Cat DP100NM1 DP100NM1S DP120NM1 DP120NM1S DP135NM1 DP135NM1S DP150NM1 Operation & Maintenance Manual

Operation & Maintenance Manual FC/LC DP100NM1 DP100NM1S DP120NM1 DP120NM1S DP135NM1 DP135NM1S DP150NM1 DP150NM1S

T15E-20011-39999 T15E-20011-39999 T15E-20011-39999 T15E-20011-39999 T15E-20011-39999 T15E-20011-39999 T24C-20011-39999 T24C-20011-39999

Original Instructions

Keep this manual in your lift truck as a ready reference

99790-47120

Cat Lift Trucks

Operation & Maintenance Manual

DP100NM1(S), DP150NM1(S) Lift Trucks

99790-47120

Mitsubishi Logisnext Asia Pacific Pte. Ltd. RCB No.: 199203169H No.1, Tuas West Street Singapore 637444

Mitsubishi Caterpillar Forklift Europe B.V. Hefbrugweg 77 1332 AM Almere, The Netherlands

© 2017. 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.

99790-47120

11/17

FOREWORD

FOREWORD This four-wheel sit-down counterbalanced lift trucks made for material lifting and transportation (hereinafter referred to as lift truck) are designed for the personnel aged 18 years old or above, and operator training is required 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: -

-

-

This manual contains information necessary for the operation and "Do-it-yourself" maintenance of standard lift trucks.

Optional equipment is sometimes installed; it can change some operating characteristics described in this manual. Before operating such a lift truck, make sure the necessary instructions are available and understood.

Lift truck operator training is provided through your authorized Cat lift truck dear.

They will be glad to help you and answer any questions you may have about operating your new truck. Lift trucks are NOT intended for use on public roads.

-

-

If you resell a lift truck, be sure to attach the original Operation & Maintenance Manual to the lift truck. In some countries, strict regulations do not allow imported lift trucks for resale. For resale information, contact your authorized Cat lift truck dealer.

If a lift truck is resold from another country, an Operation & Maintenance Manual attached to the lift truck may not meet your country's rules and regulations. For manual information, contact your authorized Cat lift truck dealer.

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.

R DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

R WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

R CAUTION

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Note:

Note indicates important matters and useful information on operation and maintenance.

Mitsubishi Logisnext Asia Pacific Pte. Ltd. (MLAP) and Mitsubishi Caterpillar Forklift Europe B.V. (MCFE) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive.

If a tool, procedure, work method, or operating technique not specifically recommended by MLAP and MCFE 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

DIRECTIONAL TERMS: The directions "Left", "Right", "Front", and "Rear" are given from the viewpoint of the operator facing forward.

FOREWORD 

Truck Models Covered in This Manual Truck model

Engine model

DP100NM1 DP100NM1S DP120NM1 DP120NM1S DP135NM1 DP135NM1S DP150NM1 DP150NM1S

Serial number

Control lever

T15E-20011-39999 T15E-20011-39999 6D16-TL Diesel Engine

FC/LC T15E-20011-39999 T24C-20011-39999

Abbreviation -

FC is short for fingertip control.

LC is short for lever control.

iii

FOREWORD

LOCKOUT/TAGOUT LOCKOUT is not only used to disconnect a power supply, but also to physically isolate power sources from supplying power to the lift truck, with a lockout device, disabling the lift truck.

TAGOUT also reduces the risk of operating the machine during LOCKOUT with the use of a "DO NOT OPERATE" or similar warning tag. Warning tags are ideally placed on the lockout device to indicate the lift truck must not be operated until the tag is removed. Combined use of LOCKOUT/TAGOUT reduces the risk of accidental or inadvertent operation.

A lift truck that has been LOCKED OUT and TAGGED OUT must not be operated until the required service has been completed and the lift truck is no longer LOCKED OUT and TAGGED OUT.

R WARNING -

Personnel could be exposed to death or serious injury if LOCKOUT/TAGOUT procedure is not performed prior to servicing the lift truck.

Only the trained technician who performs the LOCKOUT/TAGOUT procedure must release the lift truck back into service.

Only proper LOCKOUT/TAGOUT devices must be used.

R WARNING Basic requirements before servicing equipment: -

Wear appropriate personal protective equipment.

Move equipment to secure maintenance area.

Park the lift truck on a hard and level surface 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.

Turn the key switch to the OFF position.

Remove the key from the key switch.

Typical LOCKOUT/TAGOUT procedures are shown below: Engine lift truck (1) (2) (3) (4) (5)

Remove the key to the lift truck from the key switch and access the battery compartment.

Remove the negative (-) battery cable from the battery terminal and place in the proper lockout device.

Lock the lockout device with the negative (-) battery cable locked inside.

TAGOUT the lift truck by placing a “DO NOT OPERATE” or similar warning tag where it can be visibly seen.

After the work is finished, the technician with the key to the lift truck must unlock the lockout device and remove the tag.

Battery lift truck (1) (2) (3) (4) (5)

iv

Remove the key to the lift truck from the key switch and access the battery compartment.

Disconnect the battery plug/connector and their connections from the lift truck and place in the proper lockout device.

Lock the lockout device.

TAGOUT the lift truck by placing a “DO NOT OPERATE” or similar warning tag where it can be visibly seen.

After the work is finished, the technician with the key to the lift truck must unlock the lockout device and remove the tag.

TABLE OF CONTENTS 1. SAFETY RULES FOR LIFT TRUCK OPERATORS ....................... 1-1 General ............................................................................... 1-1 Warning Decals, Location...................................................... 1-2 Description of Danger, Warning, and Caution Decals .............. 1-4  Fasten Seat Belt Decal ...................................................................... 1-4  Survive in a Tipover Decal ................................................................. 1-4  Operation Warning Decal ................................................................. 1-5  Overhead Guard Decal ..................................................................... 1-5  Radiator Cap Warning Decal ............................................................. 1-6  No Access With Engine Running Decal .............................................. 1-6  Parking Brake Decal .......................................................................... 1-6  No Riders Warning Decal .................................................................. 1-6  Pinch Points Decal ............................................................................ 1-7  No One on the Fender ....................................................................... 1-7  No One Under / On Forks and No One Between Mast and Chassis Decal  .......................................................................................................... 1-7  Brake Warning Buzzer Decal ............................................................. 1-8  Capacity Plate ................................................................................... 1-8  Backup Alarm Decal .......................................................................... 1-8  Operator Restraint System Decal ...................................................... 1-9  No Contamination Permissible Decal ................................................ 1-9 Safety Rules....................................................................... 1-10 Operating Precautions........................................................ 1-20 Working Precautions .......................................................... 1-24 2. KNOW YOUR LIFT TRUCK .................................................. 2-1 Serial Number and Capacity Plate ......................................... 2-1 Electrical Components .......................................................... 2-2 Model View.......................................................................... 2-3  FC Model (Type A) ............................................................................. 2-4  FC Model (Type B) ............................................................................. 2-4  LC Model ........................................................................................... 2-5 Driving Switches and Controls............................................... 2-6  Key Switch ........................................................................................ 2-7  Direction Lever (Powershift Model) .................................................. 2-7  Inching Pedal .................................................................................... 2-7  Turn Signal / Light Switch ................................................................ 2-8  Steering Column Tilt Lever ............................................................... 2-8 Meter Panel ......................................................................... 2-9  Warning Icons Glow Check ............................................................. 2-10  LCD Screen ...................................................................................... 2-10  Warning Icons and Indicators ......................................................... 2-11  Basic Screen Display ....................................................................... 2-13  Basic Operation .............................................................................. 2-16  When Diagnostic Code Is Shown on Display ................................... 2-23  When Several Warnings Occur Simultaneously .............................. 2-25  Warning Symbols ........................................................................... 2-26  Warning Icons ................................................................................ 2-27  Optional Features ........................................................................... 2-28 Side Panel .......................................................................... 2-32  Speed Mode Selector Switch .......................................................... 2-32  Brake Warning Icon ........................................................................ 2-32 Presence Detection System................................................. 2-33  Mast Interlock System .................................................................... 2-33  Mast Interlock System Functions .................................................... 2-34  Driving Interlock System ................................................................ 2-35  Driving Interlock System Functions ................................................ 2-36  Neutral System ............................................................................... 2-36

Neutral System Functions ...............................................................2-36 Seat Belt Warning Icon ...................................................................2-37  Seat Belt Warning Functions ...........................................................2-37  Parking Brake Warning Alarm and Warning Icon ............................2-38  Parking Brake Warning Functions ...................................................2-38 Operating Switches and Controls......................................... 2-39  FC Control Box (Type-A) ..................................................................2-39  FC Control Box (Type-B) ..................................................................2-39  Lift Switch .......................................................................................2-39  Tilt Switch .......................................................................................2-39  Lowering Speed Selector Switch (Optional) ....................................2-40  Direction Switch (Optional) .............................................................2-40  Attachment Switch A/B (Optional) .................................................2-40  Selector Switch Between Fourth and Fifth Attachment (Optional) .2-40  Other Controls (Standard) ...............................................................2-41  Emergency Mast Stop Button ..........................................................2-41  Forward and Backward Adjustment Stopper Knob (FC Control Box TypeA) ....................................................................................................2-42  Up and Down Adjustment Stopper Knob (FC Control Box Type-A) ..2-42  Forward and Backward Adjustment (FC Control Box Type-B) ..........2-43  Up and Down Adjustment (FC Control Box Type-B) .........................2-43  LC Control Box .................................................................................2-43  Lift Lever .........................................................................................2-44  Tilt Lever .........................................................................................2-44  Attachment Lever A/B (Option) ......................................................2-44 Operator Seat .................................................................... 2-45  Seat Adjustment .............................................................................2-45  Forward and Back Adjustment ........................................................2-45  Reclining Angle Adjustment ...........................................................2-46  Adjustment of Suspension ..............................................................2-46  Pocket for the Operation & Maintenance Manual ...........................2-46  Operator Presence Switch and Buzzer .............................................2-46 Seat Belt ........................................................................... 2-47 Fork Locking Pins ............................................................... 2-49 Drawbar Pin ...................................................................... 2-50 Assist Grips and Foot Step ................................................... 2-50 Engine Hood ...................................................................... 2-51  Hood Latch ......................................................................................2-51 Hydraulic Tank Oil Filler Hole .............................................. 2-51 Fuel Filler .......................................................................... 2-52 Air Tank ............................................................................. 2-52  

3. HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE .............. 3-1 Know What Lift Truck Stability Is ........................................... 3-1 Center of Gravity (CG)............................................................ 3-1 Stability and Center of Gravity (Top View).............................. 3-1 Lift Truck Stability Base......................................................... 3-2 Capacity (Weight and Load Center)........................................ 3-2 Capacity Plate...................................................................... 3-3  Sample ..............................................................................................3-3 Do’s and Dont’s to Avoid Tipover ............................................ 3-4 How to Survive in a Tipover................................................... 3-9 4. REFUELING ..................................................................... 4-1 Diesel Engine Equipped......................................................... 4-1 5. OPERATION .................................................................... 5-1 New Lift Truck Break-in......................................................... 5-1 Before Starting Engine......................................................... 5-1

TOC-1

TABLE OF CONTENTS Starting Engine ................................................................... 5-3 Engine Won't Start............................................................... 5-4 After Starting Engine ........................................................... 5-5 Before Moving Lift Truck ....................................................... 5-6 Lift Truck Operation.............................................................. 5-7  Changing Speed ................................................................................ 5-8  Changing Direction ........................................................................... 5-8  Operating Techniques ....................................................................... 5-9  Steering (Turning) ............................................................................ 5-9  Inching ........................................................................................... 5-10 Stopping Lift Truck ............................................................. 5-11 Parking Lift Truck (After Stopping) ...................................... 5-12 6. OPERATING TECHNIQUES ................................................. 6-1 Stacking Methods ................................................................ 6-1  Stacking Different Size Loads ............................................................ 6-1  Stacking Small Identical Loads ......................................................... 6-1  Stacking Large Identical Loads .......................................................... 6-1 Handling Loads Safely.......................................................... 6-2  Adjusting Fork Spread ...................................................................... 6-3 Before Operating the Lift Truck ............................................. 6-4 Blinking of the Mast Interlock Indicator Icon ......................... 6-5 Lifting the Load.................................................................... 6-7 Traveling With the Load........................................................ 6-9 Unloading.......................................................................... 6-10 Working on Grades............................................................. 6-13  Normal Travel Position ................................................................... 6-13  Traveling on a Grade ....................................................................... 6-13  Stopping on a Grade ....................................................................... 6-13 Starting on a Grade (Engine Stalls on a Grade) ..................... 6-14 7. STORING THE LIFT TRUCK ................................................. 7-1 End of Each Shift Storage...................................................... 7-1 Long Term Storage............................................................... 7-1  Storage Within Three Months ........................................................... 7-1  Storage Exceeding Three Months ...................................................... 7-2 8. TRANSPORTATION HINTS ................................................. 8-1 Lift Truck Loading and Shipping ............................................ 8-1 Lift Truck Lifting and Tie Down Information ........................... 8-1 9. SPECIAL SITUATIONS ...................................................... 9-1 Care in Cold Weather ............................................................ 9-1  Fuel Oils and Lubrication Oils ............................................................ 9-1  Battery .............................................................................................. 9-1  Engine Coolant ................................................................................. 9-2 Care in Hot Weather ............................................................. 9-2  Fuel Oils and Lubrication Oils ............................................................ 9-2  Battery .............................................................................................. 9-2  Engine Coolant ................................................................................. 9-2 Severe Dust or Lint Conditions .............................................. 9-3  Air Cleaner Element .......................................................................... 9-3  Engine Oil and Engine Oil Filter ........................................................ 9-3  Hydraulic Oil ..................................................................................... 9-3  Hydraulic Tank Return Filter ............................................................. 9-3 10. TROUBLESHOOTING ...................................................... 10-1 Stalled Engine ................................................................... 10-1 If a Tire Blows Out.............................................................. 10-1

TOC-2

If a Tire Blows out During Travel or Operation .................................10-1 Replacing Tires .................................................................. 10-1 Before Replacing Tires ........................................................ 10-3  To raise front wheel ........................................................................10-3  To Remove Front Wheel ..................................................................10-4  To Install Front Wheel .....................................................................10-6  To Remove Rear Wheel ...................................................................10-7  To Install Rear Wheel ......................................................................10-8  To Add Air to Tires ...........................................................................10-8 Starting With Jumper Cables .............................................. 10-9 If Lights Won't Glow..........................................................10-11  How to Check Fuses and Lights .....................................................10-11 If the Engine Coolant Temperature Gauge Shows RED Zone ..10-12 If Torque Converter Oil Temperature Warning Icon Glows (Powershift Model) ......................................................................10-13 If the Lift Truck Won’t Change Direction..............................10-14 If the Mast Stops Moving....................................................10-14 If the Mast and Attachments Malfunction ..........................10-15 Diagnostic Codes and Explanations ....................................10-16 

11. MAINTENANCE ............................................................. 11-1 General ............................................................................. 11-1 Inspection Precautions....................................................... 11-2 Maintenance Schedule....................................................... 11-3  Every 10 Service Hours or Daily (Prestart), Whichever Comes First ..11-3  Every 50 Service Hours or Weekly, Whichever Comes First ..............11-4  One Month (30 days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever Comes First ..........................................................11-5  Every 500 Service Hours or 3 Months, Whichever Comes First .........11-5  Every 1000 Service Hours or 6 Months, Whichever Comes First .......11-6  Every 2000 Service Hours or 12 Months, Whichever Comes First .....11-6  Every 1 to 2 years ............................................................................11-7  Every 2 years ...................................................................................11-7  2 to 4 years ......................................................................................11-7 Every 10 Service Hours or Daily (Prestart), Whichever Comes First ......................................................................................... 11-8  Faulty Operation Found the Day Before ...........................................11-8  Oil, Fuel, or Coolant Leaks ...............................................................11-8  Brake Pedal .....................................................................................11-8  Parking Brake Lever ........................................................................11-9  Service Brake ...................................................................................11-9  Air Tank .........................................................................................11-10  Engine Coolant ..............................................................................11-10  Lights ...........................................................................................11-11  Horn ..............................................................................................11-12  Icons of Meter Panel ......................................................................11-12  Backup Alarm ................................................................................11-12  Backup Light .................................................................................11-12  Stop Light .....................................................................................11-13  Battery ..........................................................................................11-13  Mast Interlock System ...................................................................11-14  Driving Interlock System ...............................................................11-15  Parking Brake Warning Alarm and Warning Icon ..........................11-16  Seat Belt Warning Icon and Alarm ................................................11-16  Engine (Exhaust, Noise, and Vibration) .........................................11-17  Engine Oil ......................................................................................11-18  Fuel ...............................................................................................11-19  Overhead Guard ............................................................................11-19

TABLE OF CONTENTS Assist Grips ................................................................................... 11-20 Seat Belt ....................................................................................... 11-20  Seat Adjustment ........................................................................... 11-20  Hydraulic Oil ................................................................................. 11-21  Tilt Cylinder Locknuts ................................................................... 11-22  Lift Chains ..................................................................................... 11-22  Mast and Forks ............................................................................. 11-24  Wheel Nuts ................................................................................... 11-26  Tires and Rims .............................................................................. 11-26  Steering Wheel ............................................................................. 11-27  Accelerator Pedal ......................................................................... 11-27  Inching Pedal ................................................................................ 11-27  Transmission Oil ........................................................................... 11-28 Every 50 Service Hours or Weekly, Whichever Comes First .... 11-29  Fan and Alternator Drive Belt ....................................................... 11-29  Air Cleaner .................................................................................... 11-30 One Month (30 Days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever Comes First....................................... 11-32  Cooling Fan ................................................................................... 11-32  Battery - Electrolyte Specific Gravity ............................................. 11-32  Engine Oil and Oil Filter ................................................................ 11-32  Bolts and Nuts .............................................................................. 11-32 Every 500 Service Hours or 3 Months, Whichever Comes First 11-33  Engine Oil and Oil Filter ................................................................ 11-33  Fuel Filter ..................................................................................... 11-34 Lubrication Chart.............................................................. 11-36  Fan Belt Pulleys ............................................................................ 11-37  Mast Support ............................................................................... 11-37  Fork Guide Bar .............................................................................. 11-37  Mast Strips Surfaces ...................................................................... 11-37  Mast and Lift Bracket Side Rollers ................................................. 11-38  Lift Chains ..................................................................................... 11-38  Tilt Socket Pins ............................................................................. 11-38  Tilt Cylinder Pins ........................................................................... 11-38  Tie Rod Pins .................................................................................. 11-39  Rear Axle Supports ....................................................................... 11-39 Every 1000 Service Hours or 6 Months, Whichever Comes First ........................................................................................ 11-40  Air Dryer Desiccant ....................................................................... 11-40  Air Cleaner .................................................................................... 11-40  Universal Joints ............................................................................ 11-40  Powershift Transmission .............................................................. 11-41  Hydraulic System .......................................................................... 11-43  Front Axle ..................................................................................... 11-44 Every 2000 Service Hours or 12 Months, Whichever Comes First ........................................................................................ 11-45  Brake Fluid ................................................................................... 11-45  Air Dryer Desiccant ....................................................................... 11-45  Engine Coolant ............................................................................. 11-46  Hydraulic Oil ................................................................................. 11-49 Parts to be Replaced Periodically ....................................... 11-50  

Recommended Fuels and Oils.............................................. 12-3 Specifications (Standard Models) ........................................ 12-4 Refill Capacities ................................................................. 12-5 Capacities and Lift Truck Weight (Standard Models) ............. 12-5 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

12. SERVICE DATA ............................................................... 12-1 Fuel Information................................................................ 12-1  Fuel Specifications .......................................................................... 12-1 Coolant Information........................................................... 12-1  Coolant Water ................................................................................ 12-2  Antifreeze Solution ......................................................................... 12-2

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SAFETY RULES FOR LIFT TRUCK OPERATORS

 SAFETY RULES FOR LIFT TRUCK OPERATORS  General The safety rules and regulations in this section are representative of some, but not all rules and regulations that apply to lift trucks. Rules are paraphrased without representation that they have been reproduced verbatim.

Your lift truck was manufactured in accordance with EN ISO 3691-1 and EN16307-1 (CEN). Since regulations vary from country to country, operate this lift truck in accordance with local regulations.

The most effective way of reducing the risk of serious injuries, or even death, to you and others, is for you to know how to operate the lift truck properly. Drive alertly and avoid maneuvers or conditions that could cause accidents.

Continuing improvement and advancement of product design may have caused changes to your lift truck, which are not included in this publication. Whenever a question arises regarding your lift truck, or this publication, please contact your authorized Cat lift truck dealer for the latest available information.

All lift truck users should be familiar with their Local, Regional, and National regulations.

For European Union: Lift truck meets the requirements set to this machine in the Machinery Directive 2006/42/EC, EMC Directive 2004/108/ EC, Outdoor Noise Directive 2000/14/EC.

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

SAFETY RULES FOR LIFT TRUCK OPERATORS

 Warning Decals, Location -

-

There are several specific decals on your lift truck. Their exact location and description of the potential hazard are reviewed in this manual. See 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.

2

3

1

4 14

6 5

13

8

7

9 12 11

10

#

D00974

DANGER (1) Fasten Seat Belt Decal (2) Survive in a Tipover Decal WARNING (3) (4) (5) (6) (7)

1-2

Operation Warning Decal Overhead Guard Decal Brake Warning Buzzer Decal Radiator Cap Warning Decal No Access With Engine Running Decal

(8) No Riders Warning Decal (9) Parking Brake Decal (10) Pinch Point Decal (11) No One on the Fender Warning Decal (12) No One Under/On Forks and No One Between Mast and Chassis Decal (13) Capacity Plate (14) Backup Alarm Decal

SAFETY RULES FOR LIFT TRUCK OPERATORS

1

4 VEHICLE OPERATION AND MAINTENANCE MANUAL IS MISSING! CONTACT DEALER OR MANUFACTURER FOR REPLACEMENT!

93014-02500

5

8

6 5

7

3 2

D01015

CAUTION

OTHERS

(1) Operator Restraint System Decal (2) No Contamination Permissible Decal (Transmission) (3) Engine Coolant Decal

(4) (5) (6) (7) (8)

Operate with OMM Decal Hoist Point Decal Fuel Decal How to Open Engine Hood Decal Presence Detection System

1-3

SAFETY RULES FOR LIFT TRUCK OPERATORS

 Description of Danger, Warning, and Caution Decals 

Fasten Seat Belt Decal R DANGER

Tipover will occur if the lift truck is improperly operated.

Injury or death will result.

D00860



Survive in a Tipover Decal R DANGER

TIPOVER CAN OCCUR IF TRUCK IS IMPROPERLY OPERATED. INJURY OR DEATH WILL RESULT.

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 and/or uneven ground conditions will further aggravate the above conditions.

D00861

(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 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 grades. 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

SAFETY RULES FOR LIFT TRUCK OPERATORS 

Operation Warning Decal R WARNING

For safety observe the following warnings (1) DO NOT operate this truck unless you have been trained and authorized to do so. Read all warnings and instructions in Operation & Maintenance Manual and on this truck. Operation & Maintenance Manual is supplied with this truck or available from our lift truck dealers.

(2) DO NOT operate this 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.

(3) Operate truck only from designated operating position.

Never place any part of your body into the mast structure, between the mast and the lift truck, or outside the lift truck. DO NOT carry passengers.

(4) DO NOT operate the lift truck without the overhead guard, unless conditions prevent use of a guard. Use special care if operation without overhead guard is required.

(5) DO NOT handle loads which are higher than the load backrest or load backrest extension unless load is secured so that no part of it could fall backward.

(6) DO NOT handle unstable or loosely stacked loads. Use special care when handling long, high or wide loads to avoid losing the load, striking bystanders, or tipping the lift truck.

(7) DO NOT overload truck. Check capacity plate for load weight and load center information.

(8) Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn. Use special care when traveling without load as the risk of overturn is greater.

(9) Elevate forks or other lifting mechanism only to pick up or stack a load. Lift and lower with mast vertical or tilted slightly back---NEVER FORWARD. Watch out for obstructions, especially overhead.

(10) Operate tilting mechanism slowly and smoothly. DO NOT tilt forward when elevated except to pick up or deposit a load. When stacking, use only enough backward tilt to stabilize load.



D00892

(11) Travel with load or lifting mechanism as low as possible and tilted back. Always look in direction of travel. Keep a clear view, and when load interferes with visibility, travel with load or lifting mechanism trailing (except when climbing ramps).

(12) Use special care when operating on ramps--- travel slowly, and DO NOT angle or turn. When truck is loaded, travel with load uphill. When truck is empty, travel with lifting mechanism downhill.

(13) Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and wherever vision is obstructed.

(14) When using forks, space forks as far apart as load will permit. Before lifting, BE SURE that load is centered and forks are completely under load.

(15) DO NOT allow anyone to stand or pass under load or lifting mechanism.

(16) DO NOT lift personnel except on a securely attached specially designed Work Platform. Use extreme care when lifting personnel. Place mast in VERTICAL position, place truck controls in NEUTRAL and apply brakes. Lift and lower smoothly. Be available to operate controls as long as personnel are on the Work Platform.

Never transport personnel on forks or Work Platform.

(17) Before getting off truck, neutralize travel control, fully lower lifting mechanism and set parking brake. When leaving truck unattended, also shut off power.

Overhead Guard Decal R WARNING

-

Operation without this device in place may be hazardous.

DO NOT remove the overhead guard.

D00897

1-5

SAFETY RULES FOR LIFT TRUCK OPERATORS 

Radiator Cap Warning 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.

D00983



No Access With Engine Running Decal R WARNING

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

D00984



Parking Brake Decal R WARNING

-

When leaving machine, apply parking brake!

Parking brake is not automatically applied.

ALARM will sound if parking brake is not applied when get off machine or turn OFF key switch.

DO NOT apply parking brake while machine is in motion.

See Operation & Maintenance Manual for more important information.

-

D01018



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.

D00354

1-6

SAFETY RULES FOR LIFT TRUCK OPERATORS 

Pinch Points Decal R WARNING

Moving Mast—Crush Points.

Keep All Body Parts Clear of Mast.

D00895



No One on the Fender R WARNING

Do not step on the fender.

D00635



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.

91A83-01700

D00359

1-7

SAFETY RULES FOR LIFT TRUCK OPERATORS 

Brake Warning Buzzer Decal R WARNING

DO NOT move the lift truck if the brake warning buzzer is sounding or the brake warning icon is lit.

D00989



Capacity Plate R WARNING

Incorrect operation or maintenance could result in injury or death Capacity specified for the lift truck requires tires authorized by the manufacturer.

WARNING MODEL

ＩＭＰＲＯＰＥＲ ＯＰＥＲＡＴＩＯＮ ＯＲ ＭＡＩＮＴＥＮＡＮＣＥ ＣＯＵＬＤ ＲＥＳＵＬＴ ＩＮ ＩＮＪＵＲＹ ＯＲ ＤＥＡＴＨ

ＳＥＲＩＡＬ Ｎｏ．

ＡＵＴＨＯＲＩＺＥＤ ＢＹ ＴＨＥ ＭＡＮＵＦＡＣＴＵＲＥＲ． ＭＡＳＴ：ＶＥＲＴＩＣＡＬ

Ｂ A

A MM

B MM

FORKS ONLY KG

ATTACH KG

B

ATCH/MODEL ＥＮＧＬＩＳＨ ９２Ｇ８１−０５５００

D01019



Backup Alarm Decal R WARNING

This vehicle is equipped with a backup alarm.

Alarm must sound!

When operating this vehicle 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 vehicle.

D00863

1-8

SAFETY RULES FOR LIFT TRUCK OPERATORS 

Operator Restraint System Decal R CAUTION

This industrial truck is equipped with an operator restraint system. Should it become necessary to replace any of the components, including the seat assembly, for any reason, it must only be replaced with components approved by the manufacturer.

D00862M



No Contamination Permissible Decal R CAUTION

Clean outer surface of solenoid valve before removing for repairs to avoid contamination. No contamination permissible.

D00883

1-9

SAFETY RULES FOR LIFT TRUCK OPERATORS

 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)

D00369 1) CERTIFICATE

R WARNING DO NOT travel 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 the rules and regulations of your employer!

D00726

1-10

SAFETY RULES FOR LIFT TRUCK OPERATORS R WARNING Always be alert!

Know your employer guidelines and how to get prompt assistance if invalid 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 CAUTION Know your truck is safe!

DO NOT operate any lift truck that is not safe to operate.

D00288A

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

1-11

SAFETY RULES FOR LIFT TRUCK OPERATORS 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 before modification.

D00681

R WARNING Know the lift truck and attachments!

Read and understand the operating, inspection, and maintenance instructions in the Operation & Maintenance Manual attachment vendor manuals 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. If you cannot wait, use a heavy cloth and gloves to protect yourself. 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.

D00900

1-12

SAFETY RULES FOR LIFT TRUCK OPERATORS R WARNING Exhaust fumes could kill you!

Some of the symptoms from carbon monoxide poisoning are headaches, flu like symptoms, 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 before 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.

D00284

R WARNING DO NOT operate an unsafe lift truck!

If the lift truck has a "OUT OF SERVICE" or similar warning tag, the lift truck must not be operated until it has been restored to a safe operating condition. Inspect the lift truck before you operate it.

1)

D00966 1) OUT OF SERVICE

R CAUTION Precautions when handling controllers and sensors!

-

DO NOT allow wash water, rain, oil, or any other liquid on controllers and their related sensors.

- DO NOT apply force, open, modify controllers, or operate the lift truck without controllers.

- Turn the key switch to the OFF position. Disconnect battery cables and controller connections before conducting the following operations: - Removing controllers from the lift truck - Manufacturer-approved welding

D01017

1-13

SAFETY RULES FOR LIFT TRUCK OPERATORS R WARNING DO NOT operate the lift truck if you are pregnant or have suffered an abdominal disease or injury.

D00725A

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.

D00882

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.

D00901

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.

D00884A

1-14

SAFETY RULES FOR LIFT TRUCK OPERATORS R WARNING The backup alarm must activate when traveling in REVERSE! Make sure the backup 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.

D00374

R WARNING Operate only in approved areas!

Certain areas such as those containing hazardous flammable gases, liquid, or other combustibles require a Safety Rated 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

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 nonoperating area and remove the key. Attach a "DO NOT OPERATE" or similar warning tag on the lift truck.

Contact your authorized Cat lift truck dealer for repairs.

D00378A

1-15

SAFETY RULES FOR LIFT TRUCK OPERATORS R WARNING Face the lift truck when mounting and dismounting!

Maintain a three point contact (one foot and two hands) with the floor and handholds.

-

-

DO NOT get on or off a moving lift truck.

DO NOT jump on or off the lift truck.

DO NOT use the control levers or steering wheel as handholds when entering or leaving the operator compartment.

DO NOT get on or off the right side of the lift truck.

D00886

R WARNING Adjust the operator seat before operating the lift truck!

DO NOT adjust the operator seat while the lift truck is in motion.

D00436A

R WARNING Always check overhead clearance!

Serious accidents and damage could be caused by the mast and overhead guard hitting pipes, beams or other overhead obstructions. Watch out for power lines.

D00683

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

1-16

SAFETY RULES FOR LIFT TRUCK OPERATORS 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.

D00896

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.

D00381

R WARNING Always be aware of floor capacity!

Make sure the floor will support the weight of the loaded lift truck.

D00294A

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

1-17

SAFETY RULES FOR LIFT TRUCK OPERATORS R WARNING Stay under the overhead guard!

DO NOT hold on to the overhead guard.

D00380

R WARNING Check fork locking pins for engagement!

If the fork locking pins are not properly engaged, or not in good condition, the forks could shift and cause off-center or unstable loads.

D00632

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

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

1-18

SAFETY RULES FOR LIFT TRUCK OPERATORS 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.

F00086

1-19

SAFETY RULES FOR LIFT TRUCK OPERATORS

 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.

D01016

R WARNING Position levers correctly for starting!

Make sure the direction lever is in the NEUTRAL position and the parking brake lever is set properly.

D00383A

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 while crossing aisles and other locations where vision is obstructed.

D00316A

1-20

SAFETY RULES FOR LIFT TRUCK OPERATORS 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 are 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

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

1-21

SAFETY RULES FOR LIFT TRUCK OPERATORS 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.

D00311A

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.

D00312A

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.

D00321A

R WARNING Travel safely on grades with an empty lift truck!

Unloaded lift trucks must be operated on all grades with the forks downgrade.

D00319A

1-22

SAFETY RULES FOR LIFT TRUCK OPERATORS 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.

D00317A

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.

D00320A

R CAUTION Slow down at the top of upgrades!

Travel slowly near the top of upgrades as the visibility is limited.

D00318A

R WARNING Be careful of tail swing!

Make sure that personnel stand clear of the rear swing area before making turns.

D00899

1-23

SAFETY RULES FOR LIFT TRUCK OPERATORS 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.

D00724

 Working Precautions R WARNING Keep out!

-

DO NOT allow any unauthorized persons in the work area where the lift truck is operated.

Personnel must be clear of the lift truck operating area.

D00337

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.

D00384

1-24

SAFETY RULES FOR LIFT TRUCK OPERATORS 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

R WARNING DO NOT speed when approaching loads!

Approach the load carefully at slow speeds.

D00332

R WARNING Ensure the load isn't too high!

DO NOT pick up unsecured loads that extend above the load lift bracket extension height.

D00341A

R WARNING DO NOT move when someone's next to the lift truck!

If someone is standing next to the lift truck, DO NOT proceed until they are a safe distance away. DO NOT assume that people are aware of you and will move out of your way.

D00902

1-25

SAFETY RULES FOR LIFT TRUCK OPERATORS R WARNING Handle only stable and safely arranged loads!

If a load is unstable, it could easily shift and fall on someone.

D00331A

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

1-26

SAFETY RULES FOR LIFT TRUCK OPERATORS 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 dock plate, and if it does not have enough strength to withstand the weight of the lift truck carrying a load, DO 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 railroad.

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 railroad, and also secure the dock plate to prevent it from falling off.

Obey the instructions of the supervisor when working as a team.

D00343

R WARNING Fork positioner operation!

-

DO NOT operate the fork positioner while carrying loads.

DO NOT handle off-center loads.

R CAUTION 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

1-27

SAFETY RULES FOR LIFT TRUCK OPERATORS 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

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.

D00342A

R CAUTION Operate the direction lever smoothly!

Avoid sudden changing of traveling direction. This may cause damage to the transmission.

D00386A

1-28

SAFETY RULES FOR LIFT TRUCK OPERATORS 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.

F00081

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

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, the 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

1-29

SAFETY RULES FOR LIFT TRUCK OPERATORS 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 an "OUT OF SERVICE" or similar warning tag to the lift truck.

Contact your authorized Cat lift truck dealer.

1)

D00389A 1) OUT OF SERVICE

R WARNING When you leave or park the lift truck: -

Set 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 OFF position.

Remove the key from the key switch.

D00390

1-30

KNOW YOUR LIFT TRUCK

 KNOW YOUR LIFT TRUCK  Serial Number and Capacity Plate For quick reference, record your lift truck's serial numbers in the spaces provided on 13-4 "Service Registration".

2

1 WARNI NG MODEL

ＩＭＰＲＯＰＥＲ ＯＰＥＲＡＴＩＯＮ ＯＲ ＭＡＩＮＴＥＮＡＮＣＥ ＣＯＵＬＤ ＲＥＳＵＬＴ ＩＮ ＩＮＪＵＲＹ ＯＲ ＤＥＡＴＨ

ＳＥＲＩＡＬ Ｎｏ．

ＡＵＴＨＯＲＩＺＥＤ ＢＹ ＴＨＥ ＭＡＮＵＦＡＣＴＵＲＥＲ． ＭＡＳＴ：ＶＥＲＴＩＣＡＬ

Ｂ A

A MM

B MM

FORKSONLY KG

ATTACH KG

B

AT CH/ MODE L ＥＮＧＬＩＳＨ ９２Ｇ８１−０５５００

3 SEAIAL No.

DATE MODEL

TRUCK WEIGHT

TIRE PRESSURE FR/RE

FRONT TIRE SIZE REAR TIRE SIZE MAX REARWARD MAST TILT

kg

/ deg.

LOAD TIRE TREAD WIDTH

mm

2-1-1, HIGASHIKOTARI, NAGAOKAKYO-SHI, KYOTO, JAPAN ENGLISH 91C8104400

E01258

1.

2.

Capacity Plate Engine Serial Number

3.

Manufacturer Name Plate

2-1

KNOW YOUR LIFT TRUCK

 Electrical Components

2

1

E01123

1.

VCM controller, Output unit, and DC/DC converter

2.

Input unit, Operator presence switch

-

These system consists of precise components. DO NOT attempt to make adjustments or repair by yourself. Contact your authorized Cat lift truck dealer.

Moisture is harmful to controllers and their related sensors. When washing, DO NOT splash water or steam clean the controllers and their related sensors.

The operator is unable to move the mast unless properly seated. When replacing the operator seat, BE SURE to order a genuine Cat lift truck seat with an operator presence switch.

R CAUTION -

2-2

KNOW YOUR LIFT TRUCK

 Model View

1

2

3 4 5 6 7

17 16

15

8

14

9 10 11 12 13 19 18

20 21

E01149

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Front combination light Head light Overhead guard Exhaust muffler Counterweight Operator seat Precleaner Rear wheel Fuel tank Engine hood Tilt cylinder

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Front wheel (Outer) Front wheel (Inner) Fork Lift bracket Lift cylinder Mast Turn signal light Tail/stop light Backup light Drawbar pin

2-3

KNOW YOUR LIFT TRUCK 

FC Model (Type A) 8

9 10 11 12

1 2 3 4 5 6 7

13

14 

8.

9.

10.

11.

12.

13.

14.

Turn signal/light switch Key switch Accelerator pedal Lift switch Tilt switch Attachment switches Emergency mast stop button Meter panel Direction lever Parking brake lever Steering column tilt lever Inching pedal Brake pedal Operator seat

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Turn signal/light switch Key switch Accelerator pedal Lift switch Tilt switch Attachment switches Meter panel Direction lever Parking brake lever Steering column tilt lever Inching pedal Brake pedal Operator seat

E01150

FC Model (Type B) 7

1

8 9

2 3

10

4

11

6

5

12

13

2-4

1.

2.

3.

4.

5.

6.

7.

E01151

KNOW YOUR LIFT TRUCK 

LC Model 8

1

9 10

2 3 4

11

5 6

12

13

7

14

E01152

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Turn signal/light switch Key switch Accelerator pedal Lift lever Tilt lever Attachment levers Emergency mast stop button Meter panel Direction lever Parking brake lever Steering column tilt lever Inching pedal Brake pedal Operator seat

2-5

KNOW YOUR LIFT TRUCK

 Driving Switches and Controls 1

5

2

7

6

8

10

3 4

13

11

9

14

12

15

16

17

19

18

20

21

24

22

25

26

23

E01096

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

2-6

Direction lever FORWARD (F) NEUTRAL (N) REVERSE (R) Horn switch Push to activate Turn signal / light switch Head light (Position 2) Clearance light (Position 1) Left turn Right turn Key switch Parking brake lever

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

Release Apply Steering column tilt lever Inching pedal Released Clutch disengaged Brake applied Brake pedal Release Apply Accelerator pedal Idling Full throttle

KNOW YOUR LIFT TRUCK 

Key Switch

The key switch has as a built-in mechanical lockout that prevents the key switch from being turned to the START position while the engine is running. Turn the key switch back to the OFF position before recranking the engine.

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.

Icon

Definition

z (OFF)

The key switch in the OFF position removes power from meter panel and electrical circuits except for horn, parking brake warning alarm and lights.

U (ON)

Z (START) 

The key switch in the ON position applies power to all electrical circuits except for starter circuit.

Note: Power is applied to glow plugs for 1 to 12 seconds depending on the engine coolant temperature, intake air temperature, and glow plug icon glows.

The key switch in the START position applies power to the starter motor to crank the engine. A switch spring returns the key switch to the ON position when the key is released.

Direction Lever (Powershift Model)

This lift truck is equipped with a NEUTRAL switch. Be sure to put the direction lever in the NEUTRAL position before starting the engine.

1 2 3 J00240 1. FORWARD (F) 2. NEUTRAL (N)



3. REVERSE (R)

Inching Pedal

The operator can move the lift truck slowly by depressing the inching pedal to lower the travel speed while maintaining engine speed.

2

Full application of the inching pedal puts the transmission in NEUTRAL and applies the service brake.

1

3

E00698 1. Released 2. Clutch disengaged

3. Brake applied

2-7

KNOW YOUR LIFT TRUCK  -

Turn Signal / Light Switch When turning to the right or to the left, operate the turn signal switch in the direction of the arrow as shown on the right. The turn signal switch automatically returns when the steering wheel is returned, but it can also be returned manually.

When the light switch is placed to the Y position, the meter panel icons, tail lights, and clearance lights illuminate. When it is placed to the H position, head lights also illuminate in addition to the above lights.

-

1 3

4

2

E01113 1. Head light (Position 2) 2. Clearance light (Position 1)

3. Left turn 4. Right turn

Position Light 1

2

Meter Panel Icons

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. 

Steering Column Tilt Lever

The steering column position can be adjusted with the steering column tilt lever to the operator’s desired driving position.

Adjustment of steering column position

2 1 Lock 1)

(1) Unlock the steering column tilt lever.

(2) Hold the steering column and adjust it to the appropriate position.

(3) After adjustment, lock the steering column tilt lever.

Steering column release lever To make it easy to get on and off, unlock the steering column release lever and tilt the steering column toward the front of the lift truck.

After returning to the operator seat, tilt the steering column toward the operator seat and make sure that it is automatically locked. It will return to the same position it was set to before getting off the lift truck.

4)

1. Steering column release lever 2. Steering column tilt lever

2)

3)

E00344 1) 2) 3) 4)

Lock Unlock Lock Unlock

R WARNING -

2-8

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.

KNOW YOUR LIFT TRUCK

Meter Panel When any warning icon in the meter panel glows or blinks, stop the lift truck and take corrective action. (Except for the glow plug icon.)

1

E01045

1.

Meter panel

Meter panel consists of warning icons, Liquid Crystal Display (LCD) screen, cursor buttons (M UP button and m DOWN button) and entry/display switch button (O ENTER/DISPLAY SWITCH button).

3

1 5

2 1.

2.

3.

Warning icons LCD screen Cursor buttons

4

6 4.

5.

6.

E00958

M UP button m DOWN button O ENTER/DISPLAY SWITCH button

2-9

KNOW YOUR LIFT TRUCK 

Warning Icons Glow Check

When the key switch is turned to the ON position, warning icons and indicator icons will glow.

The warning icon marked j will keep glowing until glow plug heating is completed. If not, the Light Emitting Diode (LED) may have a defect. If the LED fails to glow with the key in the ON position, contact your authorized Cat lift truck dealer.

*

E01038



LCD Screen

The LCD screen consists of main display, fuel gauge, travel direction, service interval, time/hour meter, and engine coolant temperature gauge. The main display is divided into two parts (right and left).

1

4

2

3

5

6 E00137J

1.

2.

3.

2-10

Travel direction Service Interval (Option) Time/hour meter display

4.

5.

6.

Fuel gauge Main display Water temperature gauge

KNOW YOUR LIFT TRUCK 

Warning Icons and Indicators

1

2

3

4

5

E01039

1.

2.

3.

Parking brake warning icon Seat belt warning icon Battery charge warning icon

4.

5.

Multi-purpose warning icon Torque converter oil temperature warning icon

1. Parking brake warning icon and warning alarm

4. Multi-purpose warning icon

-

-

This warning icon glows when the parking brake is applied, and it goes OUT when released.

- Parking brake warning alarm will activate when the operator leaves the operator seat for approximately 3 seconds without applying the parking brake.

- When the operator leaves the operator seat for several more seconds while the engine is running and the parking brake is released on level ground, the parking brake warning icon blinks and warning alarm will activate.

2. Seat belt warning icon

This warning icon glows when a minor warning occurs.

The diagnostic codes and symbols are also displayed.

5. Torque converter oil temperature warning icon -

This warning icon glows when the oil temperature is high and the danger of overheating is present. See 1013 "If Torque Converter Oil Temperature Warning Icon Glows (Powershift Model)".

-

This warning icon glows when the seat belt is not worn or when the seat belt is not properly buckled.

3. Battery charge warning icon -

This warning icon glows when the battery charging system is not functioning properly. Check the alternator drive belt for slippage or breakage.

2-11

KNOW YOUR LIFT TRUCK

6

7

8

E01147.

6.

7.

Engine oil pressure warning icon Glow plug indicator icon

8.

Mast interlock indicator icon

6. Engine oil pressure warning icon -

If this icon glows during operation, turn the engine OFF and check the engine oil level. Add oil as required.

-

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.

R CAUTION

7. Glow plug indicator icon -

This indicator icon glows when the key switch is turned to the ON position and goes OUT after heating is completed. Turn the key switch to the START position.

8. Mast interlock indicator icon -

2-12

This indicator icon blinks and the mast will not move even if the lift, tilt and/or attachment levers are operated and the operator is not sitting properly in the operator seat for approximately 3 seconds. This warning icon goes OUT if the lift, tilt and/or attachment levers are placed to the NEUTRAL position and the operator sits in the operator seat in the normal operating position.

KNOW YOUR LIFT TRUCK 

Basic Screen Display

LCD screen when the key switch is turned ON When the key switch is turned to the ON position, the LCD screen changes in the following order: brand logo screen, password input screen (option), and standard screen.

Brand logo screen When the key switch is turned to the ON position, the brand logo screen will be displayed for approximately 3 seconds while the lights are being checked.

E00175

Password input screen (Option) The lift truck can be operated after inputting the registered password.

Note: Available when password option is selected.

E00142

Standard screen The screen changes to the standard display.

E00143

2-13

KNOW YOUR LIFT TRUCK Speedometer display

1

Speedometer reads the current lift truck speed.

E00144J 1. Speedometer display

Actual speed

Display

0.1 to 1.0 km/h (0.06 to 0.6 mph) 1.1 to 2.0 km/h (0.6 to 1.2 mph) · · · 29.1 to 30.0 km/h (18.04 to 18.60 mph)

1 km/h (0.6 mph) 2 km/h (1.2 mph) · · · 30 km/h (18.6 mph)

Fuel gauge display When the key switch is turned to the ON position, the fuel gauge will indicate the remaining fuel amount in the tank.

When the fuel gauge shows EMPTY (E), the low fuel level warning icon will be displayed on the LCD screen.

Note: If the ground is not level, the correct fuel amount will not be shown. See table below for estimated remaining amount of fuel when low fuel level warning icon illuminates.

1

4

3

1) With fuel gauge 1. FULL 2. Fuel gauge

2

1) 3. EMPTY 4. LOW FUEL LEVEL

1) 1) Without fuel gauge

Model

Remaining amount

DP100NM1, DP100NM1S, DP120NM1, Less than 38.7 L (10.2 U. S. gal.)

DP120NM1S, DP135NM1, DP135NM1S DP150NM1, DP150NM1S

2-14

Less than 47.3 L (12.5 U. S. gal.)

E01118

E00551

KNOW YOUR LIFT TRUCK 2

1

Engine coolant temperature gauge display This gauge indicates the engine coolant temperature. When the gauge shows the RED zone, the engine may be overheated.

See 10-12 "If the Engine Coolant Temperature Gauge Shows RED Zone".

3 1. Engine coolant temperature gauge 2. Overheat

Travel direction display

E00496

3. Suitable temperature

1

The lift truck travel direction is displayed. If the direction lever is not in the NEUTRAL position when starting the engine, the engine will not start with "N" blinking on the screen. If the operator leaves the operator seat for approximately 3 seconds while the engine is running and the direction lever is not in the NEUTRAL position, "N" on the screen will blink, and the transmission will electrically shift into NEUTRAL. E00147J 1. Travel direction

1

2

1) 1. FORWARD 2. REVERSE 3. NEUTRAL

3

E01153

1) During interlock indicator icon blinks when the direction lever is not in the NEUTRAL position

2-15

KNOW YOUR LIFT TRUCK 

Basic Operation 1

Operation buttons The operation buttons are located on the right side of the meter panel. There are three types of buttons: UP button, DOWN button, and ENTER/DISPLAY SWITCH button. The function and operation of these three buttons vary with each display screen.

2 3

Button operation is available only when the key switch is in the ON position. While the engine is running, button operation is not available.

E00149J 1. UP button 2. DOWN button

3. ENTER/DISPLAY SWITCH button

Note: -

Some changes to the display are not available when the engine is running.

Adjustment of screen contrast and selection between hour meter display and time display are available with the engine running.

Short press of button: Press button for less than two seconds.

Long press of button: Press button for more than two seconds.

Multiple button presses: All three buttons pressed at the same time for more than two seconds.

How to adjust screen contrast Turn the key switch to the ON position. Adjustment of screen contrast is available while the engine is running.

Button

Press

M m

Short press

Screen contrast Light 6 Dark Dark 6 Light

The screen contrast varies with the number of times a button is pressed.

How to display clock time, hour meter, and fuel consumption

1

Turn the key switch to the ON position. Screen display selection is available while the engine is running. With a short press of the ENTER/DISPLAY SWITCH button, the display changes in the order of hour meter, clock time, and fuel consumption.

E00150J 1. Clock time / Hour meter / fuel consumption

Button

Press

Display

O

Short

Hour meter 6 Clock time 6 Fuel consumption

2-16

KNOW YOUR LIFT TRUCK 1

Display image of hour meter When the key switch is turned to the ON position, the last selected screen is placed in memory to display next.

E00151J 1. Hour meter

Display image of fuel consumption

1

When the key switch is turned to the ON position, the last selected screen is placed in memory to display next.

L/H

E00961 1. Fuel consumption

2-17

KNOW YOUR LIFT TRUCK How to change clock system (12Hr. / 24Hr. system) Turn the key switch to the ON position. Screen display selection is available while the engine is running. With a long press of the UP button while the clock time is on display, the clock system changes alternately between 12 hour display and 24 hour display.

Button

Press

Display

M

Long press

12 Hr. 46 24 Hr 08:52PM 46 20:52

How to adjust clock time Turn the key switch to the ON position. Do not start the engine.

1

E00152 1. Blinking

Select clock time display Button

Press

Display

O

Short

Clock time (: Blinks)

Time adjust mode Button

Press

Display

O

Long

Time setting mode of hours

2-18

KNOW YOUR LIFT TRUCK Time setting of hours

1

E00153 1. Digits to be adjusted is blinking

Button M

m O

Press

Display

Short

01 to 12 / 01 to 24 (1 hour at each press)

Long

01 to 12 / 01 to 24 (continuous)

Short

12 to 01 / 24 to 01 (1 hour at each press)

Long

12 to 01 / 24 to 01 (continuous)

Short

Move to the time setting of minutes

Time setting of minutes Time accuracy Precision errors will be a minute or less per month.

1

E00154 1. Digits to be adjusted is blinking

Button M

m O

Press

Display

Short

00 to 59 (1 min. at each press)

Long

00 to 59 (continuous)

Short

59 to 00 (1 min. at each press)

Long

59 to 00 (continuous)

Short

Move to the standard screen

2-19

KNOW YOUR LIFT TRUCK 1

How to display hour meter Turn the key switch to the ON position.

Screen display selection is available while the engine is running.

With a short press of the ENTER/DISPLAY SWITCH button, the display changes in the order of hour meter, clock time, and remaining fuel amount.

E00151J

1. Hour meter

Button

Press

Display

O

Short

Clock time 46 Hour meter

How to change hour meters

1

Turn the key switch to the ON position and select the hour meter. There are three hour meter counters; key-ON time, engine-ON time, and seat switch-ON time. With a long press of the UP button, the display changes.

2

3 E00156J 1. Key-ON time display 2. Engine-ON time display

Button

Press

Display

Long

Key-ON time 2 Engine-ON time 2 Seat switch-ON time

M

3. Seat switch-ON time display

Key-ON time: Total hours of key switch ON time Engine-ON time: Total hours of engine operation time Seat switch-ON time: Total hours the operator presence switch has been activated.

Note: -

2-20

Increments of 0.1 hour are six minute intervals.

At the manufacturing facility, key-ON time is set to display on the screen.

When the key switch is turned to the OFF position, the last selected screen is placed in memory to display the next time.

KNOW YOUR LIFT TRUCK How to display fuel consumption

1

Turn the key switch to the ON position.

Screen display selection is available while the engine is running.

With a short press of the ENTER/DISPLAY SWITCH button, the display changes in the order of hour meter, clock time, and fuel consumption.

L/H

E00961 1. Fuel consumption

How to change fuel unit display Turn the key switch to the ON position and select the fuel consumption. There are two fuel units; Liter Per Hour (L/H) and Gallon Per Hour (GPH). With a long press of the UP button, the display changes.

1

2

L/H GPH

E00964

1. Liter per hour (L/H)

2. Gallon per hour (GPH)

1

How to display truck history Turn the key switch to the ON position.

A simultaneous long press of all three buttons brings up the lift truck history on the hour meter screen.

2 3

E00149J 1. UP button 2. DOWN button

Button

Press

Display

MmO

Simultaneous long press of all three buttons

Truck history

3. ENTER/DISPLAY SWITCH button

2-21

KNOW YOUR LIFT TRUCK Warning messages displayed are limited to F diagnostic codes only.

Diagnostic codes are displayed from the latest code (R-1) up to the past 32 codes (R-32). Oldest data (code) exceeding the limit (32 codes) is automatically erased.

1

2

3

4 5

E00158 1. Truck history 2. Hour meter 3. Diagnostic code

4. Truck history display 5. With the UP or DOWN buttons, truck history record on the display changes.

The display order of diagnostic codes can be changed with short press of UP button or DOWN button.

Button

Press

M m

Short

Display Oldest first Latest first

A simultaneous long press of all three buttons returns to the standard display screen.

Button

Press

Display

MmO

Simultaneous long press of all three buttons

Truck history

The following image shows the lift truck history screen when there is no truck record.

1

E00159 1. When there is no truck record

2-22

KNOW YOUR LIFT TRUCK 

When Diagnostic Code Is Shown on Display

When a warning occurs, the diagnostic code is displayed on the screen. The diagnostic codes are categorized into two types: serious and minor diagnostic codes, according to the level of fault. To erase the diagnostic code being displayed, remove the cause of the warning first. Then turn the key switch to the OFF position, and turn the key switch to the ON position. The diagnostic code will remain displayed until the cause of warning is removed. The following are the examples of display pattern.

R CAUTION When the diagnostic code is displayed on the meter panel, stop operating the lift truck immediately. Park the lift truck in a safe area and contact your authorized Cat lift truck dealer.

When a serious warning of the lift truck occurs (serious warning)

1

On main display, the diagnostic code 1) displays white characters on a black background. Also, all of the five warning icons 1 shown in the illustration on the right will blink.

1) 506138 1. All warning icons blink

When a minor warning of the lift truck occurs (minor warning)

1) The diagnostic code displays white characters on a black background

1

On main display, the diagnostic code and warning symbol 1) will glow. Also, the multi-purpose warning icon 1 will glow.

Note: The minor warning is also displayed when the fuel gauge reaches the empty level (E).

1)

506151 1. Multi-purpose warning icon glows.

1) The diagnostic code and warning symbol glow.

2-23

KNOW YOUR LIFT TRUCK Warning display according to fault level

1 Minor warning

Multi-purpose warning icon 1 glows 506528

2 Serious warning

All of the five warning icons 2 blink

506529

2-24

KNOW YOUR LIFT TRUCK 

When Several Warnings Occur Simultaneously

The following are the example of warning display pattern:

When serious and minor warnings of the lift truck occur simultaneously

1

On main display, the diagnostic code 1) changes between black characters on a white background to white characters on a black background. Also, all of the five warning icons 1 shown in the illustration on the right will blink.

When recovered from the serious warning, the diagnostic code 2) and the multi-purpose warning icon 2 will glow.

1) 2

2) 1. All warning icons blink 2. Multi-purpose warning icon glows.

506152 1) The diagnostic code changes between black characters on a white background to white characters on a black background 2) The diagnostic code glows.

2-25

KNOW YOUR LIFT TRUCK 

Warning Symbols

The following warning symbols are displayed in the main area: Symbol

2-26

Name

Indicated condition

Applied model

Fuel filter water draining warning symbol

The symbol glows when the water All models in the fuel filter needs to be drained

Low coolant level warning symbol

Coolant is low

All models

Clogged air cleaner element warning symbol

Air cleaner is clogged

All models (option)

Low fuel level warning symbol

Fuel level is low (E level)

All models

KNOW YOUR LIFT TRUCK 

Warning Icons

The actuation of each warning icon is shown in the table below: Indicator light

Name

Color

Glow (ON) or blinking condition

Parking brake warning icon

Red

Parking brake is activated (ON)

All models

Seat belt warning icon

Red

The seat belt is not fastened (ON)

All models

Battery charge warning icon

Red

Multi-purpose warning icon

Red

Presence of a minor warning or operating caution (ON)

All models

Torque converter oil temperature warning icon

Red

Torque converter oil temperature is abnormal (ON)

All models

Engine oil pressure warning icon

Red

The engine oil pressure is low (ON) The engine is not running (ON)

All models

Charge is not working properly (ON) The engine is not running (ON)

Applied model

All models

Glow icon

Orange Glow plug heating is ON (ON)

All models

Mast interlock indicator icon

Orange Mast interlock is activated (ON)

All models

2-27

KNOW YOUR LIFT TRUCK 

Optional Features

Optional features are given below: - Password authentication screen - Service interval display - Overspeed warning display - Load meter display - Overload warning display - Speed limit function Note: For the following features, the installation of special devices is required.

- Load meter display - Overload warning display Password authentication (dealer option) Purpose and function The password authentication is designed to prevent unauthorized persons from driving the lift truck. To operate the lift truck, input a 4 digit password correctly.

Inputting a password Turn the key switch to the ON position to display the brand screen. Enter the registered password when password input screen is displayed.

Password input procedure is shown in the table below:

1)

501250 1) To standard screen

Button M

m O

Press

Display

Short press

0 to 9 [8], each press increases 1

Long press

0 to 9 [8], scrolls

Short press

[2] 0 to 9, each press increases 1

Long press

[2] 0 to 9, scrolls

Short press

Enter (to move to next digit)

Note: Select [4] to return the previous digit.

Press ENTER/DISPLAY SWITCH button to move to the next digit. After inputting number at the 4th digit, press ENTER/DISPLAY SWITCH button for entry.

When the password is correct, "OK" is displayed.

If the password is wrong, the display returns to input screen after "NG" display. If "NG" message appears, you cannot move the lift truck or perform any load handling operation, but you can start the engine.

2-28

KNOW YOUR LIFT TRUCK Note: -

-

-

In case of an emergency or when the registered password is forgotten, enter "1111". Then the screen shown on the right will appear. You can conduct a minimum limit of travel and operation.

Password input is necessary when starting the operation, but if it is within 3 minutes after the key switch is turned to the OFF position, the operator does not need to enter the password again.

For changing the password expiration time, use the service tool. (For details, see the service tool Help menu.)

501251

For password registration, change, and cancellation, use the service tool. (For details, see the service tool Help menu).

Note: -

-

Password registration, change, and cancellation should be performed by service personnel.

Password registration of "0000" and "1111" are not available. Register a different 4-digit password other than those.

Up to 32 different passwords can be registered.

Service interval display When the hour meter reaches the preset number of hours, the service interval symbol mark will be displayed to notify the lift truck operator of the periodic inspection and maintenance time.

1

Note: -

Service interval symbol will not be displayed if this setup is not installed.

The service interval setting, should be set up by your authorized Cat lift truck dealer.

E00165J 1. Service interval display

Overspeed warning display

1

When the pre-set speed limit is exceeded, the speedometer display on the LCD screen will change between black and white alternately.

Also the warning buzzer will activate.

-

The overspeed setting, should be set up by your authorized Cat lift truck dealer.

The travel speed of truck is limited within the range of pre-set speed.

E00166J 1. Overspeed warning display

2-29

KNOW YOUR LIFT TRUCK Load meter display

1

Load meter display is a function to display load weight.

-

The load meter setting, should be set up by your authorized Cat lift truck dealer.

E00167J 1. Load meter display

Note: -

-

If equipped with the optional; load weight indicator / display, the weight on the forks will be displayed on the load meter display when the load is lifted. The weight shown can be set to indicate either tons (t) or pounds (lbs). The readout is an estimation of the actual load on the forks.

The estimation is for reference purposes only and CANNOT be used for legal trade.

The capacity plate on the lift truck specifies the maximum lifting capacity. Wide loads or extended load centers can change the lift capacity of the lift truck.

Overload warning display

1

When the pre-set load limit is exceeded, the load meter display on the LCD screen will change between black and white alternately.

-

The overload warning setting, should be set up by your authorized Cat lift truck dealer.

E00168J 1. Overload warning display

Speed restriction Speed restriction controls the maximum speed of both HIGH (H) and LOW (L) speeds to the preset values.

1 1. High speed symbol

2-30

2

E00546

2. High speed limit display

KNOW YOUR LIFT TRUCK

1 1. Low speed symbol

2

E00547

2. Low speed limit display

2-31

KNOW YOUR LIFT TRUCK

Side Panel 

Speed Mode Selector Switch R CAUTION

Operate the switches on the side panel after the lift truck is stopped.

1

E00997 1. Speed mode selector switch

Turn the speed mode selector switch to select the speed for your work.

-

D: Automatic speed mode (1st speed, 2nd speed, and 3rd speed) 1: 1st speed only 2: Automatic speed mode (1st speed and 2nd speed)

-

1

D 2 1

2 3 E00996

1. Automatic mode (1st, 2nd, and 3rd speed)



2. Automatic speed mode (1st and 2nd speed) 3. 1st speed only

Brake Warning Icon R WARNING

DO NOT move the lift truck if the brake warning alarm is sounding or the brake warning icon glows.

Brake warning alarm sounds and brake warning icon glows to notify the following warnings: -

Brake air pressure is too low.

Brake lining is worn too much.

D00887 1. Brake warning icon

2-32

KNOW YOUR LIFT TRUCK

 Presence Detection System Lift trucks with this label are equipped with an "Presence Detection System" (PDS). This system features an enhanced, integral computer-based feedback system which provides "certain product intelligence" to the operator.

Be sure to operate the lift truck and system correctly. Also be sure to properly maintain as well as operate the system at all times.

E01125



Mast Interlock System

The Mast Interlock System is one of the functions of the Presence Detection System installed on this lift truck. The lift truck senses when the operator is not properly seated in the operator seat and will prevent the mast from operating until the operator is properly seated. In the following cases, the mast interlock system disconnects power to the hydraulic control valve and the mast will not lift, lower or tilt even if the control levers are operated:

R WARNING -

Check the mast interlock system for proper operation during 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 ON position, it is possible for the mast to descend. Please be very careful.

The parking brake is not automatically applied when the mast interlock is activated.

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.

(1) The operator leaves the operator seat for 3 seconds with the key switch in the ON position regardless of whether the engine is running or not.

(2) When the operator leaves the operator seat for 3 seconds while the engine is running, the operator presence switch in the operator seat is activated, which causes the mast to be irresponsive, even if the lift, tilt and/or attachment levers are operated.

1)

1)

1) E00397A 1) STOP

2-33

KNOW YOUR LIFT TRUCK 

Mast Interlock System Functions Conditions

Key Switch

Engine

OFF

OFF

ON

START

2-34

OFF

ON

Mast Interlock Operator Seat Indicator Icon

Control Levers' Operation Lift Lever

Tilt Lever

Attachment Lever

Seated or Not Seated

OFF

Inoperative

Inoperative

Lowering of its own weight

Not Seated

BLINK

Inoperative

Inoperative

Lowering of its own weight

Seated

OFF

Lowering only

Inoperative

Lowering of its own weight

Seated to Not Seated

BLINK (After 3 seconds)

Lowering only (for 3 seconds)

Inoperative

Lowering of its own weight

Not Seated to Seated

OFF

Lowering only

Inoperative

Lowering of its own weight

Not Seated

BLINK

Inoperative

Inoperative

Lowering of its own weight

Seated

OFF

Operative

Operative

Lowering of its own weight

Seated to Not Seated

BLINK (After 3 seconds)

Operative (for 3 seconds)

Operative (for 3 seconds)

Lowering of its own weight

Not Seated to Seated

OFF

Operative

Operative

Lowering of its own weight

KNOW YOUR LIFT TRUCK 

Driving Interlock System R WARNING

-

Check the driving interlock system for proper operation during the daily prestart inspection.

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.

1)

1)

E00398A 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).

The driving interlock system will not allow the lift truck's transmission to stay in the FORWARD or REVERSE position when you are out of the operator seat.

If the operator leaves the operator seat for 3 seconds, a switch in the operator seat activates the driving interlock system.

This action causes the system to cut power and to electrically shift the transmission to NEUTRAL. The transmission will disengage but the direction lever will not physically move to the NEUTRAL position.

To reactivate the transmission, sit in the operator seat and place the direction lever to the NEUTRAL position and back to the direction of travel.

The parking brake does not synchronize with the driving interlock system and is not automatically applied when the interlock is activated. The lift truck will start to move in the direction of the downgrade if on a grade.

Even if the driving interlock system is activated, the lift truck may move in the direction of the downgrade when the lift truck is on a grade. In this case, apply the service brake and parking brake and sit securely in the operator seat.

2-35

KNOW YOUR LIFT TRUCK 

Driving Interlock System Functions Conditions

Key Switch

ON

Engine

ON

Safety Warning

Direction Lever

Not Seated

F/R

Driving inoperative

Driving Interlock Indicator Icon [BLINK]

Seated

F/R

Driving operative

Driving Interlock Indicator Icon [OFF]

Seated to Not Seated

F/R

For 3 seconds driving operative

After 3 seconds Driving Interlock Indicator Icon [BLINK]

Seated to Not Seated to Seated

F/R

Within 3 seconds driving operative

Within 3 seconds Driving Interlock Indicator Icon [OFF]

Not Seated to Seated

F/R

Driving inoperative

Driving Interlock Indicator Icon [BLINK]

Driving inoperative, F / R to N to F / R then operative after Neutral

Driving interlock indicator [BLINK] then [OFF] after Neutral

Not Seated to Seated 

Function

Operator Seat

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.

E00472A



Neutral System Functions Conditions Safety Function

Key Switch

Operator Seat

Direction Lever

OFF or ON

Seated or Not Seated

NEUTRAL

2-36

Engine starts only when the direction lever is in the NEUTRAL position.

KNOW YOUR LIFT TRUCK 

Seat Belt Warning Icon

The seat belt has a switch that activates a warning icon. The warning icon in the meter panel stays ON until the seat belt is buckled. The seat belt warning is one of the PDS functions installed on this lift truck.

1

E00473 1. Seat belt warning icon

R WARNING -

Before operating the lift truck, BE SURE that the seat belt warning icon is functioning.

This warning icon reminds the operator to fasten the seat belt. Maintain it so that it is always functional. 

Seat Belt Warning Functions Conditions

Key Switch

Engine

Operator Seat

Not Seated ON

ON or OFF Seated

Safety Warning Seat Belt

Seat Belt Warning Icon

Remedy

Not Buckled

ON

Fasten the seat belt or buckle the seat belt properly

Buckled

OFF

-

Not Buckled

ON

Fasten the seat belt or buckle the seat belt properly

Buckled

OFF

-

2-37

KNOW YOUR LIFT TRUCK 

Parking Brake Warning Alarm and Warning Icon R WARNING

-

Before operating the lift truck, BE SURE to check that the parking brake warning alarm and warning icon are functioning.

The alarm and warning icon remind the operator to apply the parking brake when leaving the lift truck. Maintain them so that they are always functional.

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.

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.

-

The parking brake is a double action type designed to be released while pressing the top button and pushing the lever FORWARD. Pull the parking brake lever until it locks into place. When leaving the lift truck, always apply the parking brake.

1

Note: The parking brake is not automatically applied.

2 E01000 1. Parking brake warning icon

2. Parking brake lever

PDS function Whether the engine is stopped or running, leaving or rising from the operator seat for 3 seconds or turning the key switch to the OFF position without applying the parking brake activates the parking brake warning alarm. Parking brake warning icon in the meter panel glows when the parking brake is applied. The parking brake warning alarm and warning icon are one of the PDS functions. 

Parking Brake Warning Functions Conditions

Key Switch

Engine

Operator Seat

OFF

OFF

Seated or Not Seated

Not Seated ON

ON or OFF

Seated Seated to Not Seated

2-38

Safety Warning Parking Brake

Parking Brake Warning Icon

Parking Brake Warning Alarm

Not Applied

OFF

ON

Applied

OFF

OFF

Not Applied

OFF

ON

Applied

ON

OFF

Not Applied

OFF

OFF

Applied

ON

OFF

Not Applied

OFF

After 3 seconds, Alarm will turn [ON]

KNOW YOUR LIFT TRUCK

 Operating Switches and Controls 

FC Control Box (Type-A)

The Mast Interlock System is one of the functions of the Presence Detection System installed on this lift truck. The lift truck senses when the operator is not properly seated in the operator seat and will prevent the mast from operating until the operator is properly seated. In the following cases, the mast interlock system disconnects power to the hydraulic control valve and the mast and attachment will not move even if the operating control switches are operated: (1) The operator leaves the operator seat for approximately 3 seconds with the key switch in the ON position regardless of whether the engine is running or not.

(2) When the engine is running but the emergency mast stop button is in the STOP (lock) position (being pushed down).

5

4 3 2 1

6

8 1.

2.

3.

4.

7

Attachment switch A Attachment switch B Mast vertical switch Selector switch between fourth and fifth attachment

E00039 5.

6.

7.

8.

Lowering speed selector switch Direction switch Lift switch Tilt switch

Note: The mast interlock will work for the lift, tilt, and attachment switches. If the engine is not running or the key switch is in the OFF position, the lift, tilt, and attachment switches will not move regardless of whether the operator presence switch position is ON or OFF. 

FC Control Box (Type-B)

Equipped with mast interlock system

3

The mast interlock will work for the lift, tilt, and attachment switches.

2

5

1

If the operator leaves the operator seat for 3 seconds while the key switch is in the ON position, regardless of whether the engine is running or not, the mast and attachment will not lift, lower, or tilt when the lift, tilt, or attachment switch is operated. This is not a failure, but the mast interlock system is being activated.

6 1.

2.

3.

4.



4

Lift switch Tilt switch Attachment switch A Attachment switch B

E00971 5. Adjuster button 6. FNR switch

Lift Switch

Lifting speed is controlled by the engine speed (depressed amount of the accelerator pedal) and the position of the lift switch.

Lowering speed is controlled only by the position of the lift switch regardless of the engine speed. The switch will return to the NEUTRAL position when released.

To deactivate the mast interlock system, the operator sits on the operator seat while the key switch is in the ON position with the engine running, and then operate the lift switch. 

Tilt Switch

Tilt speed is controlled by the engine speed (depressed amount of the accelerator pedal) and the position of the tilt switch. The switch will return to the NEUTRAL position when released.

To deactivate the mast interlock system, the operator sits on the operator seat while the key switch is in the ON position with the engine running, and then operate the tilt switch.

2-39

KNOW YOUR LIFT TRUCK 

Lowering Speed Selector Switch (Optional)

DO NOT touch the lift, tilt, or attachment lever when turning this switch ON or OFF.

1

SLOW This position allows you to lower the forks at 70% of the normal or rated speed. Use this switch until you feel sure of what is going to happen when you move the lift control, or when you handle fragile loads.

NORMAL

2

This position allows you to lower the forks at the normal speed.

1. NORMAL



E00037J 2. SLOW

Direction Switch (Optional)

1

2 E00038J 1. BACKWARD



2. FORWARD

Attachment Switch A/B (Optional)

To deactivate the mast interlock system, the operator sits on the operator seat while the key switch is in the ON position with engine running, and then operate the attachment switch.

Attachment switch A (optional) This switch is for operating the third attachment.

Attachment switch B (optional) This switch is for operating the fourth attachment. 

Selector Switch Between Fourth and Fifth Attachment (Optional)

For operation of the fifth attachment, operate the attachment switch B while pressing this switch.

2-40

KNOW YOUR LIFT TRUCK 

Other Controls (Standard)

Besides lift, tilt, and attachment levers, FC control box has the following standard controls: -

Emergency mast stop button Forward and backward adjustment stopper knob Up-and-down adjustment stopper knob

1

1) 2) 3

2 E00550

1. Emergency mast stop button.

2. Forward and backward adjustment stopper knob 3. Up-and-down adjustment stopper knob



1) Loosen 2) Tighten

Emergency Mast Stop Button

Use this button for the following situations.

-

When you have to stop the mast and attachment actions in an emergency without stopping the engine.

- When you get off the lift truck.

Note: FC model (Type B) is not equipped with the emergency mast stop button.

1 1. STOP (lock) position (The button will remain in this position when released.)

2

E00394

2. OPERATE (unlock) position

How to use -

-

To stop (lock) lift, tilt and attachment actions, push down on the button. The mast and attachments will not move even if the operating control levers are operated. At this time, diagnostic code "F75" is displayed on the meter panel. This does not indicate an abnormality. This diagnostic code is cleared by turning the key switch to the OFF position and then turning it to the ON position.

To operate (unlock these actions), turn the button clockwise.

The lights will go OUT when the emergency mast stop button is pushed down.

To turn ON the lights when the emergency mast stop button is being pushed down, turn the light switch to the H or Y position.

2-41

KNOW YOUR LIFT TRUCK 

Forward and Backward Adjustment Stopper Knob (FC Control Box Type-A) R CAUTION

DO NOT insert fingers under this box at the front or rear when adjusting the FC control box FORWARD or BACKWARD. (1) Loosen the knob to unlock with LEFT HAND. (2) In order to adjust the FC control box to an appropriate forward and backward position, push FORWARD with RIGHT HAND. (3) Tighten the knob to lock with LEFT HAND. (4) Make sure that the box is firmly secured.

E00444



Up and Down Adjustment Stopper Knob (FC Control Box Type-A) R CAUTION

DO NOT place fingers around the gas springs or insert fingers into the slot of the adjuster when adjusting the FC control box UP or DOWN. (1) Loosen the knob to unlock with LEFT HAND. (2) In order to adjust the FC control box to an appropriate height, push down with RIGHT HAND. The box is assisted with gas springs.

(3) Tighten the knob to lock with LEFT HAND. (4) Make sure that the box is firmly secured E00445

2-42

KNOW YOUR LIFT TRUCK 

Forward and Backward Adjustment (FC Control Box Type-B) R CAUTION

DO NOT insert fingers under this box at the front or rear when adjusting the FC control box FORWARD or BACKWARD.

1

Note: The length of the movement is 95 mm (3.74 in).

(1) Press the adjuster button to unlock the FC control box.

(2) Adjust the FC control box to an appropriate forward and backward position while pressing the adjuster button.

(3) Release the adjuster button to lock the FC control box.

(4) Make sure that the box is firmly secured.

E01154 1. Adjuster button



Up and Down Adjustment (FC Control Box Type-B) R CAUTION

DO NOT insert fingers under this box when adjusting the FC control box UP or DOWN. Note: The height of the movement is 75 mm (2.95 in).

(1) Hold the grip of the handle under the FC control box with RIGHT HAND. (2) Turn the grip clockwise (outward) to unlock the box.

(3) Adjust the FC control box to an appropriate height.

(4) Turn the grip counterclockwise (inward) to lock the box.

(5) Make sure that the box is firmly secured.

2) 1)

E01155

1) Turn the grip clockwise (outward) to unlock



2. Turn the grip counterclockwise (inward) to lock

LC Control Box

Equipped with mast interlock system The mast interlock will work for the lift, tilt, and attachment levers.

1

2

3

4

If the operator leaves the operator seat for 3 seconds while the key switch is in the ON position, regardless of whether the engine is running or not, the mast and attachment will not lift, lower, or tilt when the lift, tilt, or attachment lever is operated. This is not a failure, but the mast interlock system is being activated.

E00702 1. Lift lever 2. Tilt lever 3. Attachment lever A

4. Attachment lever B

2-43

KNOW YOUR LIFT TRUCK 

Lift Lever

Lift speed is controlled by the engine speed (depressed amount of the accelerator pedal) and the position of the lift lever. Lowering speed is controlled only by the position of the lift lever regardless of the engine speed. The lever will return to the NEUTRAL position when released.

2

To deactivate the mast interlock system, the operator sits on the operator seat while the key switch is in the ON position with the engine running, and then operate the lift lever.

1 104956 1. Raise



2. Lower

Tilt Lever

Tilt speed is controlled by the engine speed (depressed amount of the accelerator pedal) and the position of the tilt lever. The lever will return to the NEUTRAL position when released.

2

To deactivate the mast interlock system, the operator sits on the operator seat while the key switch is in the ON position with the engine running, and then operate the tilt lever.

1 104957 1. Backward



2. Forward

Attachment Lever A/B (Option)

To deactivate the mast interlock system, the operator sits on the operator seat while the key switch is in the ON position with engine running, and then operate the attachment lever.

Attachment lever A (Option) This lever is for operating the third attachment.

Attachment lever B (Option) This lever is for operating the fourth attachment.

2-44

KNOW YOUR LIFT TRUCK

 Operator Seat 

Seat Adjustment R WARNING

Adjust the operator seat before starting the engine. After adjusting, check the operator seat to make sure it is properly locked. DO NOT adjust the operator seat while the lift truck is in motion.

1 3

2

4

E00636 1. Seat belt 2. Reclining lever



3. Adjusting Knob 4. Slide lever

Forward and Back Adjustment

Move the slide lever to adjust the operator seat to one of the eleven positions, and release the lever.

1 E00679 1. Slide lever

R WARNING -

-

Your lift truck comes 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.

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.

2-45

KNOW YOUR LIFT TRUCK 

Reclining Angle Adjustment

Push the reclining lever and adjust the angle to the desired position, and release the lever.

1

E00681

1. Reclining lever



Adjustment of Suspension

Adjust the suspension before sitting in the seat. Turning the adjusting knob clockwise increases the gauge indication, and turning it counterclockwise decreases the gauge indication.

2

Weight adjustment range: 50 to 120 kg [110 to 265 lb]

3

1 1. Adjusting lever



E010 2. Heavy 3. Light

Pocket for the Operation & Maintenance Manual

Place the Operation & Maintenance Manual in this pocket.

Use both hands to open or close the pocket.

E00682



Operator Presence Switch and Buzzer

The operator seat has an operator presence switch. The mast cannot be moved unless the operator is seated in the operator seat.

1

Regardless of the running or stopping of the engine, the parking brake warning alarm activates and parking brake warning icon blinks if the operator leaves the seat without applying the parking brake.

When leaving the lift truck, always apply the parking brake and turn the key switch to the OFF position.

E00683 1. Operator presence switch

2-46

KNOW YOUR LIFT TRUCK

 Seat Belt 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.

Always fasten the seat belt when operating the lift truck.

-

Seat belts could "jack-knife" the operator (the upper body bends tightly at the waist).

If the seat belt is fastened across the operator abdomen during an accident, it could cause serious internal injuries.

R WARNING -

E01023

How to fasten the seat belt

1

(1) Hold the latch plate and pull the seat belt from the retractor.

(2) Insert the latch plate into the slot of the buckle until a snap is heard.

Note: Make sure the seat belt is not twisted.

2

3 E00684 1. Retractor 2. Latch plate

(3) Be sure to fasten the seat belt as low as possible across your hips, not across your abdomen.

Note: It is unnecessary to adjust the belt length. Tug on it to check for a tight fit.

3. Buckle

2) 1)

OK

OK

E00685 1. OK

2. Not OK

2-47

KNOW YOUR LIFT TRUCK How to release the seat belt (1) Push the button in the buckle to release the seat belt.

The seat belt will automatically retract when released.

(2) Hold the latch plate and allow the seat belt to slowly retract.

Ｅ00686

If the seat belt is torn, the pulling motion of the seat belt is interrupted during extension, or the seat belt cannot be inserted into the buckle properly, replace the seat belt assembly. The seat belt must be checked at regular service intervals.

Note: The following maintenance guidelines detail how to inspect seat belt for cuts, fraying, extreme or unusual wear of the webbing, etc., and damage to the buckle, retractor, hardware, or other factors, which indicate that belt replacement is necessary.

-

-

-

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, deformed, or buckle is damaged or casing broken.

Check the retractor web storage device operation to make sure that it locks properly and that it spools out and retracts webbing properly.

R WARNING When replacing seat belt components, replace them with genuine Cat lift truck parts.

2-48

E00454

KNOW YOUR LIFT TRUCK

 Fork Locking Pins For load stability, adjust the forks as wide as possible.

How to adjust fork spread (1) Raise the forks from the ground.

(2) Lift fork locking pins and slide fork to the new position.

(3) Secure the fork locking pins in the lift bracket slot.

Follow the same procedure for the other fork.

E01022

1

2 101984 1. Fork locking pins

2. Fork

R WARNING When adjusting the fork spread, be careful not to pinch your hand in the lift bracket slot.

R CAUTION -

After adjusting the fork spread, restore the fork locking pins or levers to the original position to lock the forks.

Position each fork the same distance from the center of the lift bracket.

2-49

KNOW YOUR LIFT TRUCK

 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.

1

101261 1. Drawbar pin

R WARNING DO NOT use the drawbar pin for towing loads.

R WARNING Precautions for the use of the drawbar pin -

-

2)

When attaching a cable to 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.

OK OK 1)

101262 1) OK

2) Not OK

 Assist Grips and Foot Step Grasp the assist grip with the left hand, the seat backrest with the right hand. Use the foot step to get on the lift truck safely.

E00988

R WARNING -

2-50

DO NOT hold the steering wheel or the operating control levers.

DO NOT jump on or off the lift truck.

KNOW YOUR LIFT TRUCK

 Engine Hood The engine hood swings up to fully expose the engine compartment for daily inspection, servicing, and lubrication.

-

1

Engine Oil Level Engine Coolant Level Fan Belt Alternator Drive Belt Brake fluid level E01001 1. Engine hood

R CAUTION When closing the engine hood, be careful not to pinch your hand. 

Hood Latch

To open (1) Pull the engine hood lever in the direction of the arrow.

(2) Raise the engine hood.

To close

1

(1) Push the engine hood down until it is locked.

E01010 1. Hood lever

 Hydraulic Tank Oil Filler Hole The oil filler hole is located on the right side of the lift truck.

To check the oil level, use the dip stick located in the hole.

The cap can be removed by turning it counterclockwise.

The sight gauge is also located on the right side of the lift truck.

E01002

2-51

KNOW YOUR LIFT TRUCK

 Fuel Filler The fuel filler is located on the left side of the lift truck. The cap can be removed by turning it counterclockwise.

100165

Air Tank The air tank is located near the right rear tire.

At the end of each shift or when operators change, pull the handle at the bottom of the brake air tank to allow water to drain.

101975

2-52

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 2. Combined CG

3. CG load

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.

The height of the lifted load.

The angle of forward or backward tilt.

-

Dynamic forces created when the lift truck accelerates, brakes, or turns.

Condition and grade of surfaces on which the lift truck is operated.

3-1

HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE These factors must be considered when the lift truck is unloaded as well. Because an empty lift truck will tipover more easily than a lift truck carrying a load in the lowered position.

CG load 1

2 3 F00089 1. CG Load 2. Combined CG

3. CG truck

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 stability base triangle drawn between the front wheels and the pivot of the rear axle.

1

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 1. Combined CG

F00090 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

HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE

 Capacity Plate 

Sample

The capacity plate shown above is for a 13.5 ton (30000 lb) model standard lift truck whose capacity is 13500 kg (30000 lb) at 600 mm (23.62 in.) load center.

The plate specifies this lift truck can lift up to 13.5 ton (30000 lb) if the load center is not more than 600 mm (23.62 in.) forward from the face of the lift bracket.

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.

MODEL

WARNING

ＩＭＰＲＯＰＥＲ ＯＰＥＲＡＴＩＯＮ ＯＲ ＭＡＩＮＴＥＮＡＮＣＥ ＣＯＵＬＤ ＲＥＳＵＬＴ ＩＮ ＩＮＪＵＲＹ ＯＲ ＤＥＡＴＨ

DP135NM1

ＳＥＲＩＡＬ Ｎｏ．

T15E-20011

ＡＵＴＨＯＲＩＺＥＤ ＢＹ ＴＨＥ ＭＡＮＵＦＡＣＴＵＲＥＲ． ＭＡＳＴ：ＶＥＲＴＩＣＡＬ

Ｂ A

B

ATCH/MODEL

A MM

3000 XXX XXX

B MM

600 XXX XXX

FORKS ONLY KG

XXX XXX XXX

ATTACH KG

13800 XXX XXX

SHIFTER / 5SS135A ＥＮＧＬＩＳＨ ９２Ｇ８１−０５５００

F00536

3-3

HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE

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.

-

Fasten the seat belt.

DO NOT jump off.

Brace your feet.

Firmly hold on to the steering wheel.

Lean away from impact.

Lean forward.

F00025

R DANGER DO NOT jump off your lift truck if it starts to tipover!

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.

F00081

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

HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE R WARNING DO check surface strengths!

Stay away from soft ground to avoid tipover.

F00085A

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.

F00079A

3-5

HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE R WARNING DO NOT elevate FORWARD titled loads!

This could also cause the lift truck to tipover.

F00080A

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 grades 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

HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE 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.

F00082A

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.

F00078A

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.

F00071

3-7

HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE 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 AVOID A TIPOVER / HOW TO SURVIVE ONE

 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.

F00087A

R DANGER 1

IF YOUR LIFT TRUCK STARTS TO TIPOVER: 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

2

4

5

F00158

3-9

REFUELING

 REFUELING Diesel Engine Equipped R WARNING -

BE SURE to use the fuels specified in the SERVICE DATA. If not, the engine could fail.

Lift trucks must be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors.

Turn the engine OFF and get off the lift truck during refueling.

-

Explosive fumes could be present during refueling.

DO NOT smoke in refueling areas.

R WARNING

R WARNING Fire caused by static electricity!

-

In dry seasons there is a lot of static electricity.

When refueling, touch grounded metals with bare hand to discharge the static electricity before opening the filler cap. If not, the fuel could catch fire due to the static electrical spark.

R CAUTION -

DO NOT allow the lift truck to become low on fuel or completely run out of fuel. Sediment or other impurities in the fuel tank could be drawn into the fuel system. This could result in difficult starting or damage to components.

Fill the fuel tank at the end of each day of operation to drive out moisture laden air and to prevent condensation.

DO NOT fill the tank to the top. Fuel expands when it gets warm and may overflow.

(1) Park the lift truck only at an authorized refueling area.

(2) Lower the forks until the forktips touch the floor or ground.

(3) Apply the parking brake.

(4) Place the direction lever in the NEUTRAL position.

(5) Turn the engine OFF. (6) Block the wheels.

(7) Open the filler cap.

(8) Fill the fuel tank slowly.

(9) Close and tighten the filler cap.

Note: If spillage occurs, wipe off excess fuel.

101540

Note: Drain water and sediment from the fuel tank as needed. Also, drain water and sediment from the main fuel storage tank before it is filled and as a weekly routine. This will help prevent water or sediment being pumped from the storage tank into the lift truck fuel tank.

How to display fuel consumption

1

Turn the key switch to the ON position.

Screen display selection is available while the engine is running. With a short press of the O button, the display changes in the order of hour meter, clock time, and fuel consumption.

L/H

E00961 1. Fuel consumption

4-1

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 the following 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 warning icons and indicator icons in the meter panel.

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 speed because 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.

Replace and lubricate parts at shorter intervals than normal periods.

Carefully check on and around the lift truck for loose bolts and nuts. Retighten them as needed.

 Before Starting Engine R WARNING -

BE SURE to read “SAFETY RULES FOR LIFT TRUCK OPERATORS” for your safety and the safety of fellow workers.

BE SURE to perform the DAILY (PRESTART) INSPECTION. Where lift trucks are used on a round-the-clock basis, they must be inspected before each shift of work and operators.

R WARNING If at any time a lift truck is found to be in need of repair, defective, or in any unsafe condition, 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 BE SURE to fasten the seat belt before operating the lift truck. Remember, the seat belt will not restrain you in an accident if it is not fastened properly.

E01023

R WARNING Before starting, always adjust the rear view mirror (if equipped) at a proper angle, as adjustment while driving could lead to accidents.

5-1

OPERATION R WARNING Before starting, always adjust the operator seat to a proper position so that you can depress the pedals fully down.

Adjusting the seat while driving may lead to accidents.

1

E01025

1. Slide lever

Always make sure that the following points are followed before starting the engine.

-

Parking brake lever is in the applied position.

J00092

-

Direction lever is in the NEUTRAL position.

- The engine will not start unless the direction lever is in the NEUTRAL position.

- If the engine stalls, place the direction lever in the NEUTRAL position and turn the key switch to the OFF position, and turn it to the START position to start the engine.

1 2 3 J00240 1. FORWARD (F) 2. NEUTRAL (N)

3. REVERSE (R)

Turn the emergency mast stop button (if equipped) clockwise to the OPERATE position (being released).

Note: -

-

You are unable to move the mast and attachments if the emergency mast stop button is in STOP (lock) position (being pushed down).

FC model (Type B) is not equipped with the emergency mast stop button.

1

J00524 1. Emergency mast stop button

5-2

OPERATION The starting mechanism in lift trucks with powershift transmission is disabled until an operator is seated.

When the key switch is in the ON position, the mast interlock indicator icon and driving interlock indicator icon in the meter panel blink unless an operator sits on the operator seat properly. In addition, the seat belt warning icon glows when the seat belt is not worn or when it is not inserted into the seat belt buckle properly.

N

J00525

 Starting Engine R CAUTION -

-

DO NOT leave the key in the ON position when the engine is NOT running. This may cause the battery to run down.

DO NOT crank the engine for more than 10 seconds at any one time. This may cause the battery to run down.

The parking brake warning buzzer will sometimes sound for a while just after the engine has been started, not because of a malfunction, but because vacuum is being created in the vacuum tank. Wait until the buzzer stops buzzing before moving the lift truck.

DO NOT turn ON the head light when the engine is starting. This may cause the battery capacity to run low.

(1) Turn the key switch to the ON position and wait until the glow plug icon goes out.

J00526

(2) Turn the key switch to the START position to crank the engine.

Note: DO NOT crank the engine for more than 10 seconds at a time.

│

J00153

(3) Release your hand when the engine starts.

J00149

5-3

OPERATION If the engine won't start Turn the key switch back to the OFF position and wait approximately 30 seconds before cranking again.

If the engine won't start, see 5-4 "Engine Won't Start".

J00150

 Engine Won't Start Contact 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 Check the fuel level gauge to see if there is enough fuel in the tank. If not, refuel it.

NO The battery is dead if the head lights won’t turn ON or dimly light.

R CAUTION Air in the fuel system may cause starting failure. In this case, have your authorized Cat lift truck dealer prime the fuel system or check the fuel system for possible problems.

5-4

OPERATION

 After Starting Engine R WARNING If the warning icon in the meter panel keeps turning 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.

Failure to warm up the engine 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 warm-up, check to see that systems are operating properly.

- Are all the warning icons in the meter panel OFF? - Does the engine coolant temperature gauge show the WHITE zone?

- Are exhaust noise and smoke color normal?

- No excessive vibration?

5-5

OPERATION

Before Moving Lift Truck R WARNING Do not move the lift truck until the air pressure warning buzzer stops sounding! Otherwise the service brake will not apply safely.

1)

J00120 1) STOP

R CAUTION Do not switch the speed selector switch during travel.

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.

Look around and behind the lift truck and sound the horn before moving.

D00302A

R CAUTION Before starting the engine, sit properly in the operator seat and make sure of the following: -

No one is around the lift truck.

The parking brake is in the applied position.

The direction lever is in the NEUTRAL position.

(1) Turn the speed selector switch to the desired position.

(2) Pull the lift lever to raise the forks to a safe traveling height of 15 to 20 cm (5.91 to 7.87 in.) from the floor.

(3) Pull the tilt lever to tilt the mast fully back.

2

1 J00193A 1. 15 to 20 cm (5.91 to 7.87 in.)

5-6

2. Tilt back

OPERATION

Lift Truck Operation R CAUTION DO NOT rest your left foot on the inching pedal during travel. This causes a partly disengaged condition that may result in premature clutch plate wear.

(1) Depress the inching pedal fully.

J00239

(2) Move the direction lever to FORWARD (F) or REVERSE (R) position.

1 2 3 E00436 1. FORWARD (F) 2. NEUTRAL (N)

3. REVERSE (R)

(3) Press the top button on the parking brake lever and push the parking brake lever FORWARD.

J00233

(4) Gradually depress the accelerator pedal while releasing the inching pedal.

J00241

5-7

OPERATION 

Changing Speed

Depress the accelerator pedal to increase travel speed.

Depress 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.

104850A

R WARNING BE SURE to watch for people or hazards in the direction of travel.

D00302A



Changing Direction R CAUTION

-

5-8

Directional changes without coming to a complete stop may cause premature damage to the driveline.

For a smooth ride and maximum service life of driveline components, bring the lift truck to a complete stop before changing direction.

OPERATION R CAUTION BE SURE to come to a complete stop before changing direction.

104848A



Operating Techniques

Hold the steering wheel with LEFT HAND.

J00244



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.

2

1 1. Other vehicles

J00171

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

5-9

OPERATION R WARNING Turning at high speeds, with or without a load, can also cause a tipover.

J00101



Inching

The purpose of the inching pedal is to provide precise lift truck inching control at very slow travel speed and high engine revolutions. The operator can move the lift truck slowly by depressing the inching pedal to lower the traveling speed while maintaining engine speed. Use the inching pedal when approaching loads for loading and unloading.

J00197

R CAUTION DO NOT rest your foot on the inching pedal during travel. This causes a partly disengaged condition that may result in premature clutch plate wear. DO NOT press inching pedal when inching is unnecessary.

(1) Stop the lift truck ahead of the load platform.

(2) Place the mast vertical, 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 lever.

(4) Gently depress the accelerator pedal.

J00245

(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.

J00251

5-10

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 service brake several times while driving slowly in a safe area until brake linings have dried out and normal braking action is restored.

Prolonged use of the service brake will reduce the amount of air in the air tank, causing the warning buzzer to sound. Once the warning buzzer sounds, immediately stop the lift truck, and wait until it stops sounding before moving the lift truck.

(1) Release the accelerator pedal.

J00246

(2) Depress the brake pedal to make a complete stop.

J00247

(3) Pull the parking brake lever all the way back.

J00092

(4) Place the direction lever to the NEUTRAL (N) position.

1 2 3 J00240 1. FORWARD (F) 2. NEUTRAL (N)

3. REVERSE (R)

5-11

OPERATION R WARNING Avoid sudden stops. This could cause the load to fall off the forks or the lift truck to tip over.

J00040A

Parking Lift Truck (After Stopping) R WARNING Park safely -

Select a hard level surface.

BE SURE to park in the designated parking area.

(1) Slightly, tilt the mast FORWARD and lower the forks to the floor or ground until the forktips touch the floor or ground.

J00094A

(2) Turn the key switch to the OFF position to turn the engine OFF. When leaving the lift truck, be sure to remove the key from the key switch.

(3) Push down on the emergency mast stop button (if equipped) to stop the movement of the mast and attachments.

(4) Block the wheels securely.

(5) Return the key to a key rack if required by supervisor.

│

104961

5-12

OPERATION (6) At the end of each shift or when operators change, pull the handle at the bottom of the brake air tank to allow water to drain.

101975

R WARNING Get off safely -

Get off after the lift truck has come to a complete stop and the parking the lift truck procedure has been followed.

DO NOT jump off.

5-13

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

OPERATING TECHNIQUES

 Handling Loads Safely R WARNING Handle ONLY stable loads to prevent 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 to collapse.

K00148

R WARNING -

Handle ONLY loads within the capacity of the lift truck as shown on the capacity plate.

DO NOT place loads at the end of the forks even if they are within the capacity.

DO NOT pick up loads that exceed the capacity.

Otherwise, it can create very dangerous situation, disabling the operation of steering wheel as the rear wheels are lifted off the ground.

WARNING MODEL

ＩＭＰＲＯＰＥＲ ＯＰＥＲＡＴＩＯＮ ＯＲ ＭＡＩＮＴＥＮＡＮＣＥ ＣＯＵＬＤ ＲＥＳＵＬＴ ＩＮ ＩＮＪＵＲＹ ＯＲ ＤＥＡＴＨ

ＳＥＲＩＡＬ Ｎｏ．

ＡＵＴＨＯＲＩＺＥＤ ＢＹ ＴＨＥ ＭＡＮＵＦＡＣＴＵＲＥＲ． ＭＡＳＴ：ＶＥＲＴＩＣＡＬ

Ｂ A

A MM

B MM

FORKS ONLY KG

ATTACH KG

B

ATCH/MODEL ＥＮＧＬＩＳＨ ９２Ｇ８１−０５５００

F00532

6-2

OPERATING TECHNIQUES 

Adjusting Fork Spread

For load stability, adjust the forks as wide as possible.

How to adjust fork spread (1) Raise the forks from the ground.

(2) Lift fork locking pins and slide fork to the new position.

(3) Secure the fork locking pins in the lift bracket slot.

Follow the same procedure for the other fork.

E01022

1

2 101984 1. Fork locking pins

2. Fork

R WARNING When adjusting the fork spread, be careful not to pinch your hand in the lift bracket slot.

R CAUTION -

After adjusting the fork spread, restore the fork locking pins or levers to the original position to lock the forks.

Position each fork the same distance from the center of the lift bracket.

R WARNING Spread the forks out depending on type of load or pallet for even distribution. Set the forks wide apart, so that the load becomes balanced while on the forks. In general, it is best around 60% of the width of the pallet.

K00107

6-3

OPERATING TECHNIQUES Not every load can be handled using only the forks. Some loads will require a special attachment.

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 icon is OUT. Note: -

Be sure to operate the operational control levers with your RIGHT HAND. See 6-7 "Lifting the Load", 6-9 "Traveling With the Load", and 6-10 "Unloading".

If the mast interlock indicator icon blinks, see 6-5 "Blinking of the Mast Interlock Indicator Icon".

Operating steps (1) Sit on the operator seat in the normal operating position and buckle the seat belt securely.

2) OK

1) OK

E01030 1) OK

2) Not OK

(2) Turn the emergency mast stop button (if equipped) clockwise to the OPERATE position (pulled-up position).

Note: FC model (Type B) is not equipped with the emergency mast stop button.

K00527

6-4

OPERATING TECHNIQUES (3) Turn the key switch to the START position. │

J00153

(4) Make sure the mast interlock indicator icon is OUT.

K00103

Blinking of the Mast Interlock Indicator Icon In the following examples, the mast interlock indicator icon blinks and the mast and attachments would not move even though the operating control levers are in the OPERATING position. This is not a fault but an indication that the mast interlock system functions. In this case, follow each instruction of each "Remedy".

K00011

Example 1 The mast interlock indicator icon will blink when the key switch is in the ON position and you are not properly sitting in the operator seat.

K00150

6-5

OPERATING TECHNIQUES Remedy (1) (2) (3) (4)

Sit properly in the operator seat.

This causes the mast interlock indicator icon to go OUT. Place the lift or tilt lever in the NEUTRAL position.

Place the lift or tilt lever in the OPERATING position.

K00151

Note: The mast interlock indicator icon will blink when you sit in the operator seat 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 blink when you turn the key switch to the ON position or start the engine while the lift or tilt lever is placed to the OPERATING position.

K00014

Remedy (1) Place the lift or tilt lever to the NEUTRAL position and turn the key switch to the OFF position once.

(2) Push down on the emergency mast stop button (if equipped) once, then return it to the OPERATE position.

(3) Make sure the mast interlock indicator icon is OUT. (4) Turn the key switch to the START position.

Note: FC model (Type B) is not equipped with the emergency mast stop button.

K00015

Example 3 The mast interlock indicator icon will blink when you return the emergency mast stop button (if equipped) to the OPERATE position while the lift or tilt lever (switch) is placed to the OPERATING position.

Note: FC model (Type B) is not equipped with the emergency mast stop button.

K00528

6-6

OPERATING TECHNIQUES Remedy (1) Place the lift or tilt lever to the NEUTRAL position.

(2) Push down on the emergency mast stop button (if equipped) once, then return it to the OPERATE position.

(3) Make sure the mast interlock indicator icon is OUT. (4) Start operation.

K00529

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.

1

K00120 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.

K00122

6-7

OPERATING TECHNIQUES 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.

K00124

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

(6) Carefully lift the load about 10 cm (4 in.) off the stack.

Slowly return the lift lever to the NEUTRAL position.

1 K00126 1. 10 cm (4 in.)

6-8

OPERATING TECHNIQUES R WARNING DO NOT mistake the direction and operating control levers!

If you operate the wrong lever, collision of the lift truck with persons or objects could occur, or you could drop the load.

K00526

Traveling With the Load (1) Look behind you.

(2) Place the direction lever in the REVERSE position.

K00222

(3) Slowly move the lift truck 20 to 30 cm (8 to 12 in.) away from the stack, and then stop the lift truck.

(4) Lower the forks to a position 15 to 20 cm (6 to 8 in.) from the ground.

1

2 K00223 1. 20 to 30 cm (8 to 12 in.)

2. 15 to 20 cm (6 to 8 in.)

(5) 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 the condition of the lift chains.

If they go slack, stop lowering. Then raise the load and lower it again.

K00159

6-9

OPERATING TECHNIQUES R WARNING DO NOT pick up an off-center load. Make sure the weight of the load is centered between the forks.

K00129

(6) Look around to make sure your work area is clear.

(7) Sound the horn.

(8) Move the lift truck into the work area.

K00132

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.

K00133

Unloading (1) Stop the lift truck 20 to 30 cm (8 to 12 in.) short of the unloading area.

1

K00134 1. 20 to 30 cm (8 to 12 in.)

6-10

OPERATING TECHNIQUES (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.

1

K00218 1. 10 to 15 cm (4 to 6 in.)

(4) Slowly move the lift truck FORWARD to position the load just over the stack.

K00219

(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.

K00138

(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.

K00128

6-11

OPERATING TECHNIQUES (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.

K00141

(12) 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.

K00142

R WARNING Be careful not to drag the forks.

K00140

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

OPERATING TECHNIQUES

 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.

Tilt the mast fully back when the lift truck is loaded.

-

2

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 an 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.

K00146



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.

K00147

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.

6-13

OPERATING TECHNIQUES

 Starting on a Grade (Engine Stalls on a Grade) (1) (2) (3) (4) (5) (6) (7)

Apply the parking brake.

Depress the brake pedal.

Place the direction lever in the NEUTRAL position.

Turn the key switch to the START position.

Place the direction lever in the direction of travel.

Raise the forks or load to the normal travel position.

Quickly shift your right foot from the brake pedal to the accelerator pedal.

(8) Release the parking brake while gradually pressing the accelerator pedal.

K00145

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) (2) (3) (4)

Park the lift truck in an authorized area.

Block the wheels securely.

Check under the lift truck for oil or coolant leaks.

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 lever 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 the 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 controllers and their related sensors to rainwater. DO NOT sprinkle water over the controllers and their related sensors 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 There is no need to drain fuel from the tank.

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 Drain the fuel from the tank and run the engine until the fuel in the lines is used up.

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. To prevent rusting of the cylinder interior and rods, and deterioration of the seals, periodically operate each cylinder for lift, tilt, and the attachment to full stroke.

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, drive until the engine warms up once a week. When using anti-rust engine oil to the engine, crank the engine several times with the starter to spread the oil uniformly on the cylinder walls.

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 splash water or steam over the controller when washing the lift truck.

-

7-2

VCM Other controllers (Input unit, Output unit, etc.)

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 lift 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 OFF position and remove the key.

Block the wheels and secure the lift truck with tiedowns.

Do not turn the steering wheel after the lift truck has been secured. It may loosen the tie-downs.

M00002

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 Cat Lift Trucks.

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 

Fuel Oils and Lubrication Oils R CAUTION

Use diesel fuel to fit the ambient temperatures. The cetane number should be 40 minimum. If you operate the lift truck where ambient temperatures are normally low, you may need fuel with a high cetane number.

N00001

R CAUTION -

Cloud point must be 6°C (11°F) below the lowest ambient temperature.

Use engine oil and gear oil to fit the ambient temperature. 

-

Battery Contact your battery manufacturer for the specific gravity of your battery.

When you park your lift truck overnight, leaving it outside in the elements, remove the battery and keep it warm.

3

4

2 1 N00013 1. Glass tube 2. Electrolyte

3. Float 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.

9-1

SPECIAL SITUATIONS 

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, contact your authorized Cat lift truck dealer.

N00018

Care in Hot Weather 

Fuel Oils and 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, contact 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 radiator. 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 engine coolant temperature gauge shows the RED zone, the engine may be overheated.

Note: If the engine coolant temperature gauge shows the RED zone, see 10-12 "If the Engine Coolant Temperature Gauge Shows RED Zone".

9-2

SPECIAL SITUATIONS

Severe Dust or Lint Conditions Check and replace 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 intervals

Every 50 service hours or monthly

Standard replacement intervals

Every 1000 service hours or 6 months



Engine Oil and Engine Oil Filter

For reference Standard replacement intervals



One month (30 days) or 200 service hours after delivery of a new lift truck.

Every 500 service hours or 3 months

Hydraulic Oil

For reference Standard replacement intervals



Every 2000 service hours or 12 months

Hydraulic Tank Return Filter

For reference Standard replacement intervals -

-

One month (30 days) or 200 service hours after delivery of a new lift truck.

Every 1000 service hours or 6 months

For the use in severe dust conditions, a dust-proof type is available. Contact your authorized Cat lift truck dealer in case of necessity.

Check the radiator core more frequently for clogging or trash build-up. Clean or wash the lift truck as needed.

N00017

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 restart the engine.

P00116

 If a Tire Blows Out 

If a Tire Blows out During Travel or Operation R CAUTION

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

Remedy (1) Stay calm and firmly hold on to the steering wheel.

(2) Gently release the accelerator pedal to slow down.

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

(4) Replace the punctured tire with a new one.

Note: Contact your authorized Cat lift truck dealer when requesting to replace tires.

 Replacing Tires R WARNING -

When replacing tires, change them in sets, even if only one of the tires is damaged. If both new and used tires are used on the same axle, tilting of the mast, and rapid tire wear will result.

Make sure the replacement tire is of the same size, type, and load range as indicated on the manufacturer name plate.

Use only tires recommended by the manufacturer. See manufacturer name plate for correct tire size.

Contact your authorized Cat lift truck dealer for proper tire changing procedure.

Replacing a tire and adjustment procedures must be made by a trained mechanic.

Perform all maintenance with proper equipment.

R WARNING DO NOT attempt to change the tire with the lift truck loaded. Injury and/or damage could result.

P00123

10-1

TROUBLESHOOTING R WARNING MAKE SURE no one is on the lift truck when raising the front or rear tires.

P00066

R WARNING Stop raising the lift truck when the tire clears the ground.

DO NOT raise the lift truck more than necessary.

P00124

R WARNING DO NOT place any part of your body under the lift truck until the lift truck is securely supported with jack stands after jacking it up.

P00068

10-2

TROUBLESHOOTING

Before Replacing Tires (1) (2) (3) (4) (5)

Park the lift truck on hard and level surface.

Lower the forks until the fork tips touch the ground.

Apply the parking brake.

Place the direction lever in the NEUTRAL position.

Turn the key switch to the OFF position.

P00121

(6) Prepare tools, jack, and wheel blocks.

(7) Block the wheel diagonally opposite to a raised wheel.

P00069

Jack capacities Front wheel

Have available two jacks, each having a capacity of 8 tons (17637 lb.).

Rear wheel

Have available two jacks, each having a capacity of 5 tons (11023 lb.).



To raise front wheel

(1) Loosen each outer wheel nut about two turns.

(2) Block the rear wheels.

(3) Raise the front wheels off the ground by either method below: - Method using a jack Position the jack under the frame near the mounting portions of right and left front axle, and jack up the right and left evenly.

- Method using a crane Hitch a hoist to the mast, and lift the mast to raise the front end of the lift truck.

500312

R WARNING -

DO NOT put any portion of your body under the lift truck being raised.

After raising the lift truck, place the stands under the right and left frame members to support the lift truck.

10-3

TROUBLESHOOTING 

To Remove Front Wheel

(1) Remove the inner tire extension bracket.

3

2

4

5

6

1

7

8 1.

2.

3.

4.

Inner wheel Spacer Outer wheel Wedge band

5.

6.

7.

8.

101545

Extension valve Extension bracket Wheel nut Clamp

R WARNING When removing the outer wheel nuts, hold each nut properly to prevent the wrench from slipping off the nut.

(2) Loosen the outer wheel nuts about two rotations.

Note: Only loosen the wheel nuts. DO NOT remove them.

(3) Raise the lift truck until the tire just clears the ground.

(4) Next, place the jack stands on both sides under the frame to support it.

104999

R CAUTION Be careful NOT to strip the threads of inner wheel studs with the edges of wheel disk holes.

(5) Remove the wheel nuts and clamps.

1

2

101552 1. Clamp

10-4

2. Wheel nut

TROUBLESHOOTING (6) Remove the wedge band with a hammer and drift as shown.

1

2

1. Wedge band

200599 2. Drift

(7) Hold the wheel with hoist or a lift truck and remove it.

104951

Truckmodel Item

Weight of wheel (standard tire)

DP100NM1 DP100NM1S

DP120NM1 DP120NM1S

85 kg (187 lb.) per wheel

90 kg (198 lb.) per wheel

DP135NM1 DP135NM1S

DP150NM1 DP150NM1S

120 kg (265 lb.) per wheel

(8) Hold the wheel with hoist or a lift truck.

(9) Remove the spacer.

(10) Remove the extension valve to prevent damage to it during wheel removal.

(11) Remove the inner wheel.

500315

10-5

TROUBLESHOOTING 

To Install Front Wheel

(1) Use the reverse of removal procedure.

(2) Tighten the wheel nut in the sequence shown, in two or three steps, to the specified torque.

1

4

6

7

9

2 3

Tightening torque for wheel nuts

8

5

539.4±53.9 N·m (55±5.5 kgf·m) [397.54±39.75 lbf·ft]

R CAUTION Use the same size and brand tire.

Make sure the clamping surfaces of the wheel nuts and counterbores are free of dirt.

Note: Even when replacing an outer wheel tire, make sure the inner wheel nuts are tightened properly.

10-6

10 101546

TROUBLESHOOTING 

To Remove Rear Wheel

(1) Loosen the wheel nuts about two rotations.

Only loosen the wheel nuts. DO NOT remove them.

1

2 3 101547 1. Rear wheel 2. Clamp

3. Wheel nut

(2) Position the jack at the specified jacking point.

(3) Raise the lift truck by operating the jack until the tire clears the ground.

(4) Support the lift truck with rigid racks.

(5) Remove the wheel nuts and clamps.

101996

(6) Hold the rear wheel with a hoist or a lift truck and remove it.

105000

R CAUTION Be careful NOT to strip the bolt threads by the edges of rim holes.

10-7

TROUBLESHOOTING 

To Install Rear Wheel

(1) Use the reverse of removal procedure.

(2) Tighten the wheel nuts in the sequence shown, in two or three steps, to the specified torque.

8

1

5 3

4 6 2

Tightening torque for wheel nuts

7 101554

539.4±53.9 N·m (55.0±5.50 kgf·m) [397.54±39.75 lbf·ft]

R CAUTION -

Use the same size and brand tire.

Make sure the clamping surfaces of the wheel nuts and counterbores are free of dirt.

DO NOT over tighten the wheel nuts.

Over tightening will strain the bolts.

A torque wrench is recommended for tightening the wheel nuts. If a torque wrench is not available, tighten the nuts with a socket wrench for wheel nuts by resting your weight on the handle of the wrench. 

To Add Air to Tires R WARNING

-

The lift truck uses high pressure tires. DO NOT overinflate the tire.

When adding air, check the rim for damage that could permit air to leak from the tire.

The use of an inflation cage, or some other safety device, helps reduce the risk of serious injury.

When adding air to the tire, or when checking tire pressure, BE SURE to keep your body away from the side.

P00077A

R WARNING -

-

When adding air to the tire using an air compressor, make sure the compressor valve is correctly set. Failure to follow this precaution could damage the tire.

Always maintain correct tire pressure.

P00078A

10-8

TROUBLESHOOTING

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

R WARNING -

Batteries give off flammable gas which could explode.

Keep flames and sparks away from batteries. They could cause gas to explode.

DO NOT smoke when checking battery electrolyte levels.

Improper jump start procedures could cause an explosion that could result in injuries. Turn OFF all lights and accessories on the stalled truck.

Always connect battery positive (+) to battery positive (+) and battery negative (-) to engine body. Jump only with a battery source of the same voltage as the stalled truck.

DO NOT allow jumper cable ends to contact each other or the lift truck.

Electrolyte is an acid and could cause injury if it contacts skin or eyes. Always wear eye protection when starting an engine in the lift truck with jumper cables.

BE SURE to connect the cable end 4 to the ENGINE BODY. If it is connected to the negative (-) terminal of the battery, sparks could ignite the gases.

R CAUTION -

Connect the jumper cables away from the moving parts in the engine compartment.

When carrying batteries, provide short circuit prevention to the terminals. If metals come in contact with the terminals, a short circuit could result.

- DO NOT touch the cable with wet hands. If touched, it may result in an electrical shock.

Note:

3)

1)

2) +

–

–

+

–

-

Use 24 volt jumper cables to jump start the lift truck. This lift truck has a 24 volt starting system. Use only equal voltage for jump starting. Use of a welder or higher voltage will damage the electrical system.

You can buy jumper cables from your authorized Cat lift truck dealer.

Turn OFF the battery switch before the boost connection to prevent damage to electrical components on the stalled lift truck. Many "dead" batteries can be recharged.

1)

+ –

-

+

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

10-9

–

–

+

–

+

r

e + –

(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 (-) terminals.

(3) After connecting the cables, increase the speed of the second lift truck's engine and then start the engine of the stalled lift truck that has the "run-down" battery.

(4) After the engine starts, disconnect the jumper cables in the reverse sequence.

w

+

q

E00688

TROUBLESHOOTING

 If Lights Won't Glow R CAUTION -

Always replace fuses with fuses of the correct amperage.

If a fuse burns out immediately after being replaced and you cannot locate the cause, have your authorized Cat lift truck dealer make a circuit check.

Always use a fuse of the same wattage.

-

Code

Capacity

Circuit

Capacity

Circuit

F10

20A

Air dryer

F11

10A

Spare power supply, Thermoswitch

F12

15A

Backup light, Back buzzer, Low air pressure buzzer, Brake warning light, Revolving Light, Lining wear buzzer

F13

10A

DC-DC converter 1&2, Alternator, Register, Engine stop timer

Heater

F14

10A

Spare

20A

Starter

F15

15A

Spare

15A

Spare power supply

F16

20A

Spare

F17

30A

Spare

F1

15A

Head light, Parking light, Tail light, Turn signal light

F2

10A

Horn, Glow timer

F3

10A

Stop light

F4

15A

DC-DC converter 1

F5

15A

Working light

F6

30A

DC-DC converter 2

F7

30A

F8 F9 

Code

How to Check Fuses and Lights

(1) Remove the fuse cover.

1 P00208

1.

Fuse box

(2) Use the puller.

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

1

E00458 1. Puller

10-11

TROUBLESHOOTING (3) Check to see if fuse is blown.

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

E00459

(5) Lights may be defective.

Light Type

Capacity

Head light

24V-60W

Working light (Option)

24V-60W

Front

Rear

Turn signal light

24V-25W

Clearance light

24V-5W

Tail / Stop light

24V-21W / 5W

Backup light

24V-21W

Turn signal light

24V-21W

(6) Install the fuse cover.

If the Engine Coolant Temperature Gauge Shows RED Zone R WARNING -

-

DO NOT add cold water to an overheated engine. This could cause engine damage. Wait for the engine to cool, if possible. If not, slowly pour water into the radiator.

Immediately turn the engine OFF if the fan belt is broken.

1

P00199 1. Overheat

R CAUTION If any of the following liquids are spilled on the floor, clean them up immediately. If not cleaned up, it could result in slipping, skidding, or environmental pollution: -

Oil or grease Coolant Diesel fuel Brake fluid Electrolyte

10-12

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

(2) Raise the engine hood to ventilate the engine compartment.

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

N00019

(5) -

Check the following: Lack of coolant Loose or broken fan belt Engine oil level Dirt buildup in radiator air passages

If Torque Converter Oil Temperature Warning Icon Glows (Powershift Model) (1) (2) (3) (4) (5)

Stop the lift truck in a non-traffic area.

Apply the parking brake.

Place the direction lever in NEUTRAL position.

Run the engine at low idle for a while.

After the warning icon has gone OUT, operate the lift truck again.

P00193

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

10-13

TROUBLESHOOTING

If the Lift Truck Won’t Change Direction If the operator half rises from the operator seat for more than approximately 3 seconds with the direction lever being placed in the FORWARD or REVERSE position, an operator presence switch in the operator seat activates the driving interlock system.

Check the following points if the lift truck will not move even after the direction lever is shifted to the FORWARD or REVERSE position: The driving interlock indicator icon starts blinking and the lift truck stops moving.

Are you seated?

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

NO Place the direction lever to the NEUTRAL position and sit securely, with the seat belt fastened.

P00201

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

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

P00200

If the Mast Stops Moving If the operator half rises from the operator seat for more than 3 seconds without the lift or tilt lever being placed in the NEUTRAL position, an operator presence switch in the operator seat activates the mast interlock system.

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

Remedy (1) Sit properly on the operator seat.

(2) Return the lift or tilt lever to the NEUTRAL position.

(3) Operate the lift or tilt lever.

Note: If the mast interlock system remains in a locked condition after taking the above Steps, contact your authorized Cat lift truck dealer immediately.

P00028

10-14

TROUBLESHOOTING

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

R WARNING -

-

If you see the mast or attachment malfunctioning, push down on the emergency mast stop button (if equipped). Contact your authorized Cat lift truck dealer immediately.

DO NOT attempt to return the emergency mast stop button to the OPERATE position for operating the lift truck before an authorized technician arrives on the scene.

P00204

P00202

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

(1) (2) (3) (4) (5)

Move the lift truck to a safe area.

Return the direction lever to the NEUTRAL position.

Apply the parking brake.

Turn the key switch to the OFF position.

Attach a "DO NOT OPERATE" or similar warning tag to the mast or fork of the lift truck in order to let other people know your lift truck down.

(6) Contact your authorized Cat lift truck dealer immediately.

10-15

TROUBLESHOOTING

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

Code

Description

Code

Description

F01

VCM Memory Check Warning

F54

Lift Solenoid Leak

F02

VCM Battery Voltage Warning

F55

Tilt Forward Solenoid Warning

F03

VCM Communication Warning

F57

Tilt Backward Solenoid Warning

F07

MP Communication Warning

F59

Tilt Solenoid Leak

F10

Lift Lever Neutral Warning

F60

Attachment 1A Solenoid Warning

F11

Tilt Lever Neutral Warning

F62

Attachment 1B Solenoid Warning

F12

Attachment 1 Lever Neutral Warning

F64

Attachment 1 Solenoid Leak

F13

Attachment 2 Lever Neutral Warning

F65

Attachment 2A Solenoid Warning

F14

Attachment 3 Lever Neutral Warning

F67

Attachment 2B Solenoid Warning

F16

Shift Lever Warning

F69

Attachment 2 Solenoid Warning

F17

Vehicle Speed Warning

F70

Attachment 3A Solenoid Warning

F20

Lift Lever Warning

F72

Attachment 3B Solenoid Warning

F22

Tilt Lever Warning

F73

Hour meter gap

F24

Attachment 1 Lever Warning

F74

Attachment 3 Solenoid Leak

F26

Attachment 2 Lever Warning

F75

Unload Solenoid Warning

F28

Attachment 3 Lever Warning

F79

Unload Solenoid Leak

F29

Joystick Lever Warning

F85

Transmission Forward Solenoid Warning

F31

VCM Sensor Voltage Warning

F87

Transmission Backward Solenoid Warning

F34

Vehicle Speed Sensor Warning

F89

Transmission Solenoid Leak

F41

Output Unit Warning

F93

Speed Change Solenoid 1 Warning

F44

Output Unit PWM Voltage Warning

F96

EAT Setting Warning

F45

Output Unit Communication Warning

F46

Input Unit Warning

P03

VCM Communication Warning

F49

Input Unit Communication Warning

P07

MP Communication Warning

F50

Lift Up Solenoid Warning

F52

Lift Down Solenoid Warning

10-16

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, contact your authorized Cat lift truck dealer. The technicians of Cat lift truck dealers are well trained and know how to safely make repairs.

R WARNING Follow these rules to help save you from injury and to service your lift truck properly.

-

Make sure the service area is safe.

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.

All repairs must be made by authorized personnel.

Use only the correct tools for the job.

R WARNING -

DO NOT bypass any electrical switches on this lift truck.

When leaving the engine running without being in the operator seat, for instance, to check or repair the lift truck, BE SURE to use the DIAGNOZER* service tool.

- When you repair the lift truck with the DIAGNOZER service tool, always contact your Cat lift truck dealer in advance. *DIAGNOZER is a service tool that is connected to the lift truck’s VCM. It is used to check the status of the controls for the entire 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 when performing an operational inspection.

If operated at higher speeds during an operational inspection, it could cause an accident if the lift truck is faulty.

Dress properly for the job. DO NOT wear loose clothing or accessories such as flapping cuffs, dangling chains, neckties, scarves, or rings that could catch in moving parts.

Wear personal protective equipment appropriate for the condition of your work places.

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 fuel, oil lines, tubes, or hoses.

DO NOT use your bare hands to check for leaks, use a board or cardboard.

Tighten connections to the recommended 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.

11-1

MAINTENANCE

 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.

1) 2)

Q00374 1) DANGER

2) DO NOT OPERATE

R WARNING If it is necessary to make an inspection while the engine is running, ALWAYS USE TWO WORKERS: 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:

-

Park the lift truck on level ground.

Lower the forks until the forktips touch the floor.

Apply the parking brake.

Place the direction lever in the NEUTRAL position.

Turn the engine OFF. Engine stopped Block the wheels.

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 use the same brand at successive service intervals.

Before refilling, clean filler holes. After filling, clean up spills.

R CAUTION Contact your authorized Cat lift truck dealer for the proper disposal of waste accumulated after replacement of tires, batteries, oils, and fluids.

11-2

MAINTENANCE

 Maintenance Schedule The operators are responsible for the performance of daily prestart inspection. The operators are also responsible for those items listed under Every 50 Service Hours or Weekly, Whichever Comes First to keep your lift truck in proper working condition.

For periodic inspection and periodic replacement of rubber parts, however, rely on the expert knowledge of the well-trained mechanics, and the service facilities at your Cat lift truck dealer’s workshop.

-

Periodic inspection time intervals

Every 10 Service Hours or Daily (Prestart), Whichever Comes First Every 50 Service Hours or Weekly, Whichever Comes First One Month (30 days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever Comes First Every 500 Service Hours or 3 Months, Whichever Comes First Every 1000 Service Hours or 6 Months, Whichever Comes First Every 2000 Service Hours or 12 Months, Whichever Comes First Every 1 to 2 years Every 2 years 2 to 4 years



Every 10 Service Hours or Daily (Prestart), Whichever Comes First Item

General

Brake System

Cooling System

Electrical System

Service

Page

Faulty Operation Found the Day Before

Check

11-8

Oil, Fuel, or Coolant Leaks

Check

11-8

Brake Pedal

Check

11-8

Parking Brake Lever

Check

11-9

Service Brake

Check fluid level

11-9

Air Tank

Drain water

11-10

Pipes and Joints

Check

-

Air Master

Check

-

Brake Control Valve

Check

-

Engine Coolant

Check coolant level

Fan Belt

Check / Adjust

Lights

Check

11-11

Horn

Check

11-12

Icons of Meter Panel

Check

11-12

Backup Alarm

Check

11-12

Backup Light

Check

11-12

Stop Light

Check

11-13

Battery

Check electrolyte level

11-13

Mast Interlock System

Check

11-14

Driving Interlock System

Check

11-15

Parking Brake Warning Alarm and Warning Icon

Check

11-16

Seat Belt Warning Icon and Alarm

Check

11-16

Battery Terminals (Looseness and Damage)

Check

-

Electrical wiring

Check

-

11-10 -

11-3

MAINTENANCE Item

Engine

Fuel System

Frame and Chassis

Hydraulic System

Mast and Forks

Front Axle, Rear Axle, and Steering System

Driving System



Page

Engine (Exhaust, Noise, and Vibration)

Check

11-17

Engine Oil

Check oil level

11-18

Leakage (incl. hose damage and deterioration)

Check Check level

Fuel

Check leakage

11-19 -

Overhead Guard

Check

11-19

Assist Grips

Check

11-20

Seat Belt

Check

11-20

Seat Adjustment

Check

11-20

Rear View Mirrors

Check

-

Hydraulic Oil

Check oil level

Loading Devices and Hydraulic System

Check

-

Tilt Cylinder Socket Nuts

Check

11-22

Lift Chains

Check damage and deformation/ Adjust

11-22

Mast and Forks

Check

11-24

Lift Cylinder

Check

-

Lift Cylinder Mounting Bolts

Check

-

Lift Bracket

Check

-

Wheel Nuts

Check / Tighten

11-26

Tires and Rims

Check

11-26

Steering Wheel

Check movement

11-27

Accelerator Pedal

Check

11-27

Inching Pedal

Check

11-27

Transmission Oil

Check oil level

11-28

Propeller Shaft Joint

Check

11-21

-

Every 50 Service Hours or Weekly, Whichever Comes First Item

Cooling System Engine System Hydraulic System Intake System Front Axle, Rear Axle, and Steering System Driving System

11-4

Service

Fan and Alternator Drive Belt Exhaust Pipe Hose, Pipes, and Joints Hydraulic Pump (oil leaks) Hydraulic motor, Cylinder, Safety Air Cleaner Each piping Steering control valve Priority valve Differential Oil

Service Check/Adjust Check Check Check Check Check / Inspect Check damage and oil leaks Check Check Check oil level

Page 11-29 11-40

-

MAINTENANCE 

One Month (30 days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever Comes First Item

Cooling System Electrical System

Cooling Fan Battery - Electrolyte Specific Gravity Engine Oil and Oil Filter Idling speed No load max. engine speed, and hunting

Engine

Fuel System

Fuel Filter Hydraulic System

Hydraulic System

Mast and Forks

Front Axle, Rear Axle, and Steering System Driving System 

Service Check Check Replace Check

Page 11-32 11-32 11-32 -

Check

-

Replace Replace return oil filter and wash strainer

11-34 11-43

Control Valves (oil leakage and functionality)

Check

-

Hydraulic Pump (oil leaks)

Check

-

Hydraulic motor, Cylinder, Safety Valve, Solenoid Valve, and Other Hydraulic System

Check

-

Hydraulic tank return filter Mast Support Lift Chains Flow Regulator Valve (Oil Leaks) Each piping Steering control valve Priority valve Differential Oil

Replace Check and lubricate Lubricate Check Check damage and oil leaks Check Check Check oil level

11-37 11-38

-

Every 500 Service Hours or 3 Months, Whichever Comes First Item

Brake System Cooling System Electrical System Engine Frame and Chassis

Mast and Forks

Front Axle, Rear Axle, and Steering System

Center Brake Drum, Shoe, and Lining Brake Drum, Shoe, and Lining Fan Belt Pulley Battery - Electrolyte Specific Gravity Engine Oil and Oil Filter Bolts and Nuts Lubricating Parts Lift Chains Mast Support Fork Guide Bar Mast Strips Surfaces Mast and Lift Bracket Side Rollers Tilt Socket Pins Tilt Cylinder Pins Tie Rod Pins Rear Axle Supports Rear Wheel Bearings Steering Knuckle, Tie Rod Pin, and King Pin

Service

Page

Check Check Lubricate Check Replace Check Looseness Lubricate Lubricate Check and Lubricate Lubricate Lubricate Lubricate Lubricate Lubricate Lubricate Lubricate Check Check

11-32 11-33 11-38 11-37 11-37 11-37 11-38 11-38 11-38 11-39 11-39 -

11-5

MAINTENANCE Item General 

Grease Nipples

Service Lubricate

Page -

Every 1000 Service Hours or 6 Months, Whichever Comes First Item

Brake System

Service

Page

Electrical System

Air Dryer Desiccant Alternator Starter Water Pump

Check Check Check Check

11-45 -

Engine

Intake and Exhaust Valve Clearance

Check

-

Cylinder head bolts and manifold nuts

Check

-

Hydraulic System

Hydraulic System

Replace return oil filter and wash strainer

11-43

Intake System

Air Cleaner

Replace element

11-40

Powershift Transmission

Replace oil, filter, and wash strainer

11-41

Front Axle

Replace oil

11-44

Universal Joints

Lubricate

11-40

Last Chance Filter

Clean

Driving System



Every 2000 Service Hours or 12 Months, Whichever Comes First Item

Parking Brake Brake Fluid Brake Master Cylinder Hoses and Rubber Parts Brake System Brake Wheel Cylinder Hoses and Rubber Parts Brake Device Air Master Air Dryer Desiccant Engine Coolant Cooling System Rubber Hose Radiator Cap Electrical System Voltage, Current, and Other Electrical System Compression Pressure Crankcase Breather Hoses Engine System Air Compressor Engine Mount Control Valve Relief Pressure Hydraulic System Hydraulic Oil Front Axle Power Steering Cylinder Front Axle, Rear Axle, and Rear Axle Steering System Wheel steering angle, rod, and arm Rear Wheel Bearings Steering Knuckle, Tie Rod Pin, and King Pin

11-6

-

Service Check Replace Replace Replace Check Check Replace Replace coolant Check Check Check Check Check Check Check Check Replace oil Check Check Check Check Check Check

Page 11-45 11-45 11-46 11-49 -

MAINTENANCE Item Driving System 

Differential wheel bearings T/M gear and bearing Propeller shaft

Service

Every 1 to 2 years

Hydraulic System

Hose (high-pressure hose)

Service Replace

Page -

Every 2 years Item

Fuel System Front Axle, Rear Axle, and Steering System 

-

Check Check Check

Item



Page

Service

Page

Fuel Hose

Replace

-

Power steering cylinder hoses and rubber parts

Replace

-

2 to 4 years Item

Mast and Forks

Lift Chain (Elongation)

Service Replace

Page -

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 procedures.  -

Faulty Operation Found the Day Before Have repairs been made properly?

Check the daily inspection sheet.

R WARNING Fill out a daily inspection sheet.

Remember, the complete performance of a daily inspection is the best protection against injury and property damage.

Q00375A



Oil, Fuel, or Coolant Leaks

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

Brake Pedal Do you have sufficient pedal travel?

Does the pedal have a correct free play?

Does the service brake apply and stop the lift truck properly without any signs of pulling, dragging, chattering, and squealing?

1)

100129 1) 15 mm (0.59 in.)

Free play Value 15 mm (0.59 in.)

11-8

MAINTENANCE  -

Parking Brake Lever 2

Can you pull the parking brake lever all the way with reasonable effort?

Can you hold your lift truck on a grade by pulling the parking brake lever?

-

1 Q00378 1. Rod

2. Release

Lever Operating Effort 245 to 295 N (24.98 to 30.08 kgf) [55.08 to 66.32 lbf] Adjusting parking brake lever operating effort Push the parking brake lever to the release position. Turn the rod clockwise to increase the lever’s tension; counterclockwise to decrease it.



Service Brake

Check 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 with the forks lowered, parking brake applied, transmission in NEUTRAL, the engine stopped, and the wheels blocked.

(1) Raise the engine hood.

(2) Check the brake fluid level at the reserve tank.

(3) Maintain the brake fluid level between the MAX and MIN marks on the reserve tank.

(4) Close the engine hood.

1

102484 1. Correct level range

11-9

MAINTENANCE Add brake fluid (1) Remove the reserve tank cap.

(2) Add brake fluid to the reserve tank slowly.

(3) Put the reserve tank cap back on.

102485



Air Tank

Drain water At the end of each shift or when operators change, pull the handle at the bottom of the brake air tank to allow water to drain.

101975



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.

Park the lift truck on a hard and level surface 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) Raise the engine hood.

(2) Maintain the coolant level between the FULL and LOW marks on the reserve tank.

(3) Close and secure the engine hood.

1

Q00493 1. Correct level range

11-10

MAINTENANCE Adding 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 protection and adversely affects the engine. Be sure to premix antifreeze/summer coolant with distilled water (soft water). See 12-4 "Specifications (Standard Models)" and 12-6 "Refill Capacities". If coolant has to be added frequently, have your Cat lift truck dealer check the cooling system.

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 antifreeze/summer coolant (ASC) when shipped from the factory.

(3) Put the reserve tank cap back on.

101299

R WARNING Antifreeze solution is TOXIC. In case of contact with your skin, FLUSH IMMEDIATELY WITH WATER. Have your Cat lift truck dealer to dispose antifreeze solution drained from the engine.

Q00294A

 -

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 switch them on?

11-11

MAINTENANCE 

Horn

Does the horn sound properly when you push the horn?

103986A



Icons of Meter Panel

Do all the warning icons glow when the key switch is in the ON position? Except warning icons marked with *.

Note: When icons do not glow with the key switch in the ON position, the bulb may be burned out.

Contact your authorized Cat lift truck dealer for repairs.

Q00729



Backup Alarm

Make sure the backup alarm sounds when operating the lift truck in REVERSE.

D00374



Backup Light

When you place the direction lever into REVERSE position: -

Do all backup lights turn ON? Does the backup alarm sound?

Q00811

11-12

MAINTENANCE 

Stop Light

Do all stop lights turn ON properly when you depress the brake pedal?

Q00812



Battery R WARNING

-

Batteries give off flammable fumes that can explode.

Do not smoke when checking the battery electrolyte levels.

Electrolyte is an acid and can cause injury if it contacts your skin or eyes.

Always wear protective glasses when working with batteries.

Check electrolyte level (1) Raise the battery cover.

(2) Clean the top of the battery and terminals.

(3) Check terminals for corrosion. Coat terminals with heavy grease.

(4) Maintain electrolyte level between the UPPER LEVEL and LOWER LEVEL marked on the case.

Note: If an addition of water is necessary, use distilled water. If not available, use clean water that is low in minerals. Do not use artificially softened water.

(5) Close and secure the battery cover.

R WARNING -

If acid gets in your eyes, FLUSH THEM IMMEDIATELY WITH LARGE AMOUNTS OF WATER AND SEE A DOCTOR AT ONCE. If you spill acid on yourself, FLUSH SKIN IMMEDIATELY WITH LARGE AMOUNTS OF WATER. APPLY BAKING SODA TO HELP NEUTRALIZE THE ACID AND SEE A DOCTOR AT ONCE.

R CAUTION If distilled water has to be added frequently, have your Cat lift truck dealer check the battery.

2 1 104051 1. Upper level

2. Lower level

11-13

MAINTENANCE 

Mast Interlock System

Check Raise the forks high enough to see them from the operator seat.

Q00282A

Apply the parking brake and place the direction lever in the NEUTRAL position. Then, with the engine idling (not depressing the accelerator pedal), half rise from the operator seat and after approximately 3 seconds: -

Check that the mast interlock indicator icon is blinking.

Operate the lift lever (switch) and check that the forks do not move up and down.

Operate the tilt lever (switch) and check that the mast does not tilt FORWARD or BACKWARD. Operate the attachment lever (switch) and check that the attachment does not move.

R CAUTION Make sure that the area is clear of pedestrians when checking the mast interlock system.

11-14

MAINTENANCE 

Driving Interlock System

Check Raise the forks a little from the floor.

Q00273A

With the engine idling (not depressing on the accelerator pedal), place the direction lever to the FORWARD or REVERSE position, and then half rise from the operator seat and after approximately 3 seconds: -

The transmission should electrically shift into NEUTRAL with the driving interlock indicator icon blinking.

If you are on a grade, the lift truck will continue to roll because the lift truck is in NEUTRAL.

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. Return the direction lever to the NEUTRAL position once, then place the direction lever to the FORWARD or REVERSE position.

R CAUTION -

Make sure that the area is clear of pedestrians when checking the driving interlock system.

Check this system on level and hard surface.

DO NOT test the lift truck on a grade or uneven surface.

Make sure that the sufficient space is available for the lift truck to move around and that no one or obstacle is around the lift truck.

11-15

MAINTENANCE 

Parking Brake Warning Alarm and Warning Icon

Check 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

Q00397 1. Release

Remove the key from the key switch.

Release the parking brake.

-

The warning alarm should sound with the warning icon blinking.

Apply the parking brake. The warning alarm should stop and the warning icon should be OFF.

-

R CAUTION Check this system on level and hard surface. 

Seat Belt Warning Icon and Alarm

Check 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.

104430

Turn the key switch to the I ON position and buckle the seat belt.

-

Unbuckle the seat belt. The warning icon should glow.

11-16

MAINTENANCE 

Engine (Exhaust, Noise, and Vibration) R WARNING

Exhaust fumes could kill you!

Fire hazards!

-

-

-

-

If it is necessary to start the engine in an enclosed area, make sure there is adequate ventilation.

Hot exhaust fumes could cause injury. DO NOT allow hot exhaust fumes to contact your skin.

-

Clean up spillage of fuel, oil, or other flammable materials in the engine compartment.

Know the location of all emergency devices (such as fire extinguisher, first aid kit, etc.) and how to use them.

Is exhaust smoke normal?

Listen for abnormal noise or excessive vibration.

Q00735

11-17

MAINTENANCE 

Engine 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.

Park the lift truck with the forks lowered, parking brake applied, transmission in NEUTRAL, the engine stopped and the wheels blocked.

(1) Raise the engine hood.

(2) Remove the dipstick and wipe it clean, then insert it.

104029

(3) Maintain the correct level range on the dipstick.

(4) Close and secure the engine hood.

1 104873 1. Correct level range

Adding engine oil

R CAUTION When adding engine oil: -

Perform the work on level ground.

Clean the filler hole to prevent dirt from dropping into the engine.

DO NOT overfill.

Clean up spillage.

(1) Remove the oil filler cap.

104030 1. Oil filler cap

11-18

MAINTENANCE (2) Add engine oil as required. For engine oil, see 12-3 "Recommended Fuels and Oils".

104041

(3) After adding oil, make sure the level is in the correct range on the dipstick.

(4) Close and tighten the filler cap. 

Fuel

Is the amount of fuel in the tank enough for the day's work?

Q00267



Overhead Guard

Inspect overhead guard for bent or cracked sections.

Note: Contact your authorized Cat lift truck dealer if repairs are needed.

Q00766

11-19

MAINTENANCE 

Assist Grips

Inspect the assist grips on both sides for damage or cracks and also check that they are secure.

Note: Contact your authorized Cat lift truck dealer if repairs are needed.

Q00488

 -

Seat Belt Is the seat belt in a safe condition?

Replace the belt assembly if the belt is torn, cut, or if the plate and/or buckle is defective.

Check the seat belt switch for operation.

-

E00454



Seat Adjustment

Can you depress the accelerator and brake pedals all the way?

Note: See 2-46 "Forward and Back Adjustment".

1 E00679 1. Slide lever

11-20

MAINTENANCE 

Hydraulic Oil

Check oil level

R WARNING -

Hot oil and components can cause serious injury.

DO NOT allow hot oil or components to contact your skin.

Remove the hydraulic tank filler cap only after the engine has been stopped and the cap is cool enough to remove with your hands.

Remove the hydraulic tank filler cap slowly to relieve pressure.

(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) Check the oil level with dipstick.

(4) Maintain the correct level range.

Note: Measurement of oil level should be conducted between three and five minutes after turning the engine OFF.

E01002

Add hydraulic oil

R CAUTION When adding hydraulic oil: -

Perform the work on level ground.

Clean the filler hole to prevent dirt from dropping into the tank.

DO NOT overfill.

Clean up spillage.

(1) Remove the hydraulic tank filler cap.

(2) Add oil to the hydraulic tank.

For Hydraulic Oil, see 12-3 "Recommended Fuels and Oils".

(3) After adding oil, make sure the level is in the correct level range.

(4) Install the hydraulic tank filler cap securely.

101541

11-21

MAINTENANCE 

Tilt Cylinder Locknuts

Are the locknuts tightened properly?

Use a wrench.

Note: After retightening the locknut, put a matchmark across the nut and tilt cylinder socket. This permits you to easily notice loosening of the locknut.

1

101969 1. Matchmark

Models

Tightening torque

DP100NM1, DP100NM1S, DP120NM1,DP120NM1S

1334 to 1468 N·m (136.03 to 149.69 kgf·m) [983.91 to 1082.72 lbf·ft]

DP135NM1, DP135NM1S, DP150NM1, DP150NM1S

1618 to 1780 N·m (164.99 to 181.51 kgf·m) [1193.38 to 1312.84 lbf·ft]



Lift Chains R WARNING

Check and adjust -

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, contact your authorized Cat lift truck dealer for repair or replacement.

DO NOT put your foot under the forks.

Turn the engine OFF before working.

DO NOT lean over from the lift truck to perform inspections. It could cause accidents.

How to check (1) Check the lift chains for wear. Use the following table to determine if it is still in usable condition.

Q00020

Lift chain elongation limit (/20 links) Models

Limit

DP100NM1, DP100NM1S, DP120NM1, DP120NM1S, DP135NM1, DP135NM1S

915 mm (36.02 in.)

DP150NM1, DP150NM1S

1046 mm (41.18 in)

11-22

MAINTENANCE (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.

Q00021

How to adjust (1) Loosen the locknut and upper nut. Then turn the lower nut to adjust tension.

(2) Hold the lower nut and tighten the upper nut to the specified torque. Hold the lower nut and tighten the locknut to the specified torque.

1 2 3 101687 1. Upper nut 2. Lower nut

Model

3. Locknut

Tightening torque

DP100NM1, DP100NM1S, DP120NM1, DP120NM1S, DP135NM1, DP135NM1S

393±39.3 N·m (40.07±4.01 kgf·m) [289.86±28.99 lbf·ft]

DP150NM1, DP150NM1S

441±44.1 N·m (44.97±4.50 kgf·m) [325.26±32.53 lbf·ft]

11-23

MAINTENANCE 

Mast and Forks

Check -

Does the mast move up and down smoothly when you operate the lift control lever?

Does the mast tilt FORWARD and back smoothly when you operate the tilt control lever?

Are there any oil leaks from the cylinders and hydraulic lines?

Check the lift cylinder mounting bolts for looseness.

J00180A

-

Are the fork locking pins properly engaged?

Are the forks free of distortion and cracks?

Are the welds of the hangers free of cracks?

1

2 101984 1. Fork locking pins

2. Fork

Heel free type of fork: If the lift truck is being used to carry maximum capacity loads, the forks should be checked daily.

(1) Carefully inspect the forks for cracks. Special attention should be given to the heel section 1, and all weld areas 2.

Forks with cracks should be removed from service.

“Wet Test” magnetic particle inspection is generally preferred 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.

Contact your Cat lift truck dealer for further information.

2

2

1 Q00495

Heel hold type of fork: If the lift truck is being used to carry maximum capacity loads, the forks should be checked daily.

(1) Carefully inspect the forks for cracks. Special attention should be given to the heel section 1, and all weld areas 2.

Forks with cracks should be removed from service.

“Wet Test” magnetic particle inspection is generally preferred 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.

Contact your Cat lift truck dealer for further information.

11-24

2

2

1 Q00496

MAINTENANCE (2) Check the difference in height of one forktip to the other when mounted on the fork carrier. A difference in forktip height can result in uneven support of the load and cause problems when entering loads.

3 101629

The maximum allowable difference in forktip elevation 3 is 5 mm (0.20 in.) for pallet forks. Replace one or both forks when the difference in forktip height exceeds the maximum allowable difference.

(3) Check the fork blade 4. The fork should be withdrawn from service if the thickness is reduced to less than the tolerant thickness.

4 101630

Fork blade length may also be reduced by wear, especially on tapered forks and platens. Remove the forks from service when the blade length is no longer adequate for the intended loads.

Tolerant thickness (standard: 1220 mm [48.03 in.])

Model

standard

Limit

DP100NM1 DP100NM1S

72 mm (2.83 in.)

65 mm (2.56 in.)

DP120NM1 DP120NM1S

79 mm (3.11 in.)

71 mm (2.80 in.)

DP135NM1 DP135NM1S

88 mm (3.46 in.)

76 mm (2.99 in.)

DP150NM1 DP150NM1S

88 mm (3.46 in.)

80 mm (3.15 in.)

11-25

MAINTENANCE 

Wheel Nuts

Check / Tighten 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.

Tighten -

Always stand behind the tread of the tire, NOT in front of the rim.

Tighten the nuts evenly and in a diagonal sequence to the specified torque.

-

Are the wheel nuts tightened properly?

Use a torque wrench.

101155

Tightening torque:

Tightening torque 539.4±53.9 N·m (55.0±5.5 kgf·m) [397.83±39.75 lbf·ft]



Tires and Rims

Check -

-

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. Contact your Cat lift truck dealer for tire replacement.

Are all the rims free of distortion or cracks?

1)

101295 1) Limit: 5 mm (0.20 in.)

R WARNING Make sure the replacement tire is of the same size, type and load range.

11-26

MAINTENANCE  -

Steering Wheel Is the free play 70 mm (2.76 in.)? Check the free play at the rim of the wheel by rotating the wheel in both directions.

Is wheel installation loose? Check by shaking the wheel up and down.

-

Q00016



Accelerator Pedal

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

2

1

3

Q00793 1. Accelerator pedal 2. Brake pedal

 -

3. Inching pedal

Inching Pedal Is the free play correct?

Is the clutch released when you slowly depress the inching pedal?

1)

E01021 1) 23 mm (0.91 in.)

Correct free play Value 23 mm (0.91 in.)

11-27

MAINTENANCE 

Transmission Oil

Check oil level

R WARNING Hot oil and components can 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.

(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) Check the oil level in the sight gauge.

Note: Measurement of oil level should be conducted between three and five minutes after turning the engine OFF.

1

101631 1. Correct level range

(4) Maintain the correct level range.

Adding oil (1) Remove the dipstick/filler cap. Fill the transmission with oil. See 12-4 "Specifications (Standard Models)" and 126 "Refill Capacities". Put the dipstick/filler cap back in place.

Q00800

(2) (3) (4) (5)

Turn the key switch to the START position.

Run the engine at low idle.

Turn the engine OFF. Let the oil level stabilize, then remove the dipstick/filler cap. Check the oil level.

Note: Measurement of oil level should be conducted between three and five minutes after turning the engine OFF.

11-28

MAINTENANCE (6) Maintain the oil level to the correct level range on the dipstick/filler cap.

1

101631 1. Correct level range

(7) Put the dipstick/filler cap back in place.

(8) Check for oil leaks at the strainer, filter, and drain plug.

Every 50 Service Hours or Weekly, Whichever Comes First You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedures. 

Fan and Alternator Drive Belt

Check – adjust

R CAUTION -

After turning the engine OFF, check and adjust the rotating part.

After adjusting the belt, tighten the bracket bolt securely.

If the belt is too tight, unnecessary stresses are placed on the alternator bearing and belt. Such stresses will shorten the service life of both.

- Keep the belt free of oil and grease to reduce the risk of slipping.

Note: If it is difficult to adjust or replace the belts, contact your Cat lift truck dealer.

Park the lift truck on a hard and level surface 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) Raise the engine hood.

(2) Push the belt downward with about 98 N (10 kgf) [22 lbf] pressure midway between the pulleys.

1

4 2 3 1. Mounting bolt 2. Adjusting bracket bolt

104022

3. Fan drive belt 4. Deflection

Deflection Fan drive belt

24 to 26 mm (0.94 to 1.02 in.)

Alternator drive belt

10 to 15 mm (0.39 to 0.59 in.)

11-29

MAINTENANCE 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 piles.

(3) To adjust the belt, loosen mounting bolt and adjusting bracket bolt. Move the alternator in or out as required.

Tighten mounting bolt and adjusting bracket bolt.

(4) Close and secure the engine hood.

1

4

2 3 1. Alternator drive belt 2. Adjusting bracket bolt



100190

3. Mounting bolt 4. Deflection

Air Cleaner

Clean / Inspect Clean the air cleaner element if the dust indicator shows RED. After installing clean element, reset the dust indicator.

Clean and replace more frequently in corrosive or abrasive environments.

2

1 104876 1. Reset button

2. Red signal

R WARNING When using compressed air for cleaning, wear a safety face shield and protective clothing.

Use a maximum air pressure of 196 kPa (2 kgf/cm2) [28 psi] for cleaning purposes.

Note: Never service the air cleaner with the engine running.

Do not clean the elements by striking them against another object.

Always inspect the element before and after cleaning.

Use a light inside the element.

Do not use elements with damaged pleats, gaskets, or seals.

Q00398

In corrosive or abrasive environments, clean and replace more frequently.

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.

11-30

MAINTENANCE (1) (2) (3) (4)

Remove the wing nut.

Remove the cover.

Remove the wing nut.

Remove the element.

6

5 4 2

7

1

3 1.

2.

3.

4.

Wing nut Cover Wing nut Element

105105 5. Body 6. Dust indicator 7. Vacuator valve

(5) Clean the cover and air cleaner body.

(6) Remove dust from the element by blowing compressed air from the inside toward the outside.

104878

Compressed air pressure

Less than 196 kPa (2.00 kgf/cm2)[28.43 psi]

(7) Shine a light through the element from the inside and check for abraded areas and damaged areas. Also, check whether the seal is damaged.

104879

(8) Use a rag to clean dust off the inside surfaces of the air cleaner body and cover.

(9) Check whether the vacuator valve is clogged. If it is clogged, clean it.

(10) Install the element by performing the removal steps in reverse.

11-31

MAINTENANCE

One Month (30 Days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever Comes First You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure. 

Cooling Fan

Check Check for damage and rotating of the cooling fan.

Q00799



Battery - Electrolyte Specific Gravity

Check - Check specific gravity of electrolyte.

Have your Cat lift truck dealer check specific gravity of electrolyte. 

Engine Oil and Oil Filter

Replace - Replace oil and filter.

Have your Cat lift truck dealer replace them. 

Bolts and Nuts

Check -

Retighten bolts and nuts of overhead guard.

11-32

MAINTENANCE

Every 500 Service Hours or 3 Months, Whichever Comes First You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure. 

Engine Oil and Oil Filter

Replace oil and filter

R WARNING Hot oil and components can 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) Raise the engine hood.

(3) 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.

(4) Remove the drain plug on the engine oil pan. Allow the oil to drain. Clean and put the drain plug back in place.

(5) Remove the drain plug and allow the oil to drain.

(6) Remove and discard the oil filter element.

Q00525

(7) Wipe the sealing surface of the oil filter element mounting base.

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

(8) Apply a small amount of clean engine oil to the oil filter element gasket. Install the new filter element.

Q00526

(9) Fill the crankcase. See 12-4 "Specifications (Standard Models)" and 12-6 "Refill Capacities".

(10) Start the engine and allow the oil to fill the filter and passages.

11-33

MAINTENANCE (11) Check for oil leaks.

(12) Stop the engine and measure the oil level.

Maintain the correct level range on the dipstick.

(13) Close and secure the engine hood.

104029

Note: In corrosive or abrasive environments, clean and lubricate more frequently.

1 104873 1. Correct level range



Fuel Filter

Replace

R WARNING -

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Clean up any spillage of fuel.

Know the location of all emergency devices (such as fire extinguishers, first aid kits, etc.) and how to use them.

Disconnect the battery when changing fuel filters.

Park the lift truck on a hard and level surface 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. Engine must be cooled down.

(1) Raise the engine hood.

(2) The fuel filter is located on the right side of the lift truck.

Remove the filter.

Q00527

11-34

MAINTENANCE (3) Use filter wrench to remove filter element.

(4) Clean sealing surface of filter base.

(5) Apply a light coat of engine oil to the gasket of the new filter element.

101682

(6) Install the new filter element by hand until the gasket contacts the filter base.

(7) Turn the key switch to the STA11-8RT position and check for fuel leaks.

(8) Turn the engine OFF. (9) Install and secure the front cover.

(10) Close and secure the engine hood.

101681

How to prime the fuel system Note: If the engine runs out of fuel, it can not be started even if the fuel tank is filled. In such a case, prime the fuel system as follows:

R CAUTION -

BE SURE that no fuel leaks from the air bleeder plug.

Clean up spillage.

Fuel filter (1) Loosen the air bleeder plug on the fuel filter about 1.5 turns with a wrench.

(2) Unlock priming pump plunger by turning it counterclockwise. Operate the priming pump until the fuel flows free of bubbles from the vent.

(3) Tighten air bleeder plug.

1

2 103733 1. Air bleeder plug

2. Pump plunger

11-35

MAINTENANCE

Lubrication Chart 4 2 1

3 5

8 6 7

9 11

10

Ref.

Lubricating point

1

Mast support bushings (Each side)

2

Fork guide bar

3

Lift chain (Each side)

4

Mast and lift bracket side rollers (Each side)

5

Mast strips surfaces (Each side)

6

Tilt socket pins (Each side)

7

Tilt cylinder pins (Each side)

8

Universal joint (2 places)

9

Fan belt pulleys (3 fittings)

10

Rear axle supports (Front and Rear)

11

Tie rod pins (4 places)

11-36

Lubricant/grease

500212

Period

Multipurpose-type grease Engine oil

Every 500 service hours or 3 months, whichever comes first Multipurpose-type grease

MAINTENANCE 

Fan Belt Pulleys

Lubricate Lubricate 3 fittings of the fan belt pulleys.

104034



Mast Support

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

101696



Fork Guide Bar

Lubricate Lubricate the fork guide bar.

Q00774



Mast Strips Surfaces

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

102007

11-37

MAINTENANCE 

Mast and Lift Bracket Side Rollers

Lubricate Lubricate 2 fittings on each side roller for a total of 4 fittings.

104032



Lift Chains

Lubricate / Inspect (1) Apply engine oil onto the chain links with a brush.

(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 lift truck must work in rapid lift cycles.

(3) Inspect the chain anchors and individual links for wear, loose pins or cracked leaves.

102010



Tilt Socket Pins

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

102005



Tilt Cylinder Pins

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

104885

11-38

MAINTENANCE 

Tie Rod Pins

Lubricate Lubricate 2 fittings on each end for a total of 4 fittings.

102891



Rear Axle Supports

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

205558

11-39

MAINTENANCE

Every 1000 Service Hours or 6 Months, Whichever Comes First You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedures. 

Air Dryer Desiccant

Check Replace the desiccant if much condensate water drains out of the air tank when the drain cock is opened. 

Air Cleaner

Replace element Cat Lift Trucks strongly recommends that the air cleaner element be replaced if it is dirty. If you attempt to clean the element, handle it carefully.

Recommended replacement intervals: Normal conditions

Severe dust or lint condition

Every 1000 hours or 6 months Every 1000 service hours or 6 months, whichever comes first In corrosive or abrasive environments, clean and replace more frequently

Note: Have spare elements on hand to use while cleaning used elements.

Care in severe dust or lint conditions Check the radiator core frequently for clogging or dirt accumulation. Clean the lift truck as needed.

See 11-30 "Air Cleaner" in Every 50 Hours or Weekly, Whichever Comes First. 

Universal Joints

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

101982

11-40

MAINTENANCE 

Powershift Transmission

Replace oil, filter, and wash strainer

R WARNING Hot oil and components can cause personal injury. DO NOT allow hot oil or components to contact your skin.

Park the lift truck on a hard and level surface 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) Raise the engine hood.

(2) Remove the drain plug. Allow the oil to drain. Remove the cover, strainer and O-ring.

1

2

1. Cover

(3) Wash the strainer and the drain plug in clean, and nonflammable solvent. Dry the strainer and the drain plug.

Wipe off the O-ring, check and replace if necessary.

Install the O-ring, strainer and cover. Put the drain plug back in place.

102006

2. Drain plug

2

3

4

5

1 1. Cover, Strainer 2. Strainer 3. Magnet

104887

4. Spring 5. O-ring

(4) Use filter wrench to remove filter element.

(5) Clean sealing surface of filter base.

(6) Apply a light coat of engine oil to the gasket of the new filter element.

(7) Install the new filter element by hand.

(8) Prime the system.

102892

11-41

MAINTENANCE (9) Remove the dipstick/filler cap. Fill the transmission with oil. See 12-4 "Specifications (Standard Models)" and 126 "Refill Capacities". Put the dipstick/filler cap back in place.

Q00800

(10) Turn the key switch to the START position.

(11) Run the engine at low idle.

(12) Turn the engine OFF. (13) Let the oil level stabilize, then remove the dipstick/filler cap. Check the oil level.

Note: Measurement of oil level should be conducted between three and five minutes after turning the engine OFF. (14) Maintain the oil level to the correct level range on the dipstick/filler cap.

1

101631 1. Correct level range

(15) Put the dipstick/filler cap back in place.

(16) Check for oil leaks at the strainer, filter and drain plug.

(17) Close and secure the engine hood.

11-42

MAINTENANCE 

Hydraulic System

Replace return oil filter and wash strainer

R WARNING Hot oil and 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.

Park the lift truck on a hard and level surface 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) Raise the engine hood.

(2) Remove the tank cover.

(3) Remove the hoses.

1

1

104888 1. Hose

(4) Remove the pipe and strainer.

(5) Remove the pipes and return oil filter.

Discard the filter element.

(6) Put the filter body assembly back in place and tighten the retaining bolts.

(7) Clean the filter parts and replace the seal and gasket, if necessary. Install a new filter element.

2 1 102002 1. Oil filter

(8) Wash the strainer in clean, and nonflammable solvent.

(9) Inspect the gasket and replace it, if necessary.

(10) Put the strainer, pipe and hose back in place. And then install the tank cover.

(11) Remove the hydraulic tank filler cap.

Check the oil level on the level gauge.

(12) Maintain the correct level range.

2. Strainer

1

101304 1. Correct level range

(13) Put the hydraulic tank filler cap back on.

(14) Check for oil leaks.

(15) Close and secure the engine hood.

11-43

MAINTENANCE 

Front Axle

Replace oil Park the lift truck on a hard and level surface 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) Align the planetary hub level/mark to the vertical position. Set drain plug in bottom position of wheel.

(2) Remove the planetary hub drain plug and bleeder plug.

(3) Allow the oil to drain. Clean and reinstall the drain plug.

(4) Now align the wheel so that the level mark is in the horizontal position.

(5) Lift opposite side of the lift truck with a jack and repeat Step 1 from above, and lower truck to the ground.

Repeat Step 2 from above. Allow the oil to drain. Clean and reinstall the bleeder plug. Align wheel so that drain plug is higher than the bleeder plug of the opposite wheel.

2

3

1

500317

1. Drain plug 2. Bleeder plug

3. Level mark

(6) Raise the lift bracket high enough to gain access to the front axle housing level/fill plug.

(7) Use blocking under inner mast to secure the lift bracket in this position.

(8) Remove the level/fill plug.

1

101697

1. Level/fill plug

(9) Remove the drain plug and allow the oil to drain.

1 1. Drain plug

(10) Clean and reinstall the drain plug.

(11) Fill with oil to the bottom of the level/fill hole. See 12-4 "Specifications (Standard Models)" and 12-6 "Refill Capacities". Install the level/fill plug.

(12) Install the planetary hub level plug.

(13) Remove blocking. Lower the lift bracket.

11-44

101701

MAINTENANCE

Every 2000 Service Hours or 12 Months, Whichever Comes First You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure. 

Brake Fluid

Replace Note: When replacing brake fluid, contact your Cat lift truck dealer.

102483



Air Dryer Desiccant

Replace The desiccant, filter, and rubber parts of the air dryer require regular replacement. Have your Cat lift truck dealer replace them.

104899

11-45

MAINTENANCE 

Engine Coolant

Replace coolant

R WARNING -

At operating temperature, the engine coolant is hot and under pressure.

Steam could cause severe burns.

Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with your skin and eyes to reduce the risk of burns and other injuries. Allow cooling system components to cool before draining. Use all cleaning solutions with care.

Park the lift truck on a hard and level surface 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 WARNING Antifreeze solution is TOXIC. In case of contact with your skin, FLUSH IMMEDIATELY WITH WATER. Have your Cat lift truck dealer discard antifreeze solution drained from the engine.

Q00294

(1) Open the radiator cover.

(2) Loosen the radiator cover retaining knob.

Lift and remove the radiator cover.

(3) Open the engine hood.

(4) Turn the radiator filler cap slowly to relieve the pressure, then remove the cap.

101738

(5) Remove the engine block drain plug.

104037

11-46

MAINTENANCE (6) Open radiator drain valve. Allow the coolant to drain.

100187

(7) Drain the reserve tank.

Q00492

(8) Close the radiator drain valve.

(9) Fill the cooling system with 1 kg (2 lb.) sodium bisulfate per 40 L (10 U.S. gal.) of water. Most commercial cooling system cleaners can be used.

(10) Turn the key switch to the START position and run the engine for 30 minutes.

(11) Turn the engine OFF and drain the cleaning solution.

(12) Flush the system with clean water until the draining water is clear.

(13) Close the drain valve. Fill the system with neutralizing solution, 250 g (0.55 lb.) sodium carbonate per 40 L (10 U.S. gal.) of water.

(14) Turn the key switch to the START position and run the engine for 10 minutes.

(15) Turn the engine OFF and drain the neutralizing solution.

(16) Flush the system with clean water until draining water is clear.

(17) Close the drain valve.

(18) Mix a coolant solution of water and antifreeze.

(19) Fill the cooling system. See 12-4 "Specifications (Standard Models)" and 12-6 "Refill Capacities". To avoid air locks, add the coolant slowly.

104991

11-47

MAINTENANCE (20) Turn the key switch to the START position and run the engine until the coolant level is stabilized.

(21) Turn the engine OFF. (22) Add coolant to the level below the bottom of the filler tube, if necessary.

101641

(23) Put the radiator filler cap back on.

(24) Remove the reserve tank filler cap.

(25) Keep the coolant level at the FULL line on the reserve tank.

Q00494

(26) Put the reserve tank filler cap back on.

(27) Close and secure the engine hood.

(28) Close the radiator cover.

11-48

MAINTENANCE 

Hydraulic Oil

Replace oil

R WARNING -

Hot oil and components can 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.

Park the lift truck on a hard and level surface 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) Operate the lift truck to warm the oil.

(2) Remove the filler cap.

101540

(3) Remove the hydraulic tank drain plug.

Allow the oil to drain. Clean and put the plug back in place.

104040

(4) Fill the hydraulic tank. See 12-6 "Refill Capacities". Put the filler cap back on.

(5) Turn the key switch to the START position and operate the hydraulic controls and the steering system through a few cycles to fill the filters and lines.

(6) Retract all hydraulic cylinders and turn the engine OFF. (7) Check the oil level on the level gauge.

(8) Maintain the correct level range.

1

101304 1. Correct level range

11-49

MAINTENANCE

Parts to be Replaced Periodically The following parts must 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. Replacement at proper intervals will reduce the risk of injury to the operator and damage to the lift truck.

Note: Periodic changes of these parts are not covered by warranty.

4

4 6

5 10

10

3

11

1 11 8 2

9

7 No.

7

Parts to be replaced

2

500660

Interval

1

Repair kit of air master cylinder

2000 service hours or 1 year, whichever comes first

2

Rubber parts of brake wheel cylinders

2000 service hours or 1 year, whichever comes first

3

Repair kit of brake valve

2000 service hours or 1 year, whichever comes first

4

Brake hoses

2000 service hours or 1 year, whichever comes first

5

Stop light switch (air type)

4000 service hours or 2 years, whichever comes first

6

Tube of brake fluid cup

2000 service hours or 1 year, whichever comes first

7

High-pressure hoses of hydraulic system

2000 to 4000 service hours or 1 to 2 years, whichever comes first

8

Inner rubber parts of power steering cylinder

4000 service hours or 2 years, whichever comes first

9

Hydraulic hoses of power steering cylinder

4000 service hours or 2 years, whichever comes first

10

Lift chains

4000 to 9000 service hours or 2 to 4 years, whichever comes first

11

Fuel hoses

4000 to 9000 service hours or 2 to 4 years, whichever comes first

11-50

SERVICE DATA

 SERVICE DATA  Fuel Information Use only fuel recommended in this section. 

Fuel Specifications

Fuel types The recommended fuels provide maximum engine service life and performance. They are distillate fuels. They are commonly called diesel fuel, furnace oil, gas oil or kerosene (for cold weather operation).

Note: The manufacturer strongly recommends the use of fuels that meet the recommended fuels specification.

Fuel sulfur content -

The percentage of sulfur in the fuel will affect the engine oil recommendations. Fuel sulfur is chemically changed during combustion to form both sulfurous and sulfuric acid. These chemically attack metal surfaces and cause corrosive wear.

Any API classification performance of oil should have sufficient Total Base Number (TBN) for fuels with less than 0. 5% sulfur.

For fuels with 0.5% to 1. 5% sulfur by weight, engine oil must have a TBN of 20 times the percentage of fuel sulfur as measured by the American Society of Testing Materials (ASTM) D-2896 method. (ASTM D-2896 can normally be found at your local technological society, library or college.)

 Coolant Information The manufacturer recommends that the coolant mix contain 50% commercially available automotive antifreeze, and 50% water.

Note: -

-

-

-

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---using a commercially available automotive antifreeze. Filling at over 5 L (1.3 U.S. gal.) 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 required 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.

12-1

SERVICE DATA 

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 outof-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 pH

250 ppm (maximum) 6.0 to 8.0

ppm = parts per million 

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.

Note: -

12-2

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.

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.

SERVICE DATA

 Recommended Fuels and Oils Recommendation for Ambient Temperatures °C (°F) Fuel or Oil

Recommendation

Fuel

-30 (-22)

-20 (-4)

0 (32)

10 (50)

20 (68)

30 (86)

Contact your authorized Cat lift truck dealer.

SAE10W-30 (Recommended ambient temperatures from -20°C (36°F) to 40°C (104°F), or SAE15W-40 (Recommended ambient temperatures from -10°C (18°F) to 50°C (122°F)

Engine oil

API service classification CF min.

Transfer and differential oil

API service classification multipurpose type

Powershift transmission oil

Dexron III

Hydraulic oil

ISO VG32

Brake fluid

FMVSS No.116-DOT3 or DOT4, or SAE J1703

Grease

-10 (14)

GL-4 GL-5

SAE80W

SAE90

Wheel bearings

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

Chassis

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

Antifreeze solution

Long life coolant

Value Ambient temperature

°C (°F)

-39 (-70)

-30 (-54)

-25 (-45)

-20 (-36)

-15 (-27)

-10 (-18)

Concentration

(%)

55

50

45

40

35

30

Note: -

Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with the same brand at successive service intervals.

For refill capacities and measurements, see "Specifications (Standard Models)" in this section.

12-3

SERVICE DATA

 Specifications (Standard Models) Truck model Item

DP100NM1 DP100NM1S

DP120NM1 DP120NM1S

DP135NM1 DP135NM1S

850±50 min-1

Engine idling speed Alternator drive belt deflection (when pushed with 98 N (10 kgf) [22 lbf] pressure)

10 to 15 mm (0.39 to 0.59 in.)

Fan drive belt deflection (when pushed with 98 N (10 kgf) [22 lbf] pressure)

24 to 26 mm (0.94 to 1.02 in.)

Steering wheel free play (when measured at rim with engine idling)

70 mm (2.76 in.)

Brake pedal free play

15 mm (0.59 in.)

Inching pedal free play

23 mm (0.91 in.)

Tire size

Front tire Rear tire Front tire

Tire pressure

DP150NM1 DP150NM1S

Rear tire

10.00-20-14FR 700 kPa (7.1 kgf/cm2) [101.5 psi]

10.00-20-16FR

12.00-20-18PR

800 kPa (8.2 kgf/cm2) [116.0 psi]

Tightening torque for wheel nuts

Front tire

539.4 ± 49 N·m (55.00 ± 5.0 kgf·m) [397.841 ± 36.14 lbf·ft]

Rear tire

490.3± 588.4 N·m (50.00 ± 60.00 kgf·m) [361.627± 433.982 lbf·ft]

Lift chain elongation limit

(mm/20 links)

Note: The service data is subject to change without notice.

12-4

915 mm (36.02 in.)

1046 mm (41.18 in.)

SERVICE DATA

 Refill Capacities Truck model Item

DP100NM1 DP100NM1S

Fuel tank

Coolant

DP120NM1 DP120NM1S

DP135NM1 DP135NM1S

180 L (47.56 US gal.)

220 L (58.12 US gal.)

Radiator

7.2 L (1.90 US gal.)

Engine

13.0 L (3.43 US gal.)

Reserve tank

0.7 L (0.2 US gal.)

Radiator hose (upper and lower)

2.1 L (0.6 US gal.)

Coolant quantity

23.0 L (6.1 US gal.)

Engine oil

12 L (3.17 US gal.)

Transmission oil

23 L (6.08 US gal.)

Transfer and differential gear oil

25 L (6.61 US gal.)

186 L (49.1 US gal.)

Hydraulic oil Hydraulic tank

195 L (51.52 US gal.)

140 L (37.0 US gal.)

Brake fluid

DP150NM1 DP150NM1S

223 L (58.9 US gal.)

168 L (44.4 US gal.)

200 cc (12.2 cu. in.)

Battery electrolyte specific gravity, corrected to 20°C (68°F)

1.280 TO 1.260

 Capacities and Lift Truck Weight (Standard Models) Truck model Item

DP100NM1 DP100NM1S

DP120NM1 DP120NM1S

DP135NM1 DP135NM1S

DP150NM1 DP150NM1S

Capacity, kg (lb)/600 mm (24 in.)

10000 (22000)

12000 (26500)

13500 (30000)

15000 (33000)

Lift truck weight kg (lb)

14590 (32137)

15830 (34868)

17470 (38480)

17930 (39493)

12-5

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 provide 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 Contact 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

TO THE CAT LIFT TRUCK OWNER

 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 WARNI NG MODEL

ＩＭＰＲＯＰＥＲ ＯＰＥＲＡＴＩＯＮ ＯＲ ＭＡＩＮＴＥＮＡＮＣＥ ＣＯＵＬＤ ＲＥＳＵＬＴ ＩＮ ＩＮＪＵＲＹ ＯＲ ＤＥＡＴＨ

ＳＥＲＩＡＬ Ｎｏ．

ＡＵＴＨＯＲＩＺＥＤ ＢＹ ＴＨＥ ＭＡＮＵＦＡＣＴＵＲＥＲ． ＭＡＳＴ：ＶＥＲＴＩＣＡＬ

Ｂ A

A MM

B MM

FORKSONLY KG

ATTACH KG

B

AT CH/ MODE L ＥＮＧＬＩＳＨ ９２Ｇ８１−０５５００

3 SEAIAL No.

DATE MODEL

TRUCK WEIGHT

TIRE PRESSURE FR/RE

FRONT TIRE SIZE REAR TIRE SIZE MAX REARWARD MAST TILT

kg

/ deg.

LOAD TIRE TREAD WIDTH

mm

2-1-1, HIGASHIKOTARI, NAGAOKAKYO-SHI, KYOTO, JAPAN ENGLISH 91C8104400

E01258

1.

2.

13-2

Capacity Plate Engine Serial Number

3.

Manufacturer Name Plate

TO THE CAT LIFT TRUCK OWNER

 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