Cat® lift truck dealer.
R CAUTION
- If the lift truck is operated with low engine oil level or with this warning icon glowing, overheating may result.
- If this warning icon glows even when the engine oil level is correct, have the engine checked by your authorized Cat lift
truck dealer.
2-14
Mast Interlock System
The lift truck senses when the operator is not properly
seated in the operator seat and will prevent the mast from 1)
operating until the operator is properly seated. In the
following cases, the mast interlock system disconnects 1)
power to the hydraulic control valve and the mast
and attachments will not lift, lower or tilt even if the
control levers are operated:
- The operator leaves the operator seat for
approximately 2 seconds with the key switch in the U 1)
(ON) position regardless of whether the engine is
running or not. E00397
 Mast Interlock System Functions
Mast Interlock Operating Control Lever

Key Switch Engine Operator Seat
Indicator Icon Lift Lever Tilt Lever
Seated OFF Not Active Not Active
z (OFF) Stop
Not Seated OFF Not Active Not Active
Seated OFF Lowering only Not Active
U (ON) Stop
Not Seated Blink Not Active Not Active
Seated OFF Active Active
Z (START) Running
Not Seated Blink Not Active Not Active
R WARNING
- Check the function of the mast interlock system at the daily (prestart) inspection.
- DO NOT leave the lift truck with the mast interlock system engaged. Lower the load completely to the ground, apply the
parking brake, and turn the key switch to the (OFF) position.
- Even when the engine is not running, while the operator is sitting correctly in the operator seat and with the key switch in
the U (ON) position, it is possible for the mast to descend. Please be very careful. (See the table above.)
- The parking brake is not automatically applied when the interlock is activated.
- When replacing the operator seat, BE SURE to select a genuine Cat lift truck seat with an operator presence switch and an
operator restraint system.
2-15
Driving Interlock System
R WARNING
- Check the function of the driving interlock system at
the daily (prestart) inspection.
- The parking brake is not automatically applied when
the driving interlock is activated.
- When replacing the operator seat, BE SURE to order a 1) 1)
genuine Cat lift truck seat with an operator presence
No No
switch and an operator restraint system. Power Power
Travel Travel
E00398
1) No Power Travel
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 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 synchronize 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.
R CAUTION
(1) Prior to operating the lift truck, be sure to check the driving interlock for function.
(2) While driving the lift truck, if you lift your hips above the seat for over 2 seconds, the driving interlock system will be
activated, the same as in case of engine idling.
(3) Always drive the lift truck correctly with safety in mind.
(4) To restore the lift truck to its normal driving condition, sit properly in the operator seat and depress the brake pedal to hold
the lift truck. Then, return the direction lever to the NEUTRAL position and then shift it back into the forward or reverse
position.
 Driving Interlock System Functions
Conditions
Key Direction Function Safety Warning

Engine Operator Seat
Switch Lever
Not Seated F/R Driving inoperative Driving interlock indicator icon [Blink]
Seated F/R Driving operative Driving interlock indicator icon [OFF]
For approximately 2
Seated to Not After approximately 2 seconds driving
F/R seconds driving
Seated interlock indicator icon [Blink]
operative
ON ON Within approximately 2
Seated to Not Within approximately 2 seconds driving
F/R seconds driving
Seated to Seated interlock indicator icon [OFF]
operative
Not Seated to
F/R Driving inoperative Driving interlock indicator icon [Blink]
Seated
Not Seated to F / R to N to Driving inoperative, then Driving interlock indicator icon [Blink] then
Seated F/R operative after NEUTRAL [OFF] after NEUTRAL
2-16
Neutral System
The lift truck is equipped with a device that prevents the
engine from being started if the direction lever is not in the
NEUTRAL position. 1
3
E00928
1. FORWARD (F) 3. REVERSE (R)
2. NEUTRAL (N)
R CAUTION
Check the following when starting the engine:
- No one is around the lift truck.
- The parking brake is applied.
- The direction lever is in the NEUTRAL (N) position.
- Seated in the operator seat properly.
 Neutral System Functions
Conditions
Safety Function
Key Switch Operator Seat Direction Lever
Engine starts only when the direction lever is in the
OFF or ON Seated or Not Seated NEUTRAL
NEUTRAL position
2-17
Operator Seat
 Seat Adjustment
R WARNING
Slide the operator seat to adjust forward and back position
before starting the engine. After adjusting, check the 3
operator seat to make sure it is properly locked. DO NOT
adjust the operator seat while the lift truck is in motion.
1
2 E00970C
1. Slide lever 3. Lumber support adjustment
2. Adjusting knob 4. Seat belt
 Forward and Back Adjustment

Move the lever to the left, slide the seat to one of the seven
positions, and release the lever. 1)
1
E00971C
1. Slide lever 1) Front to back adjustments:
165.1 mm (6.5 in.)
R WARNING
This lift truck is equipped with a genuine Cat lift truck operator restraint system and an operator presence switch. Should it
become necessary to replace the seat for any reason, it must only be replaced with a genuine Cat lift truck operator restraint
system equipped with an operator presence switch.
 Lumbar Support Adjustment

Turn the knob clockwise to raise the backrest.
Turn the knob counterclockwise to lower it.
1 1)
2)
E00943
1. Adjusting knob 1) Lower

2) Raise
2-18
 Adjustment of Suspension
Adjust the suspension before sitting on the seat. Turning
the knob clockwise, increases the gauge indication, and
turning it counterclockwise decreases the gauge indication.
Weight adjustment range: 40 to 120 kg [80 to 265 lb] 1
2) 2
1) E00944
1. Adjusting knob 1) Decrease

2. Gauge 2) Increase
 How to Tip the Operator Seat Forward

Pull the lever and adjust the angle to the desired position,
and release the lever.
1
E00945
1. Reclining lever
 Operator Presence Switch

The operator seat has an operator presence switch. The
mast and attachments cannot be moved unless the
operator is seated in the operator seat. For details, see 2-15
"Mast Interlock System".
1
If you leave or rise from the operator seat for approximately
2 seconds with the key switch in the U (ON) position, the
following occurs:
- Electrical power is interrupted to the mast hydraulics
with the mast interlock indicator light blinking until you
are seated. E00946
- Electrical power is interrupted to the transmission 1. Operator presence switch
control valve. The neutral indicator light will blink only
when the directional lever is in the FORWARD or
REVERSE position.
R WARNING
When replacing the operator seat, BE SURE to order a genuine Cat Lift Truck seat with an operator presence switch and an
operator restraint system.
2-19
Seat Belt
Always fasten the seat belt when operating the lift truck.
R WARNING
- The seat belt will help to restrain the operator in accidents such as a tipover or mast and attachment collisions.
- An unrestrained operator in a tipover could fall outside of the operator compartment and be crushed by the lift truck.
- An unrestrained operator could continue to move forward if a sudden stop occurs.
R WARNING
- Seat belts could "jack-knife" the operator, i.e., the upper
body bends tightly at the waist.
- If the seat belt is fastened across the operator's
abdomen during an accident, it could cause serious
internal injuries.
E00947
How to fasten the seat belt

(1) Hold the latch plate of the seat belt and pull the belt
1 2
from the retractor.
(2) Insert the plate into the slot of the buckle until a snap
sound is heard.
Note: Make sure the belt is not twisted.
3
E00451
1. Retractor 3. Buckle
2. Latch plate
(3) Be sure to fasten the belt as low as possible across your

hips, not across your abdomen.
Note: Adjusting the belt length is not necessary. Tug on it to OK
check for a tight fit.
OK
E00452
2-20
How to release the seat belt

(1) Push the button in the buckle to release the belt. The
belt will automatically retract when released.
(2) Hold the plate of the belt and allow the belt to slowly
retract.
E00917
If the seat belt is torn, the pulling motion of the belt is

interrupted during extension, or the belt cannot be inserted
into the buckle properly. Replace the seat belt assembly.
The seat belt must be checked at regular service intervals.
E00918
Note: The following maintenance guidelines explain 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:
- Cuts, fraying, or excessive wear on the webbing would indicate the need for replacement of the seat belt system.
- Check buckle and latch for proper operation and to determine if latch plate is worn or deformed, buckle is damaged, or the
casing is broken.
- Check the retractor web storage device operation to make sure that it locks properly and that it spools out and retracts the
webbing properly.
R WARNING
When replacing seat belt components, replace them with genuine Cat lift trucks parts.
2-21
Engine Hood
R CAUTION
Be careful not to pinch your fingers when closing the engine
hood.
E00128
R CAUTION
Keep fingers away from this area.
1 E00948
1. Lever
The engine hood swings up to fully expose the engine compartment for daily inspection, servicing, and lubrication.
For details of maintenance, see 11-1 "MAINTENANCE".
- Engine oil level
- Engine coolant level
- Hydraulic oil level
- Battery electrolyte level
- Air cleaner element
- Alternator drive belt
2-22
 Hood Latch
How to open
(1) Slide the seat assembly backward.
(2) Lower the seat back cushion.
(3) Pull the engine hood lever in the direction of the arrow. 1
(4) Raise the engine hood.
E00077
1. Engine hood lever
How to close
(1) Push the engine hood down until it is locked.
(2) Raise seat back cushion to the upright locked position.
(3) Slide seat assembly back to desired position.
(4) Tilt the steering wheel toward the operator seat and make sure that it is automatically locked.
Assist Grip
How to get on the lift truck

(1) Hold the assist grip with the left hand, the seat backrest
with the right hand.
(2) Step up with the left foot to get on the lift truck safely.
How to get off the lift truck
(1) Hold the assist grip with the left hand, the seat backrest
(2) Step down the left foot to get out the lift truck safely.
D00305L
R WARNING
- DO NOT hold the steering wheel or the operating control lever.
- DO NOT get on or off the lift truck from the right side of the lift truck.
2-23
Drawbar Pin
Use the drawbar pin for the following situations:
- Pulling the lift truck out of a drop-off or ditch.
- Loading and unloading the lift truck on a transport
truck.
- When loading the lift truck on a hauling truck by using
the drawbar pin, start the engine, and release the 1
parking brake.
E00949
1. Drawbar pin
R WARNING
DO NOT use the drawbar pin for towing loads.
R WARNING
Precautions for the use of the drawbar pin
- When attaching a cable on the pin, make sure the pin is
inserted safely.
- Take up slack slowly. DO NOT jerk. Keep the cable taut.
If the cable has slack, the sudden impact of the load
could snap it, resulting in an accident.
- A helper must stand at a safe distance and watch the
pin. Stop pulling with the lift truck, relieve tension, and
reduce load if the pin starts to come out.
E00463
 Radiator Cover
To open
(1) Turn the knobs counterclockwise. 1
(2) Lift and remove the cover.
To close
Install the cover, and turn the knobs clockwise.
E00950
1. Knobs
 Back-up Buzzer
R WARNING
- When operating in reverse, alarm must sound.
- Failure to maintain a clear view in the direction of travel could result in injury or death.
- The operator is responsible for the safe operation of this truck.
2-24
HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE
 HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE
Know What Lift Truck Stability Is
Counterbalanced lift truck design is based on the balance of
two weights on opposite sides of a fulcrum (the front axle).
The load on the forks must be balanced by the weight of the
lift truck. The location of the center of gravity of both the lift
truck and the load is also a factor.
This basic principle is used for picking up a load. The ability
of the lift truck to handle a load is discussed in terms of
center of gravity and both forward and sideways stabilities.
F00062
Center of Gravity (CG)

Center of Gravity (CG) is defined as the point of an object
where its weight is evenly distributed.
If the object is uniform, its geometric center will be the same
as its CG. If it is not uniform, the CG could be a point on
either side of the normal geometric center.
When the lift truck picks up a load, the lift truck and load
have a new, combined CG.
1
F00063
1. CG
 Stability and Center of Gravity (Top View)

The stability of the lift truck is determined by the location of
its CG, or if the lift truck is loaded, the combined CG. 1 2 3
The lift truck has moving parts and, therefore, has a CG that
moves. The CG moves forward or backward as the mast is
tilted forward or backward. The CG moves up or down as the
mast moves up or down.
F00088
1. CG truck 3. CG load
2. Combined CG
The CG and the stability of the loaded lift truck are affected by the following factors:
- The size, weight, shape, and position of the load. - Dynamic forces created when the lift truck accelerates,
- The height of the lifted load. brakes, or turns.
- The angle of forward or backward tilt. - Condition and grade of surfaces on which the lift truck
is operated.
3-1
These factors must be considered when the lift truck is

unloaded as well. Because an empty lift truck will tipover to CG load
1
the side more easily than a lift truck carrying a load in the
lowered position.
2
3
F00089
1. CG Load 3. CG truck
2. Combined CG
Lift Truck Stability Base

In order for the lift truck to be stable (not tip over forward or
to the side), the CG must stay within the area of the lift truck
1
stability base triangle drawn between the front wheels and
the pivot of the rear axle.
If the CG moves forward of the front axle, the lift truck will
tip over forward.
If the CG moves outside of the line on either side of the
stability base, the lift truck will tipover to the side.
2 F00090
1. CG truck 2. Stability base
 Capacity (Weight and Load Center)

The capacity of the lift truck is shown on the capacity plate.
It is determined by the weight and load center. The load
center is determined by the location of the CG of the load.
The load center shown on the capacity plate is the
horizontal distance from the front face of the forks, or the
load face of an attachment, to the CG in the load. The
location of the CG of the vertical direction is the same as the
horizontal dimension.
F00067
Keep in mind that, unless otherwise indicated, the capacity shown on the capacity plate is for a standard lift truck with standard
load backrest extension, forks, mast, and having no special-purpose attachment. In addition, the capacity presumes the load
center is no further from the top of the forks than it is from the face of the load backrest extension.
If these conditions do not exist, the operator may have to reduce the safe operating load because the lift truck stability may be
reduced. The lift truck should not be operated if its capacity plate does not indicate capacity.
3-2
 Capacity Plate
 Sample
R WARNING
Capacity plate originally affixed to lift trucks must not be
removed, altered or changed without the manufacturer's IMPROPER OPERATION OR
IN INJURY OR DEATH
approval.
MODEL: GC55K MAX MAST: VERTICAL
FORK
- If the lift truck is equipped with a high mast, the lift's SERIAL NO: AT88B-00001 HEIGHT
mm
capacity will be reduced. ATTACH 1:

in
ATTACH 2:
BE SURE to check the capacity plate before handling A-LOAD CENTER B-OFFSET
A
CAPACITY
B
TRUCK WEIGHT
loads. kg
±５％ mm in mm in kg lbs
lbs
3000 118 600 24 5500 12000
- If the lift truck is equipped with an attachment, the lift's
capacity will vary with the weight of attachment and MEETS DESIGN SPECIFICATIONS OF ANSI/ITSDF B56.1
ＥＮＧＬＩＳＨ９３０８３−０７８０１
the front overhang (distance from the front axle center
to the vertical surface of the forks). F00505C
Be sure to check the capacity plate before handling
loads.
The capacity plate shown above is for a 5.5 ton model
standard lift truck whose capacity is 5500 kg (12000 lb) at
600 mm (24 in.) load center.
The capacity plate specifies this lift truck can lift up to 5500
kg (12000 lb) if the load center is not more than 600 mm (20
in.) forward from the face of the load backrest extension.
Before attempting to pick up or lift a load, make sure its
weight is within the capacity of the lift truck at the load
center involved.
Note: If the load is not uniform, the heaviest portion should
be placed closer to the lift bracket and centered on
the forks.
3-3
Do’s and Dont’s to Avoid Tipover
R DANGER
FASTEN THE SEAT BELT!
The seat belt will keep you from being thrown out of the lift
truck in a tipover. The seat belt is used to protect your head
and torso from being trapped between the lift truck and the
ground. However, it may not protect the operator against all
possible injury.
F00134L
R DANGER
DO NOT jump off your lift truck if it starts to tip over!
The operator must stay in the operator seat, hold on firmly
and lean away from the point of impact to reduce the risk of
serious injury or death.
F00142
R WARNING
DO NOT overload!
DO handle loads only within the capacity shown on the
capacity plate.
F00081L
R WARNING
DO watch “tail swing!”
Always maintain a safe distance from the edge of docks,
ramps, and platforms.
The lift truck may drop off the edge if you get too close to
the edge.
F00083A
3-4
R WARNING
DO check surface strengths!
Stay away from soft ground to avoid tipover.
F00085L
R WARNING
DO avoid fast starts, turns, and sudden stops!
These movements could cause the lift truck to tipover.
F00073A
R WARNING
DO NOT cross over slope, and DO NOT turn on grades!
Avoid turning on grades, and use extreme caution on
grades, ramps, or inclines.
D00790
R WARNING
DO NOT tilt elevated loads forward!
DO NOT tilt elevated loads forward except when the load is
in a deposit position over a rack or stack. This could cause
the lift truck to tipover.
F00079L
3-5
R WARNING
DO NOT elevate forward titled loads!
This could also cause the lift truck to tipover.
F00080L
R WARNING
Travel at a reduced speed on rough surfaces!
If not, the following accidents could result:
- The lift truck may tipover.
- Hard to turn the steering wheel appropriately, leading
to incorrect operation.
- Personnel is hit by the lift truck.
F00084
R WARNING
DO NOT pick up or place a load on grades!
DO NOT attempt to pick up or place a load on ramps and
other sloped surfaces that could affect the lift truck's
stability.
F00076
R WARNING
DO avoid slippery surfaces!
Slow down for wet and slippery surfaces.
Sand, gravel, ice, or mud could cause a tipover. If
unavoidable, slow down.
F00086A
3-6
R WARNING
Avoid off-center loading!
Only stable or safely arranged loads must be handled!
- Keep the center of gravity low and avoid off-center
loading. Off-center loads may cause tipover or falling
loads.
- Slowly operate the lift truck when picking up or placing
a long or wide load, or when turning with such load.
F00077
R WARNING
DO NOT run over objects!
DO NOT run over loose objects.
F00082L
R WARNING
DO NOT travel with forks higher than 15 to 20 cm
(5.91 to 7.87 in.) above the ground!
The CG moves up increasing the possibility of a tipover.
F00078L
R WARNING
DO NOT make fast or sharp turns with a loaded or
unloaded lift truck!
When making turns, reduce speed to a safe level consistent
with the operating environment.
F00071L
3-7
R WARNING
DO NOT turn sharply, even with an empty raised
mast, to avoid a tipover!
A lift truck with a raised mast will tipover more easily than a
lift truck with a lowered mast because the stability of the lift
truck worsens.
F00072A
R WARNING
Wear a hard hat if recommended or required by your
employer or applicable regulations.
F00074
R WARNING
Be aware of the stability of an empty lift truck!
An empty lift truck will tipover more easily than a loaded
one in a lowered position.
D00313
3-8
 How to Survive in a Tipover
R DANGER
DO FASTEN YOUR SEAT BELT!
Remember, your chances for survival with the seat belt
fastened in a tipover are better if you stay in the lift truck.
F00087L
R DANGER
IF YOUR LIFT TRUCK STARTS TO TIPOVER: 1 2
(1) DO NOT jump off.
(2) Firmly hold on to the steering wheel.
(3) Brace your feet.
(4) Lean away from impact.
(5) Lean forward. 3 4 5
F00158
3-9
REFUELING
 REFUELING
 LP-Gas Equipped
R WARNING
BE SURE to use the proper fuels specified in the “SERVICE DATA”. If not, the engine could fail.
R WARNING
- Only trained and authorized personnel must fill or exchange LP-Gas tanks.
- Personnel engaged in filling LP-Gas tanks must wear protective equipment 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 collect in a pocket and cause an explosion.
- Inspect all LP-Gas tanks before filling, and again before reuse for damage to the valves, liquid gauge, fittings, and
hand wheels.
- All defective or damaged LP-Gas tanks must be removed from service.
- The careless handling of LP-Gas tanks could result in a serious accident.
- To reduce the risk of damage to tanks, use extreme care when transporting them.
R WARNING
The LP-Gas tank must not extend past the counterweight and must be inside the confines of the lift truck.
R WARNING
Reduce the risks of fire caused by static electricity!
Touch grounded metals with bare hand to discharge the static electricity before replacing compressed LP-Gas tanks. If
not, the fuel could catch fire due to the static electrical spark.
R CAUTION
LP-Gas tanks can be heavy. Follow the instructions below:
- DO NOT insert fingers into the straps or brackets. If this instruction is not adhered to, fingers may be pinched.
- DO NOT lift LP-Gas tank with your body in an incorrect position. You may injure your back.
- Be careful not to drop an LP-Gas tank. It may fall on your body and lead to serious injury including bone fractures.
- Wear appropriate personal protective equipment.
R CAUTION
Be careful not to pinch fingers in the bands when installing a LP-Gas tank.
Note:
- MOUNT THE TANK PROPERLY. To insure full usage of fuel, use the mounting holes located on the collar for horizontal
mounting and the slot in the foot ring for vertical mounting.
- Open the valve slowly so that hose and tank pressure can equalize, or the valve may shut off.
- For proper operation of LP-Gas system, use HD-5 LPG fuel.
4-1
REFUELING
 For Standard LP-Gas Tank
(1) Park the lift truck on level ground.
(2) Lower the forks until the forktips touch the ground.
(3) Apply the parking brake.
(4) Place the direction lever in the NEUTRAL position.
(5) Run the engine at low idle.
(6) Discharge static electricity.
(7) Close the fuel valve at the LP-Gas tank. Run the engine
until it stops, then turn the key switch to the z (OFF)
position.
(8) Disconnect the fuel supply line.
(9) Loosen the retaining clamps to remove the tank. D00388
R WARNING
LP-Gas tank must not extend past the counterweight.
(10) Make sure the replacement tank is the correct type.
LOCATION
2) 1)
2) 1)
G00005
33-1/2# tank 1) Use pin 2)

43-1/2# tank 2) Use pin 1)
(11) Inspect the replacement tank for damage such as dents, scrapes, or gouges and for leakage at valves or threaded
connections.
(12) Check for debris in the relief valve and for damage to various valves and the liquid level gauge.
(13) Inspect the couplings for deterioration, damage, or missing flexible seals.
(14) When lifting the tank for mounting, hold with both hands to prevent injury, and check the tank clamp lock.
(15) Clamp the tank securely.
(16) Connect the fuel supply line.
(17) Open the fuel valve by turning it slowly counterclockwise. If the fuel valve is opened too quickly, a back pressure check
valve will shut off the fuel supply. If this happens, close the fuel valve completely, wait five seconds, and then open the fuel
valve very slowly.
(18) Check the LP-Gas fuel lines and fittings with a soap solution after filling the tank or when looking for leaks.
4-2
REFUELING
 For Optional LP-Gas Tank
(1) Park the lift truck on level ground.
(2) Lower the forks until the forktips touch the ground.
(6) Discharge static electricity.
(7) Close the fuel valve at the LP-Gas tank. Run the engine until it stops, then turn the key switch to the z (OFF)
position.
(8) Disconnect the fuel supply line.
(9) Pull the stopper on left side of bracket and rotate it so that the stopper stays in the UNLOCK position. Do not
loosen the retaining clamps at this time.
(10) While holding the tank with the LEFT HAND, pull the center lock lever upward with the RIGHT HAND.
(11) Place the tank to a vertical position. Do not hands off at the time.
(12) Loosen the retaining clamps to remove the tank.
(13) Make sure the replacement tank is the correct type.
(14) Inspect the replacement tank for damage such as dents, scrapes, or gouges and for leakage at valves or threaded
connections.
(15) Check for debris in the relief valve and for damage to various valves and the liquid level gauge.
(16) Inspect the couplings for deterioration, damage, or missing flexible seals.
(17) Clamp the tank securely. When lifting the tank for mounting, hold by hand to prevent injury. Make sure tank locks
into position.
Note: The tank will lock at horizontal position automatically.
(18) Connect the fuel supply line.
(19) Open the fuel valve by turning it slowly counterclockwise. If the fuel valve is opened too quickly, a back pressure
check valve will shut off the fuel supply. If this happens, close the fuel valve completely, wait five seconds, and
then open the fuel valve very slowly.
(20) Check the LP-Gas fuel lines and fittings with a soap solution after filling the tank or when looking for leaks.
4-3
OPERATION
 OPERATION
 New Lift Truck Break-in
Correct “break-in” is important for operation and the long life of your lift truck. The first 100 service hours of operation are the
“break-in” period. Carefully read these precautionary instructions:
R CAUTION
- After starting the engine, BE SURE to run it at idle speeds with no load for about 5 minutes. During this time, check all the
meter panel indicator lights.
- DO avoid long periods of idling. This may cause cylinder wall glazing and prevent the piston rings from seating properly.
- DO NOT pump the accelerator pedal and DO NOT rev up the engine. This may cause cylinder wall scuffing and scoring.
- If the lift truck does not have to be put to work immediately, or the operation is light and slow, break in the lift truck under
a simulated working condition.
- Try NOT to drive the lift truck continuously at the same speeds as the parts tend to better adjust themselves to other parts
if various speeds are used. Also, try NOT to make severe brake applications to allow the brake linings to seat against the
brake drums.
- Operate the lift truck under a lighter load and lower speeds than normal maintenance schedule.
- Replace and lubricate parts at shorter intervals than normal periods.
- Carefully check on and around the lift truck for loose bolts and nuts. Tighten them as needed.
 Before Starting Engine
R WARNING
- BE SURE to read the 1-1 “SAFETY RULES FOR LIFT TRUCK OPERATORS” for your safety and the safety of fellow workers.
- BE SURE to perform the 11-8 “Every 10 Service Hours or Daily (Prestart), Whichever Comes First”.
- If lift trucks are used on a round-the-clock basis, they must be inspected after each shift.
R WARNING
If at any time a lift truck is found to be in need of repair, defective, or in any way unsafe, the lift truck must be taken out of
service until it has been restored to safe operating condition. Report it immediately to the designated authority.
R WARNING
Face the lift truck when getting on and off!
Hold 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
lift truck safely.
- DO NOT hold the steering wheel or the operating
control lever.
D00305L
5-1
OPERATION
R WARNING
BE SURE to fasten the seat belt before operating the lift
truck. Remember, the belt will not restrain you in an
accident if it is not fastened properly.
For the details of seat belt, see 2-20 “Seat Belt”.
E00947
R WARNING
Before starting, always adjust the rear view mirror (if equipped) at a safe location, as adjustment while driving may lead to
accidents.
R WARNING
Before starting, always adjust the operator seat to a proper
position where you can depress the pedals fully down. 1)
Adjusting the seat while driving could lead to accidents.
1
E00971C
1. Slide lever 1) Front to back adjustments:
165.1 mm (6.5 in.)
R CAUTION
Sit in the normal operating position before starting.
The seat has a built-in operator presence switch that

prevents the operation of mast and attachments unless the
operator is seated properly.
For the lift trucks equipped with powershift transmission, it
prevents the lift truck from starting.
When the key switch is in the U (ON) position, the mast
interlock indicator and driving interlock indicator lights
flicker unless the operator is seated in the operator seat
properly.
J00291
5-2
OPERATION
 Starting Engine
 LP-Gas Engine Model
R WARNING
LP-Gas fuel is flammable and could cause injuries and fires. Inspect LP-Gas fuel lines and fittings for leaks.
R CAUTION
DO NOT leave the key switch in the U (ON) position when the engine is NOT running. This may cause the battery to run down.
(1) Open the fuel valve by turning it slowly

counterclockwise. Observe the LP-Gas gauge (if l
equipped).
(2) Turn the key switch to the Z (START) position. Release
the key when the engine starts.
(3) If the engine does not start, do not depress the
accelerator pedal. Turn the key switch to the z (OFF)
position, then repeat Step 2.
J00292
Engine Won't Start

Consult your authorized Cat® lift truck dealer if the engine still does not start after you have attempted the following:
Does the starter crank the engine?
YES NO
Check the fuel gauge to see if there is fuel left in the tank. If The battery is dead if the head lights do not turn ON or
not, refuel it. dimly light.
 After Starting Engine
R WARNING
If the warning icon turns ON, correct the problem before operating the lift truck. Contact your authorized Cat® lift truck dealer
for repairs.
R CAUTION
- BE SURE to warm up the engine regardless of the weather.
- If the engine is not warmed up, it may cause poor lubrication and incomplete fuel combustion resulting in poor engine
performance.
Check the warning icons and gauges frequently during operation to make sure all systems are working properly.
(1) Run the engine at idle speeds without a load for about 5 minutes.
(2) During the warm-up, check to see that systems are operating properly.
- Are all the warning icons OFF?
- Is the water temperature warning icon OFF?
- Are exhaust noise and smoke color normal?
- No excessive vibration?
5-3
OPERATION
 Before Moving Lift Truck
(1) Turn the 1st speed mode/automatic mode selector
switch to the desired position.
- Selector switch: For 6 and 7 ton models only.
2)
J00295
(2) Use the lift control lever to raise the forks to a safe
traveling height of 15 to 20 cm (6 to 8 in.) from the floor.
(3) Use the tilt control lever to tilt the mast back all the way.
J00296
R WARNING
DO NOT allow other personnel to enter the area
around the mast!
It could cause other personnel to get caught between the
mast and lift truck when operating the mast, leading to
serious injury or death.
D00688
R CAUTION
Before starting the engine, sit properly in the operator seat and make sure the following:
- Sound the horn and make sure no one is around the lift truck.
- The parking brake is in the applied position.
- The direction lever is in the NEUTRAL position.
5-4
OPERATION
 Lift Truck Operation
R CAUTION
DO NOT "ride" the inching pedal during travel. This causes a partly disengaged condition that will result in premature clutch
plate wear.
(1) Depress the inching pedal fully.
J00163
(2) Move the direction lever in the FORWARD or REVERSE

position.
2
J00293
1. Forward 2. Reverse
(3) Place the parking brake in the release position.
J00294
(4) Release the inching pedal fully and gradually depress

the accelerator pedal.
J00166
5-5
OPERATION
 Changing Speed
Use the accelerator pedal to increase travel speed. Release
the accelerator pedal and apply the brake pedal to slow
down.
J00194
R WARNING
DO NOT move the direction lever to the NEUTRAL position
during travel. This could cause the engine to race.
J00195L
 Changing Direction
R WARNING
BE SURE to watch for people or hazards in the direction of
travel.
D00814A
R CAUTION
Directional changes without coming to a complete stop
may cause premature damage to the transmission. BE SURE
to come to a complete stop before changing direction.
(P)
J00210
5-6
OPERATION
R CAUTION
- Changing direction without coming to a complete stop may cause premature damage to the driveline.
- For a smoother ride and maximum service life of driveline components, bring the lift truck to a complete stop before
changing direction.
 Operating Techniques
Turn the steering wheel with both hands. When handling
loads, stop the truck and move the tilt and lift control levers
J00298
 Steering (Turning)
A lift truck is different from most other vehicles because it is
steered by the rear wheels. This causes an exaggerated tail
swing.
1 2
J00171
1. Car 2. Lift truck
R WARNING
When working in close quarters, drive more slowly when
making turns. Start the turn as close to the inside corner as
the tail swing will permit.
J00172
5-7
OPERATION
 Inching
The purpose of the inching pedal is to provide precise lift
truck inching control at very slow travel speed and high
engine speeds.
You can move your lift truck slowly while maintaining the
engine speed by varying the position of the inching pedal.
Use this pedal when approaching loads for loading and
unloading.
J00197
R CAUTION
DO NOT ride the inching pedal. This causes a partly disengaged condition that may result in premature clutch plate wear. DO
NOT press inching pedal when inching is not necessary.
(1) Stop ahead of the load platform.

(2) Apply the parking brake, set the direction lever to the
NEUTRAL position, place the mast vertically, and raise
the forks to the height of the pallet insertion openings.
(3) Depress the inching pedal fully down, place the
direction lever to the FORWARD position, and release
the parking brake.
(4) Gently depress the accelerator pedal.
J00176
(5) When the left foot is slowly taken off the inching pedal,
the lift truck will advance slowly.
(6) Insert the forks slowly, making sure that they do not hit
the pallet.
(7) Stop inserting the forks after the heels of the forks
come into light contact with the pallet.
J00177
5-8
OPERATION
 Stopping Lift Truck
R WARNING
If brake linings have become wet after cleaning the lift truck or after driving through a large area of water, stopping distance
could be increased. In this case, gently apply brakes several times while driving slowly in a safe area until linings have dried out
and normal braking action is restored.
R WARNING
Avoid sudden stops. This could cause the load to fall off the
forks or the lift truck to tipover.
J00203
(1) Release the accelerator pedal.
J00198
(2) Depress the brake pedal and come to a complete stop.
J00272
Parking Lift Truck (After Stopping)
R WARNING
Park safely
- Select a hard level surface.
- BE SURE to park in the designated parking area.
5-9
OPERATION
1 2
J00523
1. Release 2. Apply
(2) Place the direction lever in the NEUTRAL (N) position.
3
J00240
1. Forward (F) 3. Reverse (R)
2. Neutral (N)
(3) Slightly tilt the mast FORWARD and lower the forks to
the ground until the forktips touch the ground.
J00180L
(4) Turn the key switch back to the z (OFF) position to turn
the engine OFF. When leaving the lift truck, be sure to
remove the key.
(5) Block the wheels securely. │
(6) Return the key to a key rack if required by supervisor.
J00524
R WARNING
Get off safely
- Get off after the lift truck has come to a complete stop and 5-9 “Parking Lift Truck (After Stopping)” has been followed.
- DO NOT jump off.
5-10
OPERATING TECHNIQUES
 OPERATING TECHNIQUES
 Stacking Methods
Stability of the loads depends upon how well the stack is formed.
 Stacking Different Size Loads

Make sure larger containers in a load are at the bottom of
the stack and smaller ones at the top, or heavier containers
at the bottom and lighter ones at the top.
K00109
 Stacking Small Identical Loads

As in bricklaying, place layers of containers alternately so
each container will sit across parts of two or more containers
in the layer below. This type of stack is more stable and less
likely to fall down.
K00110
 Stacking Large Identical Loads

This is one of the most common patterns for stacking large
identical containers. Better load stability is achieved by
reversing the end-to-side direction on each succeeding
layer.
K00111
6-1
 Handling Loads Safely
R WARNING
Handle ONLY stable loads to reduce the risk of the
load from falling!
- Handle balanced loads only.
- Visually make sure that boxes or containers have
not collapsed or are potentially dangerous.
- If the loads are not balanced or there is a danger of
collapse, take appropriate measures such as
binding with a band or loading the material into
another container.
- DO NOT use broken pallets. It could cause the load K00148
to collapse.
R WARNING
Handle ONLY loads within the capacity of the lift truck
as shown on the capacity plate. IMPROPER OPERATION OR
IN INJURY OR DEATH
DO NOT place loads at the end of the forks even if they
MODEL: GC55K MAX MAST: VERTICAL
are within the capacity and DO NOT pick up loads that SERIAL NO: AT88B-00001
FORK
HEIGHT
mm
exceed the capacity. Otherwise, it can create very ATTACH 1:
in
dangerous situation, disabling the operation of steering ATTACH 2: A B
wheel as the rear wheels are lifted off the ground. TRUCK WEIGHT
±５％
A-LOAD CENTER
mm in
B-OFFSET
mm in
CAPACITY
kg lbs
kg lbs
3000 118 600 24 5500 12000
MEETS DESIGN SPECIFICATIONS OF ANSI/ITSDF B56.1

ＥＮＧＬＩＳＨ９３０８３−０７８０１
F00505C
6-2
 Adjusting Fork Spread
R WARNING
When adjusting the fork spread, DO NOT place your hands between the fork and load backrest extension or lift bracket, to
avoid pinching your hands.
How to adjust fork spread

(1) Pull up and turn the fork locking pins 90 degrees of
angle.
(2) Spread the forks to fit the load.
E00070
R CAUTION
- After adjusting the fork spread, restore the fork locking pins to the original position to lock the forks.
- Position each fork the same distance from the center of the load backrest extension.
Not every load can be handled using only the forks. Some
loads will require a special attachment.
6-3
Before Operating the Lift Truck
Follow the correct operating Steps 1 through 4 before you operate the lift truck.
Make sure the mast interlock indicator light is OUT.
Operating steps
(1) Sit on the operator seat properly and buckle the seat
belt securely.
OK
OK
E00452
(2) Start the engine.
J00153
(3) Make sure the mast interlock indicator light is OUT.
P00028
Note:
- Be sure to operate the lift, tilt, and attachment levers, and lowering speed selector switch (if equipped) with your RIGHT
HAND.
- See 6-6 “Lifting the Load”, 6-8 “Traveling With the Load”, and 6-10 “Unloading”.
- If the mast interlock indicator icon blinks, see 6-5 “Blinking of the Mast Interlock Indicator Icons”.
6-4
Blinking of the Mast Interlock Indicator Icons
In the following three examples, the mast interlock indicator icon blinks and the mast would not move even though the
operating levers are in the operating position. This is not a fault but an indication that the interlock system functions. In this
case, follow each instruction of each "Remedy".
The mast interlock will work only for the lift and tilt levers.
Attachments may move regardless of whether the mast
interlock function is activated or not. Therefore, when the
attachment lever is operated, some of the attachments will
move, even though the engine is not running or the key
switch is in the z (OFF) position, as a result of the handling
load or of its own weight.
See the table of 2-15 “Mast Interlock System”.
P00028
Example 1
The mast interlock indicator icon will blink when the key
switch is in the U (ON) position and you are not properly
sitting in the operator seat.
K00227
Remedy
(1) Sit properly in the operator seat.
(2) This causes the mast interlock indicator icon to go OUT.
(3) Place the lift or tilt lever in the NEUTRAL position.
(4) Place the lift or tilt lever in the operating position.
K00228
Note: The mast interlock indicator icon will glow when you sit in the operator seat in the normal operating position while the
lift or tilt lever is placed in the operating position. To clear this function, move the lift or tilt lever to the NEUTRAL position.
Example 2
The mast interlock indicator icon will glow when you turn
the key switch to the U (ON) position or start the engine while
the lift or tilt lever is placed to the operating position.
K00014
6-5
Remedy
(1) Place the lift or tilt lever to the NEUTRAL position and
turn the key switch to the z (OFF) position once.
(2) Turn the key switch to the U (ON) position.
(3) Make sure the mast interlock indicator icon is OUT.
K00015
Lifting the Load

(1) Move up to the load and stop the lift truck 20 to 30 cm
(8 to 12 in.) short of the load.
(2) Make sure the lift truck is square with the load and the
forks are at the correct height.
K00120L
1. 20 to 30 cm (8 to 12 in.)
R WARNING
When you pick up loads that extend above the load backrest
extension height, band them together to reduce the risk of
items from falling.
K00154
(3) Tilt the mast FORWARD to the vertical position, and

make sure the forks are at the correct height.
K00122L
6-6
R WARNING
Only stable or safely arranged loads must be handled.
DO NOT pick up an off-center load. Make sure the
weight of the load is centered between the forks.
K00123
(4) Place the direction lever in the FORWARD position and

slowly move the lift truck forward.
(5) Slide the forks into the pallet until they are fully under
the load.
K00124L
R WARNING
Avoid approaching the load at high speeds. Under all
travel conditions, operate the lift truck at a speed that
will permit it to be brought to a stop in a safe manner.
K00125

(7) Carefully lift the load about 10 cm (4 in.) off the stack.
Slowly return the lift lever to the NEUTRAL position.
K00126L
1. 10 cm (4 in.)
6-7
R WARNING
DO NOT mistake the direction and operating control
levers!
If you operate the wrong lever, collision of the lift truck
with people or objects could occur, or you could drop
the load.
K00229
Traveling With the Load

(1) Look behind you.
(2) Place the direction lever in the REVERSE position.
K00222L
(3) Slowly move the lift truck 20 to 30 cm (8 to 12 in.) away

from the stack, and then stop the lift truck.
(5) Lower the forks to a position 15 to 20 cm (6 to 8 in.)
from the ground. 1
2
K00223L
1. 20 to 30 cm (8 to 12 in.) 2. 15 to 20 cm (6 to 8 in.)
(6) Tilt the mast fully back to cradle the load.
R WARNING
Slack lift chains means there is a rail or lift bracket hang up.
Raise the mast before you move.
When stacking loads:
- Watch your lift chains.
- If they go slack, stop lowering. Then raise the load
and lower it again.
K00159
6-8
R WARNING
DO NOT pick up an off-center load. Make sure the
weight of the load is centered between the forks.
K00129
(7) Look around to make sure your work area is clear.

(8) Sound the horn.
(9) Move the lift truck into the work area.
K00132L
R WARNING
If the load blocks your view, or when you travel down a
grade with the load, drive in REVERSE. Always look in
the direction of travel.
K00133L
6-9
Unloading
(1) Stop the lift truck 20 to 30 cm (8 to 12 in.) short of the
unloading area.
1
K00134L
1. 20 to 30 cm (8 to 12 in.)
(2) Tilt the mast forward to the vertical position.

(3) Lift the load 10 to 15 cm (4 to 6 in.) higher than the
stack.
K00218L
1. 10 to 15 cm (4 to 6 in.)
(4) Slowly move the lift truck forward to position the load
just over the stack.
K00219L
(5) Carefully lower the load onto the stack.

(6) Lower the forks just enough so that the forks no longer
have contact with the load.
K00138L
6-10
(7) Look behind you.

(8) Sound the horn.
(9) Place the direction lever in the REVERSE position and
carefully back the lift truck away from the load.
K00128L
(10) When you disengage the forks from the load, stop the
lift truck.
(11) Lower the forks to a position 15 to 20 cm (6 to 8 in.)
from the ground.
K00141L
(12) Operate the tilt lever to tilt the mast fully back.
(13) Look around to see that it is safe to drive in your work
area.
(14) Place the direction lever in the REVERSE position.
(15) Sound the horn.
(16) Move up to your next position.
K00142L
R WARNING
Be careful not to drag the forks.
K00140L
6-11
R WARNING
- DO NOT travel with the mast tilted forward or with
the load in the elevated position. This will increase
the possibility of the lift truck tipping over.
- DO NOT tilt the mast with the load in the elevated
position.
- DO NOT leave the lift truck with the load in the
elevated position.
K00162
6-12
 Working on Grades
 Normal Travel Position
- Keep the forks or the load at a safe travel height, which
is 15 to 20 cm (6 to 8 in.) from the ground.
2
- Tilt the mast fully back when the lift truck is loaded.
1
K00163
1. 15 to 20 cm (6 to 8 in.) 2. Tilt back
 Traveling on a Grade
R WARNING
- DO NOT continuously use the brake pedal alone. This could result in brake failure and an accident.
- DO NOT use the inching pedal when traveling down a grade. This prevents the engine from acting as a engine
brake.
- DO NOT place the direction lever in the NEUTRAL position when traveling down a grade.
Travel up a grade in the FORWARD direction and down a

grade in the REVERSE direction when the lift truck is loaded.
When travelling down a long grade, switch the speed
selector switch to 1 speed, and use engine brake and service
brake.
K00146L
6-13
 Stopping on a Grade
R CAUTION
Depress the brake pedal when you have to stop the lift
truck on a grade. DO NOT hold the lift truck by pressing
the accelerator pedal. This may cause clutch plate wear
or torque converter failure.
K00147L
When traveling UP or DOWN a steep grade:

(1) DO NOT turn the engine OFF.
(2) DO NOT make any turns.
(3) DO NOT travel across the grade.
 Starting on a Grade (Engine Stalls on a Grade)

(2) Lower the forks to the ground.
(3) Depress the brake pedal.
(6) Place the direction lever in the FORWARD position.
(7) Raise the forks or load to the normal travel position.
(8) Quickly shift your right foot from the brake pedal to the
accelerator pedal.
(9) Release the parking brake while gradually pressing the
accelerator pedal. K00145L
6-14
STORING THE LIFT TRUCK
 STORING THE LIFT TRUCK
 End of Each Shift Storage
To ensure the long life of your lift truck, be sure to take the following steps at the end of each shift:
(1) Park the lift truck in an authorized area.
(2) Block the wheels securely.
(3) Check under the lift truck for oil or coolant leaks.
(4) Clean the lift truck to keep it free of dirt and oil. This will make it easier to spot loose or defective parts.
R WARNING
BE SURE to apply the parking brake before blocking the wheel!
- Before blocking or releasing the wheels, make sure that the parking brake is applied. If not, the lift truck could
start moving by itself, resulting in accidents.
- Perform a thorough walk-around inspection for any damage. Report all damage or faulty operation immediately.
DO NOT operate a lift truck that has a maintenance problem.
- DO NOT put your hand between the tire and wheel chock when using a wheel chock to block wheels. The lift truck may
move, causing your hand to be pinched.
R CAUTION
DO NOT expose the ECM/ECU boxes to rainwater. DO NOT sprinkle water over ECM/ECU boxes when washing the lift truck.
 Long Term Storage

If your lift truck is stored for any length of time, take the following safety precautions to reduce the risk of deterioration of the
lift truck components.
If it is necessary to store the lift truck outdoors, park it on hard level ground surrounded with wooden blocks, and cover it with
a water-proof plastic sheet to protect it from humidity or dust.
 Storage Within Three Months

Operate the lift truck for thirty minutes at least once a month. Run the engine at normal idle speed as well as high idle speed to
warm up the engine fully.
Also, move the lift, tilt, and attachment cylinders through their entire stroke.
Fuel system
Remove the fuel tank from the lift truck and take necessary safety precautions.
Hydraulic system
After moving your lift truck for storage, retract all the hydraulic cylinders to minimize rod exposure. This will reduce the risk of
rusting of the sliding contact surfaces of the rods.
7-1
STORING THE LIFT TRUCK
 Storage Exceeding Three Months
Contact your authorized local Cat® lift truck dealer and ask for proper storage procedures.
After prolonged storage, have your local Cat® lift truck dealer inspect the lift truck before operation.
Fuel system
- LP-Gas engine model:
Remove the fuel tank from the lift truck and take necessary safety precautions.
Hydraulic system
After moving your lift truck for storage, retract all the hydraulic cylinders to minimize rod exposure.
This will reduce the risk of rusting of the sliding contact surfaces of the rods.
Engine cooling system

Protect the cooling system from freezing by draining the system or by adding an antifreeze mixture.
Engine cylinders
Over a long storage period, the cylinders may rust from moisture condensation within the cylinders. To reduce the risk of
rusting of cylinder walls, remove the spark plugs (injection nozzles) and squirt a small amount of engine oil into the cylinders.
Crank the engine several times with the starter in order to spread oil uniformly onto the cylinder walls, and then install the
plugs (injection nozzles).
Perform this procedure when starting the engine after storage.
Battery
Remove the batteries from the lift truck and charge them. Store them in a dry, cool place. Check the battery fluid periodically
and add distilled water if the level is low. Also check the specific gravity of electrolyte, and charge if it is below the 1.28 (20).
Clean the battery and apply an antirust agent to the terminals.
Controller
Moisture is harmful to the controller.
DO NOT allow the controller to get wet when washing the lift truck.
- ECM
- ECU
7-2
TRANSPORTATION HINTS
 TRANSPORTATION HINTS
Lift Truck Loading and Shipping
Be sure to take the following safety precautions before
loading and shipping lift trucks:
- Always block the trailer or rail car wheels before loading
the lift truck.
- Position the lift truck on the truck bed or rail car.
- Apply the service brake and then apply the parking
brake. Place the direction lever in the NEUTRAL
position.
- Turn the key switch to the z (OFF) position and
remove the key. M00002
- Block the wheels and secure the lift truck with tie-
downs.
- Do not turn the steering wheel after the lift truck has
been secured. It may loosen the tie-downs.
R WARNING
Check travel route for overpass clearances. Make sure there is adequate clearance if the lift truck being transported is equipped
with a high mast or cab. Remove ice, snow, or other slippery material from the shipping lift truck and loading dock.
Lift Truck Lifting and Tie Down Information

Take the following safety precautions when lifting or tying down lift trucks:
- Weight and instructions given here apply to lift trucks manufactured by Mitsubishi Caterpillar Forklift America Inc.
- Use proper rated cables and slings for lifting. Position the crane so the lift truck is level when lifted.
- Spreader bar widths should be sufficient to prevent contact with the lift truck.
- Use the tie-down locations provided for lift truck tie down.
R CAUTION
Incorrect lifting or tie-downs may cause a load to shift and cause injury and/or damage.
Note: Check the state and local laws governing weight, width, and length of a load. Contact your authorized Cat® lift truck
dealer for shipping instructions for your lift truck.
8-1
SPECIAL SITUATIONS
 SPECIAL SITUATIONS
Care in Cold Weather
 Lubrication Oils
R CAUTION
- Use engine oil and gear oil to fit the ambient
temperature.
N00001
Note: For type and concentration of antifreeze, consult your authorized Cat® lift truck dealer.
 Battery
- Consult your battery manufacturer for the specific
gravity of your battery. 4
- When you park your lift truck overnight, leaving it 3
outside in the elements, remove the battery and keep it
warm.
N00013
1. Glass tube 3. Float
2. Electrolyte 4. Electrolyte level
Note: The electrolyte of a fully charged battery will not freeze to -35°C (-31°F).
R CAUTION
- After distilled water has been added to the battery, run the engine for a while. This mixes the added water with the
electrolyte and will reduce the risk of freezing and damaging the battery.
- DO NOT attempt to restore a battery's charge by pouring boiling water over it. This may break the battery case, resulting
in acid contact with skin or eyes.
 Engine Coolant
- Antifreeze used in the engine cooling system of a new
lift truck shipped from the manufacturer provides
sufficient freeze protection to -30°C (-22°F).
- If ambient temperatures are below -30°C (-22°F), add
antifreeze.
Note: For types and concentration of antifreeze, consult
your authorized Cat® lift truck dealer.
N00025
9-1
SPECIAL SITUATIONS
Care in Hot Weather
 Lubrication Oils
Use fuel oil, engine oil, and gear oil to fit the ambient
temperatures.
Note: For selection of fuel oil, engine oil, and gear oil,
consult your authorized Cat® lift truck dealer.
N00015
 Battery
In hot and/or dry weather, check the battery cells for proper electrolyte level more often than in cold weather. Add distilled
water whenever the level is low.
 Engine Coolant
R WARNING
Be careful NOT to have scalding hot coolant or steam blow out of the reserve tank. Remove the radiator cap only after engine
cools.
Note: Coolant evaporates rapidly and the engine is likely to get overheated when the lift truck is operated continuously or on a
grade. During such an operation, observe the engine coolant temperature gauge for symptoms of overheating.
R CAUTION
If the water temperature warning icon glows, the engine may be overheated.
Note: If the water temperature warning icon glows, see 10-1 “If the Water Temperature Warning Icon Glows”.
9-2
SPECIAL SITUATIONS
Severe Dust or Lint Conditions
Check and service the filters and oils more frequently.
For details, contact your authorized Cat® lift truck dealer.
 Air Cleaner Element

The air cleaner elements can be cleaned up to five times. Replace the filter after the element has been cleaned five times.
For reference
Standard
inspection Every 50 hours or weekly
intervals
Standard change
Every 6 months or every 1200 hours
intervals
 Engine Oil and Engine Oil Filter
For reference
One month or 200 hours after
Standard change
purchase of a new lift truck.
intervals
Every month or 200 hours
 Hydraulic Oil
For reference
Standard change
intervals
 Hydraulic Tank Return Filter
For reference
One month or 200 hours after
Standard change
purchase of a new lift truck.
intervals
- For the use in severe dust conditions, a dust-proof type

is available.
Contact your authorized Cat® lift truck dealer if one is
necessary.
- Check the radiator core more frequently for clogging or
trash build-up. Clean or wash the lift truck as needed.
N00017L
9-3
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 start the engine.
P00116
 Before Starting the Engine Again

Check the following items, and remove the cause of the stall:
- Lack of fuel
- Engine overloading
If the Water Temperature Warning Icon Glows
R WARNING
- DO NOT attempt to remove the radiator filler cap if the
engine is overheated to avoid scalding hot coolant and
steam from blowing out of the radiator.
- DO NOT add cold water to an overheated engine. This
could cause the engine damage. Wait for the engine to
cool, if possible. If not, slowly pour water into the
radiator.
- Immediately turn the engine OFF if the fan belt is
broken.
P00081
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
- Brake fluid
- Electrolyte
10-1
TROUBLESHOOTING
(1) Park the lift truck in a safe area.

(2) Raise the engine hood and seat assembly 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

(1) Stop the lift truck in a non-traffic area.
(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.
N00026
R CAUTION
If the warning icon does not go out, or if it constantly glows, consult your authorized Cat® lift truck dealer.
10-2
TROUBLESHOOTING
Starting With Jumper Cables
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 allow jumper cable ends to contact each other or the lift truck.
- DO NOT smoke when checking battery electrolyte levels.
- Electrolyte is an acid and could cause injury if it contacts skin or eyes. Always wear eye protection when starting an engine
in the lift truck with jumper cables.
- Incorrect jump start procedures could cause an explosion that could result in injuries. Turn OFF all lights and accessories
on the stalled lift 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 lift truck.
R WARNING
- BE SURE to connect the cable end to the ENGINE BODY. If it is connected to the negative (-) terminal of the battery, sparks
could ignite the gases.
R CAUTION
- Connect the jumper cables away from the moving parts in the engine compartment.
- DO NOT touch the cable with wet hands. If touched, it may result in an electrical shock.
- When carrying batteries, provide short circuit prevention to the terminals. If metals come in contact with the terminals, a
short circuit could result.
Note:
- Use 12 volt jumper cables to jump start the lift truck. This lift truck has a 12 volt starting system.
Use only equal voltage for jump starting. Use of a welder or higher voltage will damage the electrical system.
- Turn OFF the battery switch prior to the boost connection to prevent damage to electrical components on the stalled lift
truck. Many "dead" batteries can be charged.
- To start a lift truck with a "run-down" battery, use a booster battery or jumper cables from the battery of a second lift truck.
10-3
TROUBLESHOOTING
1)
3) 2)
P00197
1) Cable end 3) "Good" Battery
2) Lift 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
NOT short across the positive (+) and negative (-) 4
terminals.
3
(3) After connecting the cables, increase the engine 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 2 1
the reverse sequence.
J00192
Note: Jumper cables are available at your authorized Cat® lift truck dealer.
If Lights Won't Glow
R CAUTION
- DO NOT use a fuse that is overrated. DO NOT use a wire or aluminum foil for a fuse. It can overheat or burn.
- Always replace fuses with fuses of the correct amperage.
- If a fuse burns out immediately after being changed and you cannot locate the cause, have your authorized Cat® lift truck
dealer test the circuit.
- Always use a light bulb of the same wattage.
Circuit Capacity
Park lamp, tail lamp, rear working lamp, head lamp 15 A
Stop lamp 10 A
Horn, IGN lamp, starter relay 10 A
Neutral lock controller, FWD/REV solenoid, start safety relay, seat switch,
10 A
mast lock controller, lift lock solenoid, unload solenoid
Engine harness, engine check lamp 10 A
Back lamp, back buzzer, flasher relay, turn signal lamp, strobe lamp, T/M
15 A
change solenoid
Meter panel, T/M controller, T/C oil temp. relay, dust indicator lamp, T/C
10 A
oil temp. lamp, inter lock lamp relay 2
Spare 10 A
Spare 15 A
10-4
TROUBLESHOOTING
 How to Check Fuses and Lights
(1) Check for burned-out or blown fuses first.
(2) Check the fuses one by one by operating the light

switch and observing which light turns ON.
P00195
1. Fuse
(3) All lights of the circuit fail to light.
(4) 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
(5) Check to see if fuse is blown.
OK OK
E00068
10-5
TROUBLESHOOTING
(6) There is no problem with the fuses.

- Check to see if light is burned out.
- Lights may be burned out.
Light Type Capacity

Head light 12V-24W
Working light (Option) 12V-12W
Front Turn signal light

12V-6W
(option) Clearance light
Tail / stop light
Rear Back-up light 12V/4.8W
Turn signal light
Trouble with the LP-Gas Equipment
R WARNING
- If you smell gas or notice something wrong with LP-Gas equipment during operation, immediately stop the lift truck in a
safe area, turn the key switch to the z (OFF) position, close the fuel valve of the LP-Gas tank, and try to find the cause. It is
recommended that a test kit be available 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, extinguish any fire or flame source (such as glow pilot light) and eliminate
the possibility of creating sparks near the lift truck. Ventilate the work place.
- 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 the lift 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 dioxide type extinguisher. DO NOT 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.
10-6
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, a built-in 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
N
engine OFF and consult your authorized Cat® lift truck
dealer.
NO
Place the direction lever to the NEUTRAL position and sit
securely, with the seat belt fastened.
P00193
The driving interlock indicator light is OFF but the lift truck fails to move.
dealer.
N
P00194
10-7
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, a built-in 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
N
dealer.
NO
Sit securely with the seat belt fastened, and apply the
parking brake. Then release the parking brake.
P00193
The driving interlock indicator icon is OFF but the lift truck fails to move.
dealer.
N
P00194
10-8
TROUBLESHOOTING
If the Mast Stops Moving
If the operator half rises from the operator seat for more than approximately 2 seconds without the lift or tilt lever being placed
in the NEUTRAL position, a built-in operator presence switch in the operator seat activates the mast interlock system.
The mast interlock indicator icon glows and the mast stops moving.
Are you seated?

YES
dealer.
NO
Place the lift and tilt levers to the NEUTRAL position and sit
securely with the seat belt fastened.
P00196
The mast interlock indicator icon is OFF but the mast fails to move.
dealer.
Note: The mast interlock will work only for the lift and tilt
levers. Attachments can be moved regardless of
whether the mast interlock function is operating or
not. Therefore, when the attachment lever is
operated, some of the attachments will move, even
though the engine is not running or the key switch is
in the z (OFF) position, as a result of the handling
load or of its own weight. P00029
10-9
MAINTENANCE
 MAINTENANCE
General
Taking proper care of your lift truck is a vital part of the overall planned maintenance program.
Your participation in this program will provide an early identification of potential maintenance problems. Do-it-yourself
maintenance does not include repairs. If your lift truck requires any repairs, consult your Cat® lift truck dealer. The dealer's lift
truck mechanics are well trained and know how to safely make repairs.
R WARNING
Follow these rules to help reduce the risk of injury and to service your lift truck properly.
- Make sure the service area is safe.
- (1) Park the lift truck on level ground with the forks lowered until the forktips touch the floor.
(2) Parking brake applied
(3) Direction lever in the NEUTRAL position
(4) Engine stopped
(5) The wheels blocked
- All repairs must be made by authorized personnel.
- Follow the recommended safety procedures.
- Use only the proper tools for the job.
R WARNING
DO NOT bypass any electrical switches on this lift truck.
R WARNING
If during operation the lift truck becomes unsafe in any way, the matter must be reported immediately to the user's designated
authority, and the lift truck must not be operated until it has been restored to a safe operating condition.
R WARNING
BE SURE to perform inspections.
- If you fail to perform required inspections, it could lead to accidents.
- Operate the lift truck at a reduced speed during inspections. An accident could be caused if operated at normal speed and
the lift truck is faulty.
- Dress properly for the job. DO NOT wear loose clothing or accessories (flapping cuffs, dangling chains, neck ties, scarves, or
rings) that could catch in moving parts.
- Wear personal protective equipment appropriate for the conditions of your work places.
11-1
MAINTENANCE
R WARNING
Lines, tubes, and hoses
- Leaks could cause fires. Contact your authorized Cat® lift truck dealer for repair or replacement.
- DO NOT bend or strike high pressure lines. Check lines, tubes, and hoses carefully.
- DO NOT install bent or damaged lines, tubes, or hoses.
- Repair loose or damaged oil lines, tubes, or hoses.
- DO NOT use your bare hands to check for leaks, use a board or cardboard.
- Tighten connections to the specified torque.
- 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.
- 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
Inspection Precautions
R WARNING
If the lift truck requires any repair, attach a "DO NOT
OPERATE" or similar warning tag to the steering wheel or
other controls, remove the key from the key switch, and
contact your authorized Cat® lift truck dealer.
ER T
E
OP O NO
AT
D
Q00374
R WARNING
If it is necessary to make an inspection while the engine is running, ALWAYS USE TWO WORKERS i.e., one, the operator, at the
controls and the other checking within visual contact of the operator.
R CAUTION
A daily (prestart) inspection is the key for safety. At the beginning of each shift, check your lift truck to make sure it is in a safe
operating condition. Always inspect your lift truck under the following conditions:
- Lift truck on level ground
- Mast in vertical position
- Forktips on ground
- Engine stopped
- Operating control levers in the NEUTRAL position.
- Wheels blocked.
11-2
MAINTENANCE
R CAUTION
- 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.
- Before refilling, clean filler holes. After filling, clean up spills.
R CAUTION
Consult your authorized Cat® lift truck dealer for the proper disposal of wastes accumulated after replacement of tires,
batteries, oils, and fluids.
Maintenance Schedule
As an operator, you are responsible to perform the daily (prestart) 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 a proper working condition.
For periodic inspection and replacement of rubber parts, however, rely on the expert knowledge of the dealer's well-trained
mechanics, and consult your authorized Cat® lift truck dealer's workshop.
Periodic inspection time intervals

- Every 10 Service Hours or Daily (Prestart), whichever comes first
- One month (30 days) or 200 service hours after delivery of a new lift truck, whichever comes first
- Every 200 service hours or monthly, whichever comes first
- Every 1200 service hours or 6 months, whichever comes first
- Every 2400 service hours or 12 months, whichever comes first
 Every 10 Service Hours or Daily (Prestart), Whichever Comes First
Item Service Page

Faulty Operation Found the Day Before Check 11-8
Brake System Brake Pedal Check free play 11-8
Parking Brake Lever Check 11-9
Brake Hose, Pipes and Joint Check -
Brake Fluid Level Check fluid level 11-9
Cooling System Engine Coolant Check coolant level 11-10
Electrical System Battery (Not required if battery type is
Check electrolyte level 11-11
maintenance free)
Electric Wires Check any loosen wires 11-12
Horn Check 11-12
Icons of Meter Panel Check 11-12
Head Lights and Working Lights
Check 11-12
(If Equipped)
Backup Lights Check 11-13
Stop Lights Check 11-13
Turn Signal Lights (If Equipped) Check 11-13
Driving Interlock System Check 11-14
Mast Interlock System Check 11-15
Engine (Exhaust, Noise, and Vibration) Check 11-15
Engine
Engine Crankcase Check oil level and dirt 11-16
11-3
MAINTENANCE
Item Service Page

Assist Grip Check 11-17
Overhead Guard Check 11-17
Frame & Chassis Operator Seat Adjust operator seat 11-18
Seat Belt Check 11-18
Rear View Mirror (If Equipped) Check 11-18
Fuel System Amount of Fuel (Lift truck level) Check fuel level 11-18
Hydraulic System Hydraulic Oil Check oil level and dirt 11-19
Operation Lever and linkage Check -
Mast & Forks Check damage and
Lift Chains 11-20
distortion
Mast, Lift Bracket, and Forks Check 11-21
Load Backrest Extension Check 11-23
Lift and Tilt Cylinder Check -
Mast Strip Sliding Surfaces Check -
Tilt Cylinder Socket Bolts Check -
Lift Bracket Main Roller and Side Roller Check -
Steering System Steering Column Check -
Steering Wheel Check movement 11-23
Driving System Accelerator Pedal Check 11-23
Inching Pedal Check 11-24
Wheel Wheel Nuts Check 11-24
Check abnormal wear an
Tires and Rims 11-24
measure tire tread depth
General Oil, Fuel, or Coolant Leaks Check 11-25
 Every 50 Service Hours or Weekly, Whichever Comes First
Item Service Page

Cooling System V-belt (fan and altornator) tension Check 11-25
Hydraulic System Hydraulic Hose, Pipes, and Joints Check -
Intake System Air Cleaner Element Clean 11-27
Mast & Forks Mast Supports Lubricate 11-29
General Bolts and Nuts Check 11-29
 One Month (30 Days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever
Comes First
Item Service Page

Fuel System LPG Filter Replace 11-29
Hydraulic System Hydraulic Tank Return Oil Filter Replace 11-29
11-4
MAINTENANCE
 Every 200 Service Hours or Monthly, Whichever Comes First
Item Service Page

Brake System Brake Pedal Lubricate 11-29
Brake Shoe Clearance Check -
Cooling System Cooling fan Check -
Radiator Filler Cap Check -
Rubber Hose Condition Check -
Electrical Alternator Check -
Battery Electrolyte Specific
Check -
Gravity
Starter Check -
Engine Engine Crankcase Replace oil and filter 11-30
Engine Idle Speed Maximum No-
Check -
load Speed
Idling and Acceleration Check -
Positive Crankcase Ventilation
Check -
Valves and Hoses
Exhaust Pipe and Muffler Check -
Exhaust Smoke Check -
Frame and Chassis Frame Assist Grip Check -
Loosen Bolts and Nuts Check -
Operator Seat Check damage and Looseness -
Fuel Tar in Vaporizer Check -
LPG Hose, Pipes, and Joints Check Damage -
Injection Nozzle Check -
Hydraulic Hydraulic Pump Check Oil Leakage -
Loading Devices and Hydraulic Check
-
System
Mast & Forks Lift and Tilt Cylinder Check -
Lift Cylinder Mounting Bolts Check -
Lift Chains Lubricate 11-31
Lift Bracket Side Rollers Lubricate 11-31
Mast Strips, Roller Sliding Lubricate
11-32
Surfaces
Tilt Socket Pins Lubricate 11-32
Tilt Cylinder Pins Lubricate 11-32
Fork Lowering Speed Check -
Steering and Axles Steering Gear Box Lubricate -
Rear Axle Mount Bushings Lubricate -
Rear Axle Center Pin (Front, Rear) Lubricate 11-32
Tie Rod Pins Lubricate 11-33
11-5
MAINTENANCE
Item Service Page

Transmission Transmission Oil Filter Check -
Differential Oil Check Oil Level 11-33
Inching Pedal Check -
Transmission Oil Check Oil Level 11-34
Universal Joint Lubricate -
Wheel Wheel Nuts Check -
General Hydraulic Lines, Tubes, and Check
-
Hoses
Grease Nipples Lubricate -
 Every 1200 Service Hours or 6 Months, Whichever Comes First
Item Service Page

Fuel System Fuel Filter Replace 11-35
Hydraulic System Wash Strainer Clean 11-38
Return Oil Filter Clean 11-38
Intake System Air Cleaner Element Replace 11-39
Transmission Return Oil Filter, Wash Strainer Replace 11-42
Transmission Oil Replace oil 11-42
Differential Oil Replace oil 11-43
*In corrosive or abrasive environments, more frequent cleaning, lubrication, changing, or replacement is required.
 Every 2400 Service Hours or 12 Months, Whichever Comes First
Item Service Page

Brake System Brake Fluid Replace fluid 11-40
Brake Hose and Tube Replace -
Brake Wheel Cylinder Rubber Replace
-
Parts
Brake Booster Rubber Parts Replace -
Braking Force, Brake Drum and Check
-
Shoe, and Other Devices
Backing Plate, Fitting Cable, Check
-
Ratchet
Hydraulic System Control Valve Check -
Hydraulic Oil Replace oil 11-40
Cylinder, Safety Valve, Solenoid Check
Valve, and Other Hydraulic -
System
11-6
MAINTENANCE
Item Service Page

Steering and Axles Front Axle Check -
Power Steering Cylinder Check -
Rear Axle Check -
Rear Wheel Bearings Check -
Knuckles Check -
Wheel Bearings and Other Check
-
Traveling Devices
Wheel Steering Angle, Rod, Arm, Check
-
and Other Operating Devices
Cooling System Engine Coolant Replace 11-44
Transmission Transmission Gear and Bearing Check -
Differential and Other Power Check
-
Flow Devices
11-7
MAINTENANCE
Every 10 Service Hours or Daily (Prestart), Whichever Comes First
You must read and understand the warnings and instructions contained in this manual before performing any operation or
maintenance procedure.
 Faulty Operation Found the Day Before

- Have repairs been made properly?
- Check the daily inspection sheet.
R WARNING
Fill out the daily inspection sheet.
Remember, the complete performance of a daily inspection
is the best protection against injury and property damage.
Q00375
 Brake Pedal
Check
- Do you have sufficient pedal travel?
- Does the brake pedal return to the full, upward
position?
Q00262
Free play
Value
5 mm (0.2 in.)
11-8
MAINTENANCE
 Parking Brake Lever
- Can you pull the parking brake lever all the way with
reasonable effort?
- Can you hold the lift truck on a grade by pulling the
brake lever?
- Check if the lift truck stops when pulling the parking 1 2
brake lever on a grade.
J00523
1) Release 2) Apply
Lever operating effort:

250 to 290 N (25 to 30 kgf) [55 to 66 lbf]
 Brake Fluid Level

Check brake fluid level
R WARNING
If the brake fluid in the reserve tank decreases rapidly, the brake system is leaking.
Have your Cat lift truck dealer check the system.
R CAUTION
Before refilling the reserve tank, clean the ports to reduce the risk of dirt from getting inside the reserve tank.
Park the lift truck on level ground with the forks lowered
until the forktips touch the ground, parking brake applied,
direction lever in the NEUTRAL position, engine stopped
and the wheels blocked.
(1) Check the brake fluid level at the reserve tank.
1)
(2) Maintain the brake fluid level between the MAX and
MIN marks on the reserve tank.
Q00672
1) Correct level range
Adding brake fluid

(1) Remove the reserve tank cap.
(2) Add brake fluid to the reserve tank.
(3) Put the reserve tank cap back on.
11-9
MAINTENANCE
 Engine Coolant
Check coolant level
R WARNING
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.
How to check coolant level

and cold.
(1) Raise the engine hood. 1)
(2) Maintain the coolant level between the FULL (F) and
LOW (L) marks on the reserve tank.
(3) Close and secure the hood.
Q00668
Add coolant
R WARNING
Keep fire away from undiluted antifreeze as it is FLAMMABLE.
R CAUTION
DO NOT add water only. This dilutes the antifreeze/summer coolant (ASC) protection and adversely affects the engine. BE SURE
to premix ASC with tap water (soft water). See 12-3 "Specifications".
If coolant has to be added frequently, have your Cat® lift truck dealer check the cooling system.
R CAUTION
- Antifreeze/summer coolant (ASC) contains 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 transfer
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.
(1) Remove the reserve tank cap and add coolant to the
FULL mark.
(2) When adding coolant, maintain the same
concentration of antifreeze solution.
Note: The engine cooling system is protected to -30°C (-
22°F) with 50% concentration of ASC when shipped
from the manufacturer.
Q00031
11-10
MAINTENANCE
R WARNING
Antifreeze solution is TOXIC. In case of contact with your
skin, FLUSH IMMEDIATELY WITH WATER. Have your
authorized Cat® lift truck dealer dispose of antifreeze
solution drained from the engine.
D00692
 Battery
Check electrolyte level
R WARNING
- If acid contacts your skin or clothes which could cause burns, FLUSH THEM IMMEDIATELY WITH LARGE AMOUNTS OF
WATER.
- If acid gets in your eyes by accident, FLUSH THEM IMMEDIATELY WITH LARGE AMOUNTS OF WATER AND SEE A DOCTOR.
- If you drink acid by accident, DRINK LARGE AMOUNTS OF WATER AND SEE A DOCTOR AT ONCE.
R WARNING
- To disconnect battery terminals, negative terminal (-) must be removed first.
- To connect battery terminals, negative terminal (-) must be installed last in reverse sequence from the disconnection.
How to check electrolyte level

(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 distilled water, tighten the caps 1)
securely.
Q00257
11-11
MAINTENANCE
 Electric Wires
Check
Check for loose or disconnected electric wires.
Q00724
 Horn
- Does the horn activate properly when you push the
horn switch?
Q00653
 Icons of Meter Panel

Do all the warning icons glow when the key is in the U ON
position (except for the lights marked*)?
Note: When a warning icon does not glow with the key in
the U ON position, the bulb may be burned out.
Contact your authorized Cat lift truck dealer for repair
or replacement. * * *
Q00661
 Head Lights and Working Lights

- Are all the lights in a safe working condition?
- Are their lenses clean and not defective?
- Do the tail and head lights turn ON properly when you
turn them ON?
Q00728
11-12
MAINTENANCE
 Backup Lights
When you move the direction lever into REVERSE position:
- Do all backup lights turn ON?
- Does the backup buzzer activate (if equipped)?
Q00660
 Stop Lights
When you press the brake pedal:
- Do the stop lights turn ON?
Q00726
 Turn Signal Lights (If Equipped)

Place the turn signal switch into left or right turn position,
and check the following:
- Do the turn signal lights turn ON?
Q00727
11-13
MAINTENANCE
 Driving Interlock System
Check
R CAUTION
- Make sure that the area is clear of pedestrians and obstacles when checking the driving interlock systems.
- Check this system on level and hard ground.
- To ensure the lift truck does not begin rolling, DO NOT park the lift truck on a grade.
- Make sure that the sufficient space is available for the lift truck to move around and that no persons or obstacles are
around the lift truck.
- The operator must always apply the parking brake before leaving the lift truck when stopped on level ground or a grade.
How to check
(1) Slightly raise the forks from the floor or ground.
(2) Run the engine idling (not depressing on the
accelerator pedal).
(3) Place the direction lever in the FORWARD or REVERSE
position.
(4) Half rise from the operator seat.
(5) Check the following after approximately 2 seconds:
Q00273
- Does the neutral indicator icon "N" glow?

Note: The transmission should electrically shift into
NEUTRAL with the driving interlock indicator icon
glowing. If you are on a grade, the lift truck will
N
continue to roll because the transmission is in
NEUTRAL.
P00193
How to restore
(1) Sit properly in the operator seat and depress the brake pedal to hold the lift truck.
(2) Place the direction lever in the NEUTRAL position, then place the lever in the FORWARD or REVERSE position.
11-14
MAINTENANCE
 Mast Interlock System
Check
R CAUTION
Make sure that the area is clear of pedestrians when checking the mast interlock systems.
(1) Release the accelerator pedal and apply the brake

pedal.
(2) Raise the forks high enough to see them from the
operator seat.
(4) Place the direction lever to the NEUTRAL position.
(5) Half rise from the operator seat.
(6) Check the following after approximately 2 seconds:
Q00282
- Check that the mast interlock indicator icon glows in

approximately 2 seconds.
- Operate the lift lever and check that the forks do not
move UP and DOWN.
- Operate the tilt lever and check that the mast does not
tilt FORWARD or BACKWARD.
P00028
 Engine (Exhaust, Noise, and Vibration)
R WARNING
Exhaust fumes could kill you!
Some of the systems from carbon monoxide poisoning are
headaches, flu like systems, food poisoning like symptoms,
fatigue or weakness. If you feel any of these symptoms,
leave the area and consult a doctor.
Fire hazards!
- Clean up spillage of fuel, oil, or other flammable
materials in the engine compartment.
- Check the location of all emergency devices such as fire
extinguisher, first aid kit, etc. and know how to use Q00654
them.
- Is exhaust smoke normal?

- Listen for abnormal noise or excessive vibration.
11-15
MAINTENANCE
 Engine Crankcase
Check oil level
R WARNING
Hot oil and components could cause serious injury. DO NOT allow hot oil or components to contact your skin.
and the wheels blocked.
(1) Raise the hood.
(2) Remove the dipstick and wipe it clean, then insert it all
the way.
Q00664
(3) Maintain the correct level range on the dipstick.
Q00665
1. Correct level range
Adding engine oil
R CAUTION
- Perform the work on level ground.
- Clean the filler hole to prevent dirt from dropping into the engine.
- DO NOT overfill.
- Clean up spillage.
(1) Remove the oil filler cap.
Q00666
11-16
MAINTENANCE
(2) Add engine oil as required.

For engine oil, see 12-3 "Specifications".
Q00667
(3) After adding oil, make sure the level is in the correct
range on the dipstick.
(4) Close and tighten the filler cap.
Q00665
 Assist Grip
Inspect the assist grip for damage or cracks and also check
that it is secure. Tighten the screws of the assist grip if
necessary.
Q00377
 Overhead Guard
(1) Check the front and rear overhead guard mounting
bolts on each side.
(2) Inspect overhead guard for bent or cracked sections.
Contact your Cat lift truck dealer if repairs are needed.
Q00252
Tightening torque for the bolt

285 to 178.5 N·m (26.3 to 18.2 kgf·m) [190.2 to 131.6 lbf·ft]
11-17
MAINTENANCE
 Operator Seat
Can you depress the pedals all the way?
Note: See 2-18 "Seat Adjustment".
Q00658
 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.
E00918
 Rear View Mirror (If Equipped)

Inspect the rear view mirror for damage or cracks and also
check that it is secure.
QA0503
 Amount of Fuel (Lift truck level)

Does the LPG empty indicator light turn OFF? If the LPG
empty indicator light glows, replace the LPG tank.
Q00659
11-18
MAINTENANCE
 Hydraulic Oil
Check oil level
R WARNING
- Hot oil and components could cause personal 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 bare hand.
- Remove the hydraulic tank filler cap slowly to relieve pressure.
(1) Operate the lift truck for a few minutes to warm the oil.
(2) Park the lift truck on level ground with the forks
lowered until the forktips touch the ground, parking
brake applied, direction lever in the NEUTRAL position,
engine stopped and the wheels blocked.
(3) Remove the hydraulic tank filler cap by turning it
counterclockwise.
Q00669
(4) Add oil needed to raise it to the correct level range on

the dipstick.
Q00670
(5) Put the hydraulic tank filler cap back on.

(6) Check for oil leaks.
(7) Close and secure the engine hood. 1
H
QA0111
Add hydraulic oil
R CAUTION
When adding hydraulic oil:
- Perform the work on level ground.
- Clean the filler hole to reduce the risk of dirt from dropping into the tank.
- DO NOT overfill.
- Clean up spillage.
11-19
MAINTENANCE
(1) Remove the hydraulic tank filler cap.

(2) Add oil to the hydraulic tank.
For hydraulic oil, see 12-2 "Recommended Fuels and
Oils".
Q00671
(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.
 Lift Chains
Check and adjust
R WARNING
- Check the lift chains periodically and determine if they are still in usable condition.
- Check the lift chains for wear, cracks, worn, or seized link pins.
- Improper maintenance of the lift chains could cause accidents. If something is wrong with the chains, consult your Cat lift
truck dealer for repair or replacement.
- DO NOT put your foot under the fork.
How to check
(1) Check the lift chains for wear. Use the following chart to
determine if it is still in usable condition.
Q00381
(2) Lift the forks high enough to put their full weight on the
carriage and chains.
(3) Make sure the lift chains have equal tension.
(4) If the chains are loose or the tension is not equal, adjust
the chain tension.
Q00274
Lift chain elongation limit (/20 links)
Models Limit
3.5 to 4 ton 523 mm (20.6 in.)
4.5 to 7 ton 654 mm (25.7 in.)
11-20
MAINTENANCE
How to adjust
(1) Loosen the locknut 1. Then turn the nut 2 to adjust
tension. 1
(2) Hold the nut 2 and tighten the locknut 1 to the
following torque.
2
Q00662
1. Locknut 2. Nut
Models Tightening torque

3.5 to 4 ton 210 N·m (21.4 kgf·m) [155 lbf·ft]
4.5 to 7 ton 290 N·m (29.6 kgf·m) [214 lbf·ft]
 Tilt Cylinder Socket Bolts

- Are the bolts tightened properly?
Use a wrench.
Q00656
Tightening torque for the bolt

262 ± 13 N·m (26.7 ± 1.3 kgf·m) [193.4 ± 9.6 lbf·ft]
Note: After retightening the bolt, put a mark across the bolt and tilt cylinder socket. This permits you to easily notice loosening
of the bolt.
 Mast and Forks
Check
- Does the mast move UP and DOWN smoothly when
you operate the lift lever?
- Does the mast tilt FORWARD and BACKWARD smoothly
when you operate the tilt lever?
- Are there any oil leaks from the cylinders and hydraulic
lines?
Q00448L
11-21
MAINTENANCE
- Is the fork locking pin properly engaged?

- Are the forks free of distortion and cracks? 1) 1)
- Are the welds of the hangers free of cracks? OK OK
Q00730
1) OK
Note: If the lift truck is 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 mounting brackets B.
B
Forks with cracks should be removed from service.
Note: “Wet Test" magnetic particle inspection is generally
recommended due to its sensitivity and the ease of
interpreting the results. Portable equipment is usually
recommended so it can be moved to the lift truck. A
Contact your authorized Cat® lift truck dealer for
further information.
Q00394
(2) Check the difference in height of one forktip to the

other when mounted on the lift bracket.
A difference in forktip height could result in uneven support
of the load and cause problems when entering loads.
The maximum allowable difference in forktip elevation C is 5
mm (0.2 in.) for pallet forks. Replace one or both forks when
the difference in forktip height exceeds the maximum C
allowable difference.
Q00395
(3) Check the fork blade D.

Note: The fork should be withdrawn from service if the
thickness is reduced to less than the tolerant
thickness.
Fork blade length may also be reduced by wear,
especially on tapered forks and platens. DO NOT use
the forks when the blade length is no longer adequate D
for the intended loads.
Q00396
11-22
MAINTENANCE
 Load Backrest Extension
Is the load backrest extension free of distortion, cracks, and
other defects? Shake the load backrest extension to check
for excessive rattle.
Q00655
 Steering Wheel
- 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 directions.
- Is the steering wheel installation loose?
Check by shaking the steering wheel up and down.
J00298
 Accelerator Pedal
- Can you depress the accelerator pedal smoothly
without any sign of rubbing?
Q00261
Foot direction control (option)
Q00657
11-23
MAINTENANCE
 Inching Pedal
- Does the lift truck inch when you slowly depress the
inching pedal?
Q00262
 Wheel Nuts
Check tightening torque when required

Wheel nuts should be visually inspected every day. Any loose nuts should be tightened and any missing or damaged nuts
should be replaced.
Retightening
(1) Always stand behind the tread of the tire, NOT in front
of the rim.
(2) Tighten the nuts evenly and in a diagonal sequence to
the specified torque.
Q00673
(3) Are the wheel nuts tightened properly? Use a torque wrench.
Tightening torques for wheel nuts
Side Torque
wheel nut 551 N·m (56.2 kgf·m) [406.5 lbf·ft]
 Tires and Rims

Check and inspect
R WARNING
Make sure the replacement tire is of the same size, type, and load range.
- Is the tread area thickness more than service 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?
Q00674
11-24
MAINTENANCE
Q00665
 Lift Chains
Lubricate each chain on the left and right of the mast.
Q00692
(1) Brush a film of engine oil onto the chain links, or spray with chain and cable lubricant.
(2) Raise and lower the lift bracket a few times to work lubricant into the chain links.
Note: Lubricate chains more frequently 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.
 Lift Bracket Side Rollers
Lubricate
Lubricate 1 fitting on each side roller for a total of 2 fittings.
Q00691
11-31
MAINTENANCE
 Oil Leaks and Damage of Piping
- Check on the floor for oil leaks.
- Inspect the piping for damage or cracks and also check
that it is secure.
Q00723
 Oil, Fuel, or Coolant Leaks

Check on the floor for oil, fuel, or coolant leaks.
Q00243
Every 50 Service Hours or Weekly, Whichever Comes First

 Alternator Drive Belt
Check and adjust
R CAUTION
- After stopping the engine, check and adjust the rotating parts.
- 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.
Note: If it is difficult to adjust or replace the belts, consult your Cat lift truck dealer.
Park the lift truck on level ground with the forks lowered until the forktips touch the ground, parking brake applied, direction
lever in the NEUTRAL position, engine stopped and the wheels blocked.
11-25
MAINTENANCE
(1) Raise the hood.

(2) Push the belt downward with about 98 N (10 kgf) [22
lbf] pressure midway between the pulleys as shown. 1)
Note: 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 plies.
Q00678
1) Deflection
Deflection 11 to 13 mm (0.4 to 0.5 in.)
11-26
MAINTENANCE
Clean and inspect

When using compressed air for cleaning, wear an approved
face shield and protective clothing.
Use a maximum air pressure of 196 kPa (2 kgf/cm2) [30 psi]
for cleaning purposes.
Q00398
R WARNING
- DO NOT wash the air cleaner element.
- DO NOT use damaged air cleaner element.
- DO NOT operate the lift truck without the air cleaner element installed. If not followed, dust, water droplets, or foreign
objects will get in the engine, which may result in engine damage.
- Park the lift truck on level ground with the forks lowered until the forktips touch the ground, parking brake applied,
direction lever in the NEUTRAL position, engine stopped and the wheels blocked.
R CAUTION
Install the dust pan with its arrow mark up.
(1) Raise the engine hood.
(2) Remove dust pan 1 by releasing the latches at three

places.
(3) Unscrew wing nut 2, and remove element 3 by pulling 3
it.
2
1
Q00675
1. Dust pan 3. Element
2. Wing nut
(4) Remove cover 1 from the dust pan, and clean the inside
of the pan by removing dust.
(5) Clean the inside of the air cleaner housing.
Q00676
1. Cover
11-27
MAINTENANCE
(6) Clean the inside of the air cleaner housing.
Q00296
(7) Insert a light inside a dry and clean element and check.
Dispose of the element if tears or rips are found.
Q00677
(8) Put the element back in place.

(9) Install the dust cap.
(10) Close the engine hood.
Note:
- DO NOT service the air cleaner element with the engine running.
- DO NOT clean the elements by pounding them against another object.
- Always inspect the element before and after cleaning.
- After the fifth cleaning, you must replace the air cleaner element even if it is within the scheduled maintenance period.
- Clean and replace more frequently in corrosive or abrasive environments.
Replace
The air cleaner element should be changed if it is dirty. If you attempt to clean the element, handle it carefully.
Recommended replace intervals
Conditions Interval
Normal conditions Every 1200 service hours or 6 months, whichever comes first
Severe dust or lint conditions Clean and replace more frequently in corrosive or abrasive environments.
Note:
- Have spare elements available to use while cleaning used elements.
- In severe dust or lint conditions, check the radiator core frequently for clogging or dirt accumulation. Clean or wash the lift
truck as needed. See "Air Cleaner Element, Clean and Inspect" under "Every 50 Hours or Weekly, Whichever comes first".
11-28
MAINTENANCE
 Mast Supports
Lubricate
Lubricate 1 fitting on each support for a total of 2 fittings.
Q00681
 Bolts and Nuts

- Bolts and nuts of overhead guard should be tightened.
One Month (30 days) or 200 Service Hours after Delivery of a New Lift Truck,
Whichever Comes First
 Fuel Filter
Replace
- Replace fuel filter.
See 11-35 "Fuel Filter".
 Hydraulic Tank Return Oil Filter
Replace
- Replace return filter.
See 11-38 "Hydraulic System".
Every 200 Service Hours or Monthly, Whichever Comes First

 Brake Pedal
Lubricate
Lubricate 1 fitting.
Q00693
11-29
MAINTENANCE
 Engine Crankcase
Replace oil and filter
R WARNING
Hot oil and components could cause serious injury. DO NOT allow hot oil or components to contact skin.
(1) Operate the lift truck a few minutes to warm the oil.
(2) Park the lift truck on level ground with the forks lowered until the forktips touch the ground, parking brake applied,
direction lever in the NEUTRAL position, 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.
Q00687
(5) Remove and dispose of the oil filter element.

(6) Wipe the sealing surface of the oil filter element
mounting base.
(7) Apply a small amount of clean engine oil to the oil filter
element gasket. Install the new filter element.
Q00688
(8) Fill the crankcase. See 12-3 "Specifications".
Q00666
(9) Start the engine and allow the oil to fill the filter and
passages.
(11) Turn the engine OFF and measure the oil level.
Maintain the correct level range on the dipstick.
Q00689
11-30
MAINTENANCE
 Mast Strip Roller Surfaces
Lubricate
Lubricate 1 fitting on each side of the inner mast for a total
of 2 fittings.
Q00690
 Tilt Socket Pins
Lubricate
Lubricate 1 fitting on each pin for a total of 2 fittings.
Q00694
 Tilt Cylinder Pins
Lubricate
Q00695
 Rear Axle Center Pins
Lubricate
Q00697
11-32
MAINTENANCE
 Tie Rod Ends
Lubricate
Q00696
 Differential Oil
Check oil level

lever in the NEUTRAL position, 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.
Q00682
(3) Remove the level/fill plug.

Maintain lubricant level to the bottom of the level/ fill
hole.
(4) Clean and install the level/fill plug.
(5) Remove the blocking. Lower the lift bracket.
Q00683
Adding oil
See the topic, 11-33 "Differential Oil".
11-33
MAINTENANCE
 Transmission Oil
Check oil level
R WARNING
Hot oil and components could cause injury. DO NOT allow hot oil or components to contact your skin.
(1) Operate the lift truck a few minutes to warm the oil.
(3) Remove the floor plate.
Q00684
(4) Remove the dipstick/filler cap. Check the oil level.
Q00685
(5) Maintain the correct level range indicated on the

dipstick/filler cap.
Q00686
Adding oil
See 11-34 "Transmission Oil".
11-34
MAINTENANCE
Every 1200 Service Hours or 6 Months, Whichever Comes First
 Fuel Filter
Replace
Note: Engine must be stopped and cooled.
Park the lift truck in an authorized refueling area with the forks lowered until the forktips touch the floor or ground,
parking brake applied, direction lever in the NEUTRAL position, engine stopped and the wheels blocked.
(1) Close the fuel valve on the LP-Gas tank.

The fuel valve turns clockwise to close. Run the engine
until fuel in the fuel line runs out and the engine stops.
Turn the key switch to OFF.
(2) Raise the hood.
1)
Q00069
1) Close
(3) Disconnect the fuel line.
Q00707
(4) Remove the bolts 1 and bracket 2.

1
2
Q00708
1. Bolts 2. Bracket
11-35
MAINTENANCE
(5) Remove the bolts and bracket.
Q00709
(6) Remove the cover and gasket.
Q00710
(7) Replace the screen in recess as shown.

(8) Install the filter and bracket.
(9) Connect the fuel line.
Q00711
(10) Open the fuel valve.

(11) Check the filter for fuel leaks with a soap solution.
1)
Q00072
1) Open
11-36
MAINTENANCE
 Fuel Filter Tier II
Replace
Note: Park the lift truck in an authorized refueling area with the forks lowered until the forktips touch the floor or ground,
parking brake applied, direction lever in the NEUTRAL position, engine stopped and the wheels blocked.
To replace the LP-Gas fuel filter use the following steps:
(1) Close the fuel valve on the LP-Gas tank.

The fuel valve turns clockwise to close. Run the engine
until fuel in the fuel line runs out and the engine stops.
Turn the key switch to OFF.
(2) The fuel filter is located on the left side of the lift truck.
(3) Disconnect the fuel hose from the LP-Gas tank and the
filter assembly.
1)
Q00069
1) Close
(4) Raise the hood and disconnect the fuel hose from the
bottom of the filter assembly.
(5) Remove the nut from the bottom of the filter and
remove the filter assembly.
(6) Remove the relief valve, nipple, and the elbow from the
filter assembly and add to the new filter.
(7) Install the new filter assembly on the lift truck.
(8) connect the fuel hose to the bottom of the assembly.
(9) connect the fuel hose to the inlet side of the assembly
and the LP-Gas tank.
Q00712L
(10) Open the fuel valve.

(11) Check the fuel lines for leaks with a soap solution.
1)
Q00072
1) Open
11-37
MAINTENANCE
 Hydraulic System
Replace return oil filter and wash strainer
R WARNING
Hot oil components could cause personal injury. DO NOT allow hot oil or components to contact your skin.
At operating temperature, the hydraulic tank is hot and can be under pressure.
(1) Raise the hood.

(2) Remove the battery and tank cover.
Q00699
(3) Remove the hose.
(4) Remove the gasket and strainer 1.

(5) Remove the gasket and return oil filter 2.
Dispose of the filter element.
1
2
Q00700
1. Strainer 2. Return oil filter
(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.
(8) Wash the strainer in clean, nonflammable solvent.
(9) Inspect the gasket and replace it, if necessary.
(10) Put the strainer, gasket, cover, and battery back in
place.
Q00702
11-38
MAINTENANCE
(11) Remove the filler cap. Check the oil level.

(12) Add oil, if needed, to reach the correct level range on
the dipstick.
Q00701
(13) Put the dipstick and filler cap back in place.

(15) Close and secure the hood. 1
L
QA0111
Replace air cleaner element

The air cleaner element should be replaced if it is dirty. If you attempt to clean the element, handle it carefully.
Recommended replacement intervals

Normal conditions Every 1200 service hours or 6 months, whichever comes first
Severe dust or lint conditions Every 200 service hours or monthly, whichever comes first
Care in severe dust or lint conditions

Check the radiator core frequently for clogging or dirt accumulation. Clean or wash the truck as needed.
See 11-27 "Air Cleaner Element".
11-39
MAINTENANCE
Every 2400 Service Hours or 12 Months, Whichever Comes First
 Brake Fluid
Replace
Note: When replacing brake fluid consult with your Cat lift
truck dealer.
Q00721
 Hydraulic Oil
Replace
R WARNING
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 hand.
Remove the filler cap slowly to relieve pressure.
(1) Operate the lift truck to warm the oil.

(3) Remove the filler cap.
Q00718
(4) Remove the hydraulic tank drain plug.

Allow the oil to drain. Clean and put the plug back in
place.
Q00719
11-40
MAINTENANCE
(5) Fill the hydraulic tank. See 12-3 "Specifications". 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 turn the engine OFF.
(8) Remove the filler cap and the dipstick.
Keep the oil level at the HIGH mark on the dipstick.
Q00720
(9) Put the dipstick and the filler cap back in place.
L
QA0111
11-41
MAINTENANCE
 Transmission Oil
Replace oil, return oil filter, and wash strainer
R WARNING
Hot oil components could cause personal injury. DO NOT allow hot oil or components to contact your skin.
(1) Remove the drain plug 1. Allow the oil to drain. Remove
the cover 2, the O-ring seal, and the strainer.
1
2
Q00698
1. Drain plug 2. Cover
(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 dipstick/filler cap. Fill the transmission

with oil. See 12-3 "Specifications". Put the dipstick/filler
cap back in place.
(7) Turn the engine OFF.
(8) Remove the dipstick/filler cap. Check the oil level.

(9) Add oil, if needed, to reach the correct level range on
the dipstick/filler cap.
(10) Check for oil leaks at the strainer and drain plug.
(11) Put the floor plate back in place.
Q00686
11-42
MAINTENANCE
 Differential Oil
Replace oil
Q00682
(1) Raise the lift bracket high enough to gain access to the
level/fill plug 2.
(2) Use blocking under inner mast to secure the lift bracket
in this position.
(3) Remove the drain plug 1 and the level/fill plug 2.
(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.
2
1 Q00703
1. Drain plug 2. Level/fill plug
11-43
MAINTENANCE
 Engine Coolant
Replace
R WARNING
- At operating temperature, the engine coolant is hot
and could be under pressure.
- Steam could cause severe burns.
- Park the lift truck in an authorized refueling area with
the forks lowered until the forktips touch the floor or
ground, parking brake applied, direction lever in the
NEUTRAL position, engine stopped and cooled.
- 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. D00692
- Cooling system conditioner contains alkali. Avoid

contact with your skin and eyes to reduce the risk of
burns and other injuries.
- Allow cooling system components to cool before
draining.
- Use all cleaning solutions with care.
(1) Loosen the radiator cover retaining knob.

Lift and remove the radiator cover.
Q00713
(2) Turn the radiator filler cap slowly to relieve the

pressure, then remove the cap.
Q00714
11-44
MAINTENANCE
(3) Open radiator drain valve. Allow the coolant to drain.
Q00715
(4) Drain the reserve tank.
Q00716
(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) Turn the engine OFF 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) Turn the engine OFF and drain the neutralizing solution.
(13) Flush the system with clean water until draining water is clear.
(14) Close the drain valve.

(15) Mix a coolant solution of water and antifreeze.
(16) Fill the cooling system. See 12-3 "Specifications". To
avoid air locks, add the coolant slowly.
Q00717
11-45
MAINTENANCE
(17) Start and run the engine until the coolant level is
stabilized.
(18) Turn the engine OFF.
(19) Add coolant, if necessary, to maintain the level to below
the bottom of the filler tube.
Q00095
(20) Put the radiator filler cap back on.
(21) Remove the reserve tank filler cap.
Q00031
(22) Keep the coolant level at the FULL line on the reserve
tank.
Q00716
(23) Put the reserve tank filler cap back on.
11-46
MAINTENANCE
Parts to Be Replaced Periodically
The following parts should be periodically replaced as listed below:
These parts are made of materials which will deteriorate over time. Further, it is difficult 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 lift truck.
 Safety Critical Parts
Replacement period
No. Periodic Replacement Parts
Year(s) Service hours(s)
1 Cups and dust seals of the wheel cylinders 1 2400
2 Cup and dust seal of the master cylinder 1 2400
3 Brake booster 1 2400
4 Hydraulic hoses of steering system 2 4800
5 Fuel hoses (Include LP-Gas) 2 to 4 4800 to 9600
6 Inner rubber parts of the power steering cylinders 2 4800
7 Lift chains 2 to 4 4800 to 9600
8 Hydraulic hoses on and around mast 1 to 2 2400 to 4800
9 Tube of brake fluid cup 1 2400
10 Brake hoses 1 2400
11 LP-Gas repair kit (Converter and fuel lock filter) 1 2400
3 5
8 7 9
6
8
10
4
1 2
8 Q00722
11-47
SERVICE DATA
 SERVICE DATA
Fuel Information
Use only fuel recommended in this section.
 LP-Gas Specifications
Use grade HD5 LPB. LP-Gas is a highly volatile fuel with an octane rating of 100 to 140. Follow local ordinances regarding
storage and/or filling of LP-Gas tanks.
Coolant Information
The manufacturer recommends that the coolant mix contain 50% commercially available automotive antifreeze, and 50%
water.
- To reduce the risk of damage to your engine, DO NOT 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 boiling point. These lowered
temperatures will cause overheating at a lower ambient temperature than an ethylene glycol and water mix. If Dowtherm
is used, follow the instructions provided and use only the inhibitor package recommended 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 protection.
- 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 recommended. Use a commercially
available automotive antifreeze. Filling at over 20 liters per minute could 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 system all year
round. Cooling system problems could arise without a thermostat.
 Coolant Water
- The manufacturer recommends the use of distilled water or deionized water to reduce the potential and severity of
chemical insolubility.
- Hard water, or water with high levels of calcium and magnesium ions, encourages the formation 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 magnesium ions, encourages the formation of insoluble chemicals,
especially after a number of heating and cooling cycles.
- Using water that meets the minimum acceptable water requirement may not prevent dropout of these chemical
compounds completely but should control the dropout rate at acceptable levels.
Acceptable water
Water content Limits (ppm)

Chlorides (CI) 50 ppm (maximum)
Sulfates (SO4) 50 ppm (maximum)
Total hardness 80 mg/l
Total solids 250 ppm (maximum)
pH 6.0 to 8.0
ppm = parts per million
12-1
SERVICE DATA
 Antifreeze Solution
The manufacturer 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 protection 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 (ambient) 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, therefore, have high silicate
content.
- DO NOT add pure (100%) antifreeze to the cooling system. Add antifreeze mixed with distilled water using the same freeze
protection ratio that is in your cooling system.
Recommended Fuels and Oils
Recommendation for Ambient Temperatures °C [°F]
-30 -20 -10 0 10 20 30

Fuel or Oil Recommendation
(-22) (-4) (14) (32) (50) (68) (86)
Fuel Consult your authorized Cat® lift truck dealer.

SAE10W or
API service classification SJ, SAE10W-30 SAE30
Engine oil
MIN.
SAE20
API service classification
Front axle oil SAE80W SAE90
multi-purpose type GL-4
Powershift Transmission Oil Dexron Consult your authorized Cat® lift truck dealer.
Hydraulic Oil SAE5W SAE10W
F.M.V.S.S. No.116-DOT3 or
Brake fluid See Recommended Brands of Lubricants.
DOT4 (SAE J1703)
Wheel
NLGI No.2 grade multipurpose type (lithium base), consistency: 265-295
Grease bearings
Chassis NLGI No.1 grade multipurpose type (lithium base), consistency: 310-340
Item Value
Ambient temperature (°C [°F]) -45 -39 -30 -25 -20 -15 -10
Antifreeze (Long Life Coolant) (-49) (-38) (-22) (-13) (-4) (5) (14)
solution
Concentration (%) 60 55 50 45 40 35 30
R CAUTION
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 one and the same brand at successive service intervals.
Note: For refill capacities and measurements, see 12-3 "Specifications" in this section.
12-2
SERVICE DATA
Specifications
R CAUTION
Note: The values in the table below are for the standard model.
Class (ton)
Item
3.5 4.0 4.5 5.5 6.0 7.0
Alternator drive belt deflection
when pushed inward with 11 to 13 mm (0.43 to 0.51 in.)
98 N (10 kgf) [22 lbf] pressure
Spark plug type AC-DELCO #41-932
Spark plug gap 1.01 mm (0.040 in.)
Engine idling speed (RPM) 750 to 800 min-1
Steering wheel free play
(when measured at rim with 15 to 30 mm (0.59 to 1.18 in.)
engine idling)
Brake pedal free play 5 mm (0.20 in.)
Parking brake lever effort 250 to 290 N (25 to 30 kgf) [55 to 65 lbf]
Front tire 22 × 9 × 16 22 × 12 × 16 22 × 12 × 22
Tire size 18 × 8 × 12-
Rear tire 18 × 7 × 12-1/8 22 × 8 × 16
1/8
Tightening torque of Front
551 N·m (56.2 kgf·m) [406.5 lbf·ft]
wheel nuts tire
Lift chain elongation limit 523 mm (20.6 in.)/20 links 654 mm (25.7 in.)/20 links
80 L
Fuel tank capacity 66 L (17.4 US gal.) 128 L (33.8 US gal.)
(21.1 US gal.)
Engine cooling system
(0.65 liter [0.17 US gal.] reserve tank 17 L (4.5 US gal.)
included)
Crankcase 4.2 L (1.1 US gal.)
Engine oil Oil filter 0.8 L (0.2 US gal.)
Total 5.0 L (1.3 US gal.)
Transmission oil 14 L (3.7 US gal.) 15 L (4.0 US gal.)
Differential (P/T) 9.1 L (2.4 US gal.)
51.6 L
Hydraulic tank 45.9 L (12.1 US gal.) 68.8 L (18.2 US gal.)
(13.6 US gal.)
Brake fluid reserve tank 149 cc (9.1 cu in.)
Battery electrolyte specific gravity,
Consult your battery manufacturer for the specific gravity of your battery.
corrected to 20°C (68°F)
12-3
SERVICE DATA
Capacities and Lift Truck Weight
Lift truck model

Item
35K 40K 40K STR 45KC-STR
3500 4000 4000 4500
Rated capacity, kg (lb)/500 mm (20 in.)
(7000) (8000) (8000) (10000)
Lift truck weight, unloaded kg 5200 5600 5700 6500
Single drive tires
(lb) (11500) (12300) (12700) (14300)
Lift truck model

Item
55K 55K-STR 60K 70K 70K-STR
5500 5500 6000 7000 7000
Rated capacity, kg (lb)/500 mm (20 in.)
(12000) (12000) (13500) (15500) (15500)
Lift truck weight, unloaded kg 7200 7400 8800 9500 10000
Single drive tires
(lb) (15800) (16200) (19300) (20900) (22000)
Note: Capacities shown apply to lift trucks with standard (high grip wide) tires and 130 simplex mast.
12-4
TO THE CAT LIFT TRUCK OWNER
 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 a short part life and a higher maintenance cost.
Genuine parts give safe and reliable performance.
R CAUTION
The damage caused by parts other than genuine parts is not
covered by Cat Lift Trucks' warranty.
R00008C
 Proper Disposal of Your Lift Truck

Consult your authorized Cat® lift truck dealer for how and where to dispose of your lift truck. Improper disposal of lift trucks and
other wastes such as tires, batteries, coolant, and hydraulic oil can be harmful to the environment, and this act is strictly
prohibited by the law.
13-1
Instructions for Ordering Parts
When ordering parts, or when asking your authorized Cat® lift truck dealer to have your lift truck repaired, be sure to provide
the following items:
- Lift truck model

- Lift truck serial number
- Engine serial number
2
1 IMPROPER OPERATION OR
IN INJURY OR DEATH

FORK
SERIAL NO: HEIGHT
AS TO FIRE HAZARD ONLY mm
ATTACH 1:
in
TYPE ＬＰ ATTACH 2: A B
TRUCK WEIGHT A-LOAD CENTER B-OFFSET CAPACITY

R
INDUSTRIAL TRUCK ±５％ mm in mm in kg lbs
No. kg lbs
AU2187 MEETS DESIGN SPECIFICATIONS OF ANSI/ITSDF B56.1

ＥＮＧＬＩＳＨ９３０８３−０７８０１
4
3
MODEL SERIAL No.
㹒㹇㹐㹃ࠉ㹎㹐㹃㹑㹑㹓㹐㹃ࠉ㹄㹐㹐㹃 psi
deg.
in.
HOUSTON,USA
ＥＮＧＬＩＳＨ９３０８３−０８６０１
E00951C
1. UL Plate 3. Engine Serial Number

2. Capacity Plate 4. Manufacturer Name Plate
13-2
Service Registration
Fill out this sheet for your ready reference.
SERVICE REGISTRATION
Lift Truck Model, Serial No. Engine Model, Serial No.
Mast Model, Serial No. Attachment Model, Serial No.
Delivering Dealer: Name:
Address:
Delivery Date:
13-3
Transfer of Ownership Report for Cat Lift Trucks Customers Only
TRANSFER REPORT
TRANSFER OF OWNERSHIP REPORT
Copies distributed to:

Dealer Sales Department
Dealer Service Department / Warranty
CUSTOMER’ S SIGNATURE DATE
MCFA Marketing Services [FAX (713) 365-1414]
S00014
INDEX
A F
Accelerator Pedal .........................................................11-23 Faulty Operation Found the Day Before ......................... 11-8
Adjustment of Suspension .............................................2-19 For Standard LP-Gas Tank ............................................... 4-2
After Starting Engine ...................................................... 5-3 Forward and Back Adjustment ...................................... 2-18
Air Cleaner Element .....................................................11-27 Fuel Information ........................................................... 12-1
Antifreeze Solution ........................................................12-2 Fuel Oils and Lubrication Oils ...................................9-1, 9-2
Assist Grip .......................................................... 2-23, 11-17 Fuel System ..............................................................7-1, 7-2
B G
Back-up Alarm Decal ......................................................1-10 General ...................................................................1-1, 11-1
Battery .......................................................... 9-1, 9-2, 11-11 H
Before Moving Lift Truck ................................................. 5-4 Handling Loads Safely ..................................................... 6-2
Before Operating the Lift Truck ....................................... 6-4 Hood Latch .................................................................... 2-23
Before Starting Engine .................................................... 5-1 Horn ............................................................................ 11-12
Brake Pedal ....................................................................11-8 How to Check Fuses and Lamps ..................................... 10-5
C How to Survive in a Tipover ............................................. 3-9
Capacities and Lift Truck Weight ....................................12-4 Hydraulic Oil ................................................................ 11-19
Capacity (Weight and Load Center) ................................ 3-2 Hydraulic System .....................................................7-1, 7-2
Capacity Plate ................................................................. 1-9 I
Care in Cold Weather ...................................................... 9-1 Icons of Meter Panel .................................................... 11-12
Care in Hot Weather ........................................................ 9-2 If Lamps Won't Glow ..................................................... 10-4
Center of Gravity (CG) ..................................................... 3-1 If the Mast Stops Moving ............................................... 10-9
Changing Direction ......................................................... 5-6 Inching ............................................................................ 5-8
Changing Speed .............................................................. 5-6 Inching Pedal .......................................................2-8, 11-24
Coolant Information ......................................................12-1 Inspection Precautions .................................................. 11-2
Coolant Water ................................................................12-1 Instructions for Ordering Parts ...................................... 13-2
Cooling Fan ..................................................................... 1-7 K
D Key Switch ...................................................................... 2-5
Differential ..................................................................11-33 Know What Lift Truck Stability Is ..................................... 3-1
Do’s and Dont’s to Avoid Tipover .................................... 3-4 L
Drawbar Pin ...................................................................2-24 Lift Chains ................................................................... 11-20
Driving Interlock System .................................... 2-16, 11-14 Lift Truck Lifting and Tie Down Information .................... 8-1
E Lift Truck Operation ......................................................... 5-5
End of Each Shift Storage ................................................ 7-1 Lift Truck Stability Base ................................................... 3-2
Engine (Exhaust, Noise and Vibration) .........................11-15 Long Term Storage .......................................................... 7-1
Engine Coolant .............................................. 9-1, 9-2, 11-10 LP-Gas ........................................................................... 1-35
Engine Cooling System ................................................... 7-2 M
Engine Cylinders ............................................................. 7-2 MAINTENANCE ............................................................... 11-1
Engine Hood ..................................................................2-22 Maintenance Schedule .................................................. 11-3
Engine Won't Start .......................................................... 5-3 Mast Interlock System ................................................. 11-15
Every 10 Service Hours or Daily (Pre-Start), Meter Panel ................................................................... 2-13
Whichever Comes First ......................................... 11-3, 11-8 Model View ..................................................................... 2-2
Every 200 Service Hours or Monthly, N
Whichever Comes First ...................................................11-6 Neutral System .............................................................. 2-17
Every 50 Service Hours or Weekly, New Forklift Truck Break-in ............................................. 5-1
Whichever Comes First ...................................................11-4 New Lift Truck Break-in ................................................... 5-1
Normal travel position .................................................. 6-13
INDEX-1
INDEX
O
Oil, Fuel or Coolant Leaks ............................................ 11-25
Operating Techniques ..................................................... 5-7
Operator Presence Switch and Buzzer ........................... 2-19
Overhead Guard .......................................................... 11-17
R
Reclining Angle Adjustment ......................................... 2-19
S
Seat Adjustment ........................................................... 2-18
Stability and Center of Gravity (Top View) ...................... 3-1
Stacking Large Identical Loads ........................................ 6-1
Stacking Methods ........................................................... 6-1
Stacking Small Identical Loads ........................................ 6-1
Starting Engine ............................................................... 5-3
Starting on a Grade (Engine Stalls on a Grade) .............. 6-14
Starting with Jumper Cables ......................................... 10-3
Steering (Turning) .......................................................... 5-7
Steering Column Tilt Lever .............................................. 2-9
Steering Wheel and Column ....................................... 11-23
Stopping Forklift Truck .................................................... 5-9
Stopping on a Grade ..................................................... 6-14
T
Tilt Cylinder Socket Bolts ............................................. 11-21
Tires and Rims ............................................................. 11-24
TRANSPORTATION HINTS ................................................. 8-1
Traveling on a Grade ..................................................... 6-13
Trouble with the LP-Gas Equipment ............................. 10-6
W
Warning Icons and Indicators ........................................ 2-14
Wheel Nuts ................................................................. 11-24
Working on Grades ....................................................... 6-13
INDEX-2
Mitsubishi Caterpillar Forklift America Inc.
2121 W. Sam Houston Parkway N.
Houston, TX 77043-2305
Copyright © 2013. All rights reserved. CAT, CATERPILLAR, their

respective logos, "Caterpillar Yellow", the "Power Edge" trade dress as well
as corporate and product identity used herein are trademarks of Caterpillar
and may not be used without permission. All registered trademarks are the
property of their respective owners. Some products may be shown with
optional equipment.
99730-86120 05/13

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Operation & Maintenance Manual

Keep this manual in your lift truck as a ready reference 99730-86120

Note: - If you resell a lift truck, be sure to attach the original

Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot DIRECTIONAL TERMS:

Truck model Class Serial number

 Fasten Seat Belt Decal ...................................................................... 1-4 Operator Seat..................................................................... 2-18

 Radiator Cap Decal ........................................................................... 1-7 Seat Belt ............................................................................ 2-20

 Pinch Point Decal .............................................................................. 1-8 Assist Grip .......................................................................... 2-23

 Operation Warning Decal ................................................................. 1-9  Back-up Buzzer ............................................................................... 2-24

 No Riders Warning Decal ................................................................ 1-10

 Backup Alarm Decal ........................................................................ 1-10

Model View.......................................................................... 2-2  For Optional LP-Gas Tank .................................................................. 4-3

Driving Switches and Controls............................................... 2-3

 Warning Icons and Indicators ......................................................... 2-14

 Traveling on a Grade ....................................................................... 6-13  Brake Pedal .....................................................................................11-8

 Stopping on a Grade ....................................................................... 6-14  Parking Brake Lever ........................................................................11-9

 Engine Coolant ..............................................................................11-10

 Backup Lights ................................................................................11-13

9. SPECIAL SITUATIONS ...................................................... 9-1  Mast Interlock System ...................................................................11-15

 Engine Crankcase ..........................................................................11-16

 Seat Belt ........................................................................................11-18

 Hydraulic Tank Return Oil Filter .....................................................11-29

 Engine Crankcase ......................................................................... 11-30

 Lift Chains ..................................................................................... 11-31

 Lift Bracket Side Rollers ................................................................ 11-31

 Mast Strip Roller Surfaces ............................................................. 11-32

 Tilt Cylinder Pins ........................................................................... 11-32

 Rear Axle Center Pins .................................................................... 11-32

 Tie Rod Ends ................................................................................. 11-33

 Differential Oil .............................................................................. 11-33

 Transmission Oil ........................................................................... 11-34

 Fuel Filter Tier II ........................................................................... 11-37

 Hydraulic System .......................................................................... 11-38

 Air Cleaner Element ...................................................................... 11-39

 Hydraulic Oil ................................................................................. 11-40

 Transmission Oil ........................................................................... 11-42

 Differential Oil .............................................................................. 11-43

 Engine Coolant ............................................................................. 11-44

12. SERVICE DATA ............................................................... 12-1

 Antifreeze Solution ......................................................................... 12-2

13. TO THE CAT LIFT TRUCK OWNER ...................................... 13-1

MODEL: MAX MAST: VERTICAL

TRUCK WEIGHT A-LOAD CENTER

DANGER (8) No Access With Engine Running Decal

 Survive in a Tipover Decal

 LPG Fuel Cylinder Replacement Procedure Decal

 No Access With Engine Running Decal

 Radiator Cap Decal

 Pinch Point Decal

 Load Backrest Extension Decal

 Operation Warning Decal

 Backup Alarm Decal

 Operator Restraint System Decal

(2) After refilling, tighten radiator filler cap (pressure valve)

 No Contamination Permissible Decal

 Precautions for Handling ECU Decal

EVERY 200HR,OR MONTHLY EVERY 2400HR,OR 1YEAR WATER PUMP

 Designated Tire Type Decal

1. Apply (Push) 2. Release (Pull)

MODEL: MAX MAST: VERTICAL

TRUCK WEIGHT A-LOAD CENTER B-OFFSET CAPACITY

AU2187 MEETS DESIGN SPECIFICATIONS OF ANSI/ITSDF B56.1

1. UL Plate 3. Engine Serial Number