Caterpillar Dp45k Manual de Operacion
Caterpillar Dp45k Manual de Operacion
Caterpillar Dp45k Manual de Operacion
99730-85141
100588A
i i
HOW TO USE THIS MANUAL
The following safety signs and NOTICE are used in this manual to
emphasize important and critical instructions.
Be sure to read these precautionary
This is the safety alert symbol. It is used to alert you to instructions and all safety related
! potential personal injury hazards. Obey all safety messages decals installed on your truck
that follow this symbol to avoid possible injury or death. before you operate it.
Indicates a imminently hazardous situation
! DANGER which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation
! WARNING which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
! CAUTION moderate injury, or damage to your machine.
REFUELING
TRANSPORTATION HINTS
Lift Truck Shipping79 Machine Lifting and Tiedown Information79
SPECIAL SITUATIONS
Care in Cold Weather80 Care in Severe Dust or Lint Conditions81
Care in Hot Weather81
TROUBLESHOOTING
Changing a Tire....................................................................................82 Powershift Transmission Oil Temperature Warning Light Glows........91
Stalled Engine......................................................................................90 Driving Interlock Indicator Light Flickers or Flashes,
Engine Coolant Temperature Gauge Needle and the Truck Stops Moving.............................................................92
Moves Into Red Zone........................................................................91 Trouble with the LP-Gas Equipment....................................................93
MAINTENANCE Every 200 Service Hours or Monthly, Whichever Comes First 117
General.................................................................................................94 Every 400 Service Hours or 2 Months, Whichever Comes First........124
Inspection Precautions..........................................................................95 Every 600 Service Hours or 3 Months, Whichever Comes First........127
Maintenance Schedule..........................................................................96 Every 1200 Service Hours or 6 Months, Whichever Comes First......128
Every 10 Service Hours or Daily (Pre-start), Whichever Comes First.......99 Every 2400 Service Hours or 1 Year, Whichever Comes First...........136
Every 50 Service Hours or Weekly, Whichever Comes First.............114 Parts to be Changed Periodically........................................................137
One Month After Delivery of a New Truck........................................116
SERVICE DATA
Fuel Information.................................................................................138
Coolant Information...........................................................................140 Specifications and Refill Capacities (Standard Models).....................145
Recommended Fuels and Oils............................................................142 Capacity and Truck Weight (Standard Models)..................................146
INDEX
Index151
|||||||||||||||||||||||||||||||| SAFETY RULES FOR LIFT TRUCK OPERATORS |||||||||||||||||||||||||||||
◆ In General
The safety rules and regulations in this section Continuing improvement and advancement of
are representative of some, but not all rules product design may have caused changes to
and regulations that apply to lift trucks. Rules your lift truck which are not included in this
are paraphrased without representation they publication. Whenever a question arises
have been reproduced verbatim. regarding your lift truck, or this publication,
Your lift truck was manufactured in accor- please consult your Cat lift truck dealer for the
dance with the National Fire Protection latest available information.
Association (NFPA) No. 505 and the All lift truck users should be familiar with
American National Standards Institute, their Local, Regional, and National
Inc./Industrial Truck Standards Development regulations.
Foundation (ANSI/ITSDF) B56.1, Safety
United States users should be familiar with the
Standard for Low and High Lift Trucks.
Occupational Safety and Health Administration
Operate this lift truck in accordance with local
(OSHA), and American National Standards
regulations. See www.ITSDF.org web site for
Industrial Forklift Trucks.
more information on the B56.1 Safety
Standard for Low and High Lift Trucks. You should also be familiar with areas of use
of different types of lift trucks as specified in
The most effective way of preventing serious
the National Fire Protection Association
injuries, or even death, to you and others, is
(NFPA).
for you to know how to operate the truck
properly. Drive alertly and avoid maneuvers
or condi- tions that can cause accidents. Be
professional.
Do not operate a lift truck if it is in need of
maintenance, repair or appears to be unsafe in
any way. Report all unsafe conditions
immedi- ately to your supervisor and contact
your authorized Cat lift truck dealer. Do not
attempt any adjustments or repairs unless you
are trained and authorized to do so.
1 1
SAFETY RULES FOR LIFT TRUCK OPERATORS
◆ Warning Decals, Location
There are several specific warning decals on Be sure you can read all warning and instruc- You must replace a decal if it is damaged,
your lift truck. Their exact location and tion decals. If you cannot, clean or replace missing or cannot be read. If a decal is on a
description of the potential hazard are them. Use a cloth and soap and water to clean part that is replaced, make sure a new decal is
reviewed in this section. Please take the time them. placed on the new part. Contact your Cat lift
to familiar- ize yourself with these decals. truck dealer for new decals.
Inspection/Lubrication
Hoist Point decal chart
Operator Restraint
System decal
Precautions
for Handling
E.C.U. decal
Radiator Cap
(Inside of Right Step) Warning decal
No Access with
Engine Running
No One Under
decal
Forks decal
No One On
Forks decal
Engine Coolant
No One decal
Between Mast
and Body
decal
Parking Brake
Adjustment decal
Fuel decal
105363
No Riders decal
Impact Test
Rating decal
Capacity decal
With Backrest
Extension decal Requirement Tires Authorized
Direction Lever
decal
3 10
◆ Decals for LP-Gas Only
Fuel decal
Location decal L.P.G.
decal
Maintenance decal
! WARNING ! WARNING
ant level only after the engine has been stopped
Operation and the
without filler
this cap in
device is place
cool enough
may beto touch with
hazardous. your
This hands. guard conforms to ANSI/ITSDF B56.1. This design also passed a v
overhead
er cap slowly to relieve pressure.
103937 102513
Located on the radiator cap. Located inside the top frame member of the overhead guard.
• Back-up Buzzer
! WARNING ! WARNING
To avoid serious injury, stay clear of the moving fan. The Back-up Buzzer must sound when operating this vehicle in reverse.
103936 103964
Located on the frame of the cooling fan. Located inside the front frame member of the overhead guard.
• No One Under/On Forks • Load Backrest Extension • Pinch Point
104757
77 / A 66 11 + 0 // 55 0 0
105180 105181
• Tipover Warnings
! WARNING
TIPOVER WARNINGS actions may exceed the stability or the
! DANGER
1. Side tipover of an unloaded truck can truck.
4. Serious injury or death can occur if the
r can occur if truck is improperly operated. Injury or death could result.occur if the combination of speed and a
sharp turn which exceeds the stability of operator is trapped between the truck and
the truck. the ground.
2. Side tipover can occur if overloaded, or
loaded within capacity and: IN CASE OF TIPOVER
– The load is elevated. 1. The operator should stay with the truck if
– Turning and/or braking when traveling side or forward tipover occurs. The
in reverse. operator should hold on firmly to the
– Turning and/or accelerating when travel- steering wheel, brace feet, lean forward
ing forward. and lean away from the point of impact.
These actions may exceed the stability of 2. If the truck falls off of a loading dock or
the truck. ramp, you should try to stay within the
Backward tilt and/or off-center positioning of con- fines of the operator’s seat area.
the load and/or uneven ground conditions will Should the landing area present a more
further aggravate the above conditions. severe hazard, you may find it prudent to
3. Forward tipover can occur if overloaded or leave the truck.
when loaded within capacity and the load
is elevated in forward tilt, braking in
102514A forward travel, or commencing reverse
Located inside the top frame member of the travel. These
overhead guard.
102514B
103267A
Located inside the front frame member of the
Located inside the top frame member of the
overhead guard.
overhead guard.
◆ Safety Rules
100870 100605
Authorized, trained operator only! Be alert!
Thoroughly learn how to operate a lift truck Know how to use a first aid kit and a fire
and the safe areas and surfaces to travel before extin- guisher—and where to get prompt
you drive one. assistance.
! WARNING
! WARNING
100604
101003
DO NOT travel on public roads! Dress properly for the job! 100989
ECM
(Controller for engine)
201317A 103926
LP-gas tank replacement! For handling frequency transducer, ECU
LP-gases are flammable. Do not attempt to and ECM!
change LP-gas tanks unless you are trained 1. Do not directly expose these equipment to
and authorized to do so. Be sure to get a washing water, rain, oil and every other
trained and qualified mechanic to change liq- uid.
them. 2. Do not apply force, open, modify these
equipment nor operate the truck without
! WARNING these equipment.
3. Turn key switch OFF. Disconnect battery
cable and then disconnect these equipment
before following operations:
• Removing these equipment from truck
• Factory approved welding
103907
101115C
Always check overhead clearance! Use lights in dark, dim areas! Stay within the confines of the truck!
Serious accidents may be caused by the mast Even with lights on, DO NOT assume people Keep your arms and legs inside the operator’s
and overhead guard hitting pipes, beams or see you and will move out of your way. compartment.
other overhead obstructions. Watch out for
power lines.
! WARNING ! WARNING ! WARNING
101015 100626
DO NOT allow any riders! If you cannot see where you are going, DO
DO NOT allow anyone to ride on the forks or NOT MOVE!
on any other part of the lift truck—at any time. Travel slowly around corners. Sound the horn
at cross aisles and other areas where you can-
not see clearly or where visibility is restricted.
! WARNING ! WARNING ! WARNING
DO NOT pass another truck! DO NOT allow anyone to hold loads! Always look in the direction of travel!
DO NOT pass another lift truck traveling in Always be aware of people near your lift truck.
the same direction at intersections, blind spots DO NOT proceed until they are aware of you.
or at other dangerous areas.
Start lift truck upgrade carefully! DO NOT turn on a ramp or grade! Move your lift truck safely!
When starting the lift truck upgrade, be sure to Turning on a ramp or grade can cause a lift Sound the horn and be sure no people or
use the parking brake. truck, loaded or unloaded, to tip over. objects are in your path before moving.
! WARNING ! WARNING ! WARNING
Allow for counterweight swing distance! A helper should NOT be near the lift truck! Always be alert for tipovers!
When turning in aisles, especially narrow People should be clear of the lift truck operat- Turning sharply with a raised load, even at a
aisles keep as far away as possible from ing area. slow speed, may result in a tipover. Realize
stock and that the overhead guard is not designed to
racks. Be cautious near people. provide total protection in the event of a
tipover.
◆ Working Precautions
! WARNING ! WARNING
101031 100924
Danger! Keep out! Be careful of changes in capacity!
DO NOT allow any unauthorized people in the Optional attachments which change the capac-
work area. ity are sometimes installed. Know the capacity
before operating the truck.
! WARNING ! WARNING
101034 100648
! WARNING
101615
Use forks properly! DO NOT allow anyone to walk or stand DO NOT speed when approaching loads! Bring
Fork misuse could cause accidents, serious under raised forks! truck to a full stop in front of a load, then approach
injuries and equipment damage. carefully.
101041
! WARNING ! WARNING ! WARNING
100992
102527B 100658A
101044
Only trained, authorized personnel should fill All defective or damaged LP-Gas tanks must The storage and handling of liquid fuels in the
or exchange LP-Gas tanks. be removed from service. U.S.A. should be in accordance with the
Personnel engaged in filling LP-Gas tanks Inspect the LP-Gas fuel lines and fittings with NFPA No. 30, “Flammable and Combustion
should wear protective clothing such as a face a soap solution after filling the tank or when Code.” Outside the U.S.A., store and handle in
shield, long sleeves and gauntlet gloves. looking for leaks. accor- dance with local regulations.
Do not refuel or store LP-Gas powered lift The lift truck should be refueled only at desig-
trucks near underground entrances, elevator nated safe locations. Safe outdoor locations
shafts, or other places where LP-Gas could are preferable to those indoors.
col- lect in a pocket and cause potential danger DO NOT completely fill the tank. The fuel
for an explosion. expands when it gets warm and it may over-
Do not leave the lift truck, for even a short flow. This will create a fire hazard.
time, near equipment that generates high Only trained, authorized personnel should fill
tempera- tures. Ovens and furnaces are or exchange LP-Gas tanks.
examples. The heat may raise the pressure of Do not drop, throw, roll or drag LP-gas tanks.
the fuel and open the relief valve. Do not strike LP-Gas tanks or any associated
Close the service valve on the tank when LP- parts of the tanks or fuel systems.
Gas fueled lift trucks are parked overnight or Check the LP-Gas tank for secure mounting.
stored for long periods indoors with the fuel 100717A
Loose tanks can cause pressure fuel lines to
tank in place. The careless handling of LP-Gas tanks can
leak resulting in serious injury.
result in a serious accident. To reduce the risk
Close the valves on empty tanks.
of damage to tanks, use extreme care when
Examine LP-Gas tanks before filling and transporting them.
before reuse. Look for damage to the valve,
liq- uid gauge, fittings and hand wheels.
Check for dents, scrapes or other damage to
the pressure vessel and for dirt or debris in the
openings.
||||||||||||||||||||||||||||||||||||||||||||||||| KNOW YOUR LIFT TRUCK |||||||||||||||||||||||||||||||||||||||||||||||
◆ Serial Number and Capacity Plate
Capacity Plate
For quick reference, record your lift truck’s serial numbers in the spaces provided.
UL Plate
UL Plate 103963
103256
103916
UL Plate
UL Plate 103963
103256
103916
102993
KNOW YOUR LIFT TRUCK
◆ Model View
Overhead Guard
Head Light
Counterweight
Lift Chain
Instrument Panel
Operator’s Seat Belt
Lift Cylinder
Fuel tank
Backrest Extension
Rear Wheel
Fork
Engine Hood
l and
Tai Sto p Light
Tur Bac
n Signal Light
Tilt Cylinder
103193 kup Light
Front Wheel
103255
Parking brake lever Horn switch Turn signal switch (optional) Left turn
Release Push to sound horn
d with a neutral switch. Be sure to put the transmission in NEUTRAL when starting the engine.
ht) Apply
Right turn
101363 102592 100311
Neutral (N)
Attachment control levers
Reverse (R) 101619A
ECU
103259
Brake applied
100037
100038 100039
28 28
KNOW YOUR LIFT TRUCK
Lower
Steering tilt lever
Forward
Unlock
Raise
Backward
Lock
29 103259 29
KNOW YOUR LIFT TRUCK
engine. The mast will not tilt forward even if the
The lever will return to the NEUTRAL posi- tion when released.
! WARNING
Always adjust the steering wheel tilt angle while stopped at a safe place, as adjustment while driving could lead to accidents.
The mast descends downward if the lift co
29 103259 29
KNOW YOUR LIFT TRUCK
◆ Instrument Panel
Engine coolant temperature gauge Hourmeter Fuel gauge
0.1 hour
(6 minutes)
Empty (red)
Full
Normal (white)
Overheat (red)
Normal (white)
104788
102792
1 hour 102386Engine
The gauge needle is normally in the white zone. IfStarts
the needle
registering
movesthe
into
operating
the red zone,
hoursset
of the
the engine
topic. when the
coolant
key switch
temperature
Indicates
is turned
gauge
the l (ON)
to amount
theneedle
ofmoves
position.
fuel in into
thePeriodic
tank
red zone.
when
maint
OK monitor
When any warning light (except glow plug indicator light) glows during operation, stop the truck and take corrective action.
1
T
30 32
ulb check
Anti-restart starter switch and key
warning lights should glow when the key switch is turned to the l (ON) position.
go out when the engine is started; if not, the charging system has a defect.
s model)
103524
Powershift transmission Air cleaner warning Alternator not LP-Gas residual pressure alarm
oil temperature warning light (optional) charging warning light light (optional)
light (optional) Glows when the air cleaner ele- Glows when the charging system Lights when the residual quantity
Glows when the oil temperature ment is clogged. If the light is out of operation. If the light becomes small.
is high and the danger of glows, clean or replace the glows, check the alternator drive
overheat- ing is present. element. belt for slippage or breakage.
If this light glows, see the topic,
Powershift transmission oil
tem- perature warning light
glows.
104131
This switch is built in the seat.
KNOW YOUR LIFT TRUCK
• Neutral System
The lift truck is provided with a device that
pre- vents the engine from being started when
the direction lever is not in the neutral
position.
104016
! CAUTION
34 34
KNOW YOUR LIFT TRUCK
◆ Operator’s Seat
• Adjustment
• How to tip the seat forward
! WARNING
100974A
! WARNING
Plate
domen, the belt will dig into your abdomen in an accident and could cause serious internal injuries.
Buckle
100981 100983
1. Grip the plate (connector) of the belt and Push the button in the buckle to release the
pull the belt from the retractor. Then insert belt. The belt will automatically retract when
NOTICE: It is not necessary to adjust the belt the plate into the slot of the buckle until a released. Hold the plate of the belt and allow
length. snap is heard. the belt to slowly retract.
The belt is designed to fit any body 2. Make sure the belt is not twisted.
size.
Tug on it to confirm a tight fit.
100982A
3. Be sure to fasten the belt as low as
possible across your hips, not across your
abdomen.
IMPORTANT
The following maintenance guidelines detail how to inspect seat belt for "cuts, fraying, extreme or unusual wear of the webbing, etc., and damage to the buckle, retract
Check the web wear at the buckle/latch area. The webbing must be closely examined to deter- mine if there are any cuts, fraying or extreme wear in the webbing. Cuts,
Check buckle and latch for proper operation and to determine if latch plate is worn, deformed, or buckle is damaged or casing broken.
The retractor web storage device, is mounted on the seat. The retractor is the heart of the occu- pant restraint system and can be damaged if abused, even unintention
Hardware for seat belt mounting points should be evaluated for corrosion, all attachment points of system should be checked for tightness of bolts and nuts.
Check web in areas exposed to ultraviolet rays from the sun or extreme dust or dirt. If the origi- nal color of the web in these areas is extremely faded, the physical stren
! CAUTION
h fuses of the correct amperage.
ately and you cannot locate the cause, have your Cat lift truck dealer make a circuit check.
bulb of the same wattage.
• Lights Won’t Come On
Check for burned-out or “blown-out” Lamp type Gasoline Diesel
fuses first. models (12V) models (24V)
Meter panel lamp 3W (14V) 3W (28V)
Tail/Stop lamp 8W/23W 10W/25W
Headlamp 45W 60W
Check the fuses one by one by Turn signal lamp 27W 25W
operating the light switch and seeing if Back-up lamp 10W 12W
each light comes on.
Working lamp (opt) 45W 60W
Lights are suspected
Gasoline models Diesel models ABCD to have burned out.
Code Capa Capa EFGH
city Circuit city Circuit J
! WARNING
e fork spread, be care- ful not to pinch your hand between forks and lift bracket.
installation/removal truck.
notch on the bottom
car- riage bar. Tilt
the carriage
forward, then lower ! WARNING
it until the hook
fork disengages the DO NOT try to move a fork without a lift- ing device. Each fork can weigh in exces
forks from the
carriage. Use a
lifting device to
move the forks
away from the ◆ Safety Equipment
100864A
Open
Close
103196 103938
! CAUTION
Confirm the engine type before filling the tank with the recommended fuel.
The oil level/filler hole is located on the right The fuel shut-off valve is located near the air
side of the truck inside the engine hood. To cleaner inside the engine hood. In an emer-
check the oil level, use the dipstick located in gency or when performing maintenance, close
the hole. this valve.
◆ Fuel Filler
! WARNING ! WARNING
100989 102538
103197
The fuel filler is located on the left side of the Never fill the tank near an open flame or when After refueling, close the cap tightly and wipe
truck. The cap can be removed by turning it the engine is running. When filling, keep the up spillage.
counterclockwise. funnel or fuel hose nozzle in contact with the
tank’s metal. This reduces the risk of an
electric spark igniting the fuel.
◆ Engine Hood
◆ Back-up Buzzer
! WARNING
When closing the engine hood, be careful not to pinch your hand.
! WARNING
–
When operating in reverse, ALARM MUST SOUND.
Failure to maintain a clear view in the direction of travel could result in in
–
The operator is responsible for the
safe operation of this truck.
102539 –
The engine hood swings up to fully expose the
engine compartment 100328
for daily inspection, serv-
Lever
icing and lubrication.
To close
CG
Counterbalanced lift truck design is based on CG is defined as the point of an object where The stability of the lift truck is determined by
the balance of two weights on opposite sides its weight is evenly distributed. If the object is the location of its CG, or if the truck is loaded,
of a fulcrum (the front axle). The load on the uni- form, its geometric center will be the the combined CG. The lift truck has moving
forks must be balanced by the weight of the same as its CG. If it is not uniform, the CG parts and, therefore, has a CG that moves. The
lift truck. The location of the center of gravity could be a point on either side of the normal CG moves forward or backward as the mast is
of both the truck and the load is also a factor. geometric center. When the lift truck picks up tilted forward or backward. The CG moves up
This basic principle is used for picking up a a load, the truck and load have a new, or down as the mast moves up or down. The
load. The abil- ity of the lift truck to handle a combined CG. CG and, therefore, the stability of the loaded
load is discussed in terms of center of gravity lift truck, is affected by a number of factors
and both forward and sideways stabilities. such as:
– The size, weight, shape and position of the
load.
– The height of the lifted load.
– The amount of forward or backward tilt.
– Dynamic forces created when the lift truck
is accelerated, braked or turned.
– Condition and grade of surfaces on which
the lift truck is operated.
– Tire pressure.
47 44
HOW TO AVOID A TIPOVER; HOW TO SURVIVE
ONE ◆ Lift Truck Stability ◆ Capacity
Base (Weight and Load Center)
100860
100676
49 45
◆ Capacity Chart
• For example
103446 103447
The capacity chart shown above is for a 4 ton
! CAUTION model standard lift truck whose capacity is
4000without
d to lift trucks sold by MCFA shall not be removed, altered or replaced kg (9000 pounds)
MCFA’s at 600 mm (24 in.)
approval.
load center. The chart specifies this lift truck
y for lift trucks placed in service without a valid MCFA capacity chart.
can lift up to 4000 kg (9000 pounds) if the
ecifica- tion, contact your Cat lift truck dealer.
load center is not more than 600 mm (24 in.)
forward from the face of the backrest. Before
attempting to pick up or lift a load, make sure
its weight is within the capacity of the truck at
the load cen- ter involved.
NOTICE: If the load is not uniform, the heav-
iest portion should be placed closer
to the backrest and centered on the
forks.
◆ Do’s and Don'ts to Avoid Tipover
DO NOT tilt elevated loads forward! DO NOT elevate tilted loads! DO NOT pick up an off-center load!
This can cause the lift truck to tip over This can also cause the lift truck to tip over. Such a load increases the possibility of a
forward. tipover to the side.
! WARNING ! WARNING
! WARNING
100671 100999
100998
DO NOT attempt to pick up or deposit a DO NOT go over obstacles—curbs, ditches,
DO avoid slippery surfaces! load unless the lift truck is level! ridges and railroad tracks!
Sand, gravel, ice or mud can cause a tipover. If
unavoidable, slow down.
! WARNING ! WARNING ! WARNING
! DANGER
th your seat belt fastened in a tipover are better if you stay in your truck. If your truck starts to tipover:
(1) (2)
(3) (4)
(5)
101002 101524
||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| REFUELING ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ Gasoline and Diesel Engine Equipped
55 51
REFUELING
◆ LP-Gas Equipment
56 52
6. Inspect the replacement tank for damage 10. Connect the fuel supply line.
! WARNING
such as dents, scrapes or gouges and for 11. Turn the fuel valve on by slowly turning it
LP-Gas tank must not extend past the counterweight. leakage at valves or threaded connections. counterclockwise. If the fuel valve is
7. Check for debris in the relief valve and for opened too quickly, a back pressure check
damage to various valves and the liquid valve will shut off the fuel supply. If this
5. Check to be sure the replacement tank is level gauge. happens, close the fuel valve completely,
of the correct type. 8. Inspect the couplings for deterioration, wait five seconds, and then open the fuel
damage or missing flexible seals. valve very slowly.
LOCATION 9. Clamp the tank securely.
33-1/2# tank (A) Use pin (B)
43-1/2# tank (B) Use pin (A)
BA
BA
100717A
12. Inspect the LP-Gas fuel lines and fittings
with a soap solution after filling the tank
101618 or when looking for leaks.
||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||| OPERATION ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ New Lift Truck Break-In ◆ Before Starting Engine
! CAUTION
If during operation the truck becomes unsafe in any way, the matter shall be reported immediately to the designated authority, and the truck shall not be operated unti
58 54
! CAUTION
Before starting the engine, sit properly in the operator’s seat.
OPERATION
! CAUTION
If this truck will be operated with LP-Gas for a long time, check gasoline fuel line in accordance with STORING
104576
Your truck has an operator presence switch (a
switch built in the seat).
The starting mechanism in vehicles with pow-
ershift transmission is disabled until the opera-
tor is seated.
When the key switch is in I (ON) position,
driv- ing interlock indicator light in the switch
box on the overhead guard flickers unless an
opera- tor sits on the seat properly.
59 55
Released Lock
Applied
Neutral
101363
101623A
– Pull the parking brake lever. – Be sure the lock knob is in the LOCK
posi- tion and the direction lever is in the
NEU- TRAL position.
– The engine will not start unless the direc-
tion lever is in the NEUTRAL position.
– If the engine stalls, place the direction
lever in the NEUTRAL position; turn the
key switch to the (OFF) position; and
turn it to the (START) position to
start the engine.
! CAUTION
Turn the key switch to (OFF)
on when the engine is NOT run- ning. This may cause the battery tothe
run down and damage
(START) posi- the ignition coil.
(START)
0 seconds at any one time. This may cause run down the battery. tion to crank the
engine (no more than
10 seconds at a time).
100724
Release the key when the engine starts. Turn the key switch to (OFF)
(START)
the and (OFF) position
recrank the
engine after 30 sec- onds.
100725 100728A
! CAUTION
(OFF)
Turn the key switch
l (ON) position when the engine is NOT run- ning. This may cause the battery to run down.
more than 10 seconds at any one time. This may cause damage to theto the l (ON)
starter Youposition
and do not
run need to lturn
down.
(ON)
the key switch to the l (ON) position and preheat the engine or depress the
and wait until the
heater plug indicator
goes out.
100731
ON (12 to 18 seconds) OFF 102071A
Depress the acceler- ator pedal all the way and hold in this position.
If the engine won’t start:
100725
◆ Engine Won’t Start
Consult your Cat lift truck dealer if the engine still does not start after you have
Does the starter crank the engine?
attempted several times.
(OFF)
(START)
Air may be in the fuel system to
101055A
cause failure to start. In such a
case, prime the fuel system or
have your Cat lift truck dealer No Yes
make a check.
rn the key switch to the (START) position and crank the
The head lights The head lights do Is the fuel gauge
come ON. not come ON or are showing there is
engine several times. dimmed. fuel in the tank?
100724
NOTICE: The head lights should be Yes
OFF for easier starting.
100735
! WARNING
Batteries give off flammable vapors which may explode.
To start a truck with a “run-down” battery, use
Keep flames and sparks away from bat- teries. They could cause vapors to explode. Do not allow jumper cable aends to contact
booster batteryeach other orcables
or jumper the liftfrom
truck.the
Do not smoke when checking battery electrolyte levels. bat- tery of another vehicle.
Electrolyte is an acid and can cause injury if it contacts skin or eyes.
1. Position another vehicle, with its engine
Always wear eye protection when starting a lift truck with jumper cables.
running, within jumper cable distance.
Improper jump start procedures can cause an explosion that can result in injuries.
Turn off all lights and accessories on the stalled lift truck.
Always connect battery positive (+) to battery positive (+) and battery negative (–) to battery negative (–). NOTICE: Use a 12 volt jumper system to
Jump only with a battery source of the same voltage as the stalled lift truck. jump start trucks with a 12 volt
sys- tem. Use a 24 volt jumper
system to jump start the trucks
! CAUTION with a 24 volt system.
This lift truck has a 12 volt starting system or
Connect the jumper cables away from the moving parts in the engine compartment.
a 24 volt starting system. Use only equal
voltage for jump starting. Use of a welder or
higher volt- age will damage the electrical
system.
12 Volt System Turn on (close) the battery switch prior to the
boost connection to prevent damage to electri-
➃ cal components on the stalled lift truck.
➂ Many “dead” batteries can be recharged.
Truck being started
2. Connect the jumper cables in the sequence
shown.
DO NOT short across the positive (+) and
➁ ➀ negative (–) terminals.
“Good” Battery
100842 3. After connecting the cables, increase the
speed of the other vehicle’s engine and
24 Volt System
start the engine of the stalled truck with a
➃ “run-down” battery.
➂ 4. After the engine starts, disconnect the
Truck being started
jumper cables in the reverse sequence.
Check the OK monitor and gauges frequently 2. During warm-up, check to see that systems
! WARNING
during operation to be sure all systems are are operating properly.
working properly.
LP-Gas fuel is flammable and can cause injuries and fires.
Inspect LP-Gas fuel lines and fittings for leaks. – Are all the OK monitor warning lights
Inspect tank for secure mounting. ! WARNING OFF?
– Is the engine coolant gauge needle in
the WHITE
If a monitor light comes on, correct the problem before operating thezone?
lift truck.
– Are exhaust noise and smoke color nor-
mal?
– No excessive vibration?
1. Run the engine at idle speeds with no load
! CAUTION for about 5 minutes.
osition when the engine is NOT running. This may cause the battery to run down and damage the ignition coil.
seconds at any one time. This may damage the starter and run down the battery. ! CAUTION
! WARNING
102473A 101013
1. Turn the 1st speed mode/automatic mode to 8 in.) from the floor.
selector switch to the desired position. 3. Use the tilt control lever to tilt the mast back all the way.
– Selector switch: For 5 ton model as stan-
dard and others as optional.
101056A
2. Use the lift control lever to raise the forks
to a safe traveling height of 15 to 20 cm (6
L ound the horn before moving.
o
o
k
a
r
o
u
n
d
a
n
d
b
e
h
i
n
d
t
h
e
t
r
u
c
k
a
n
d
s
◆ Lift Truck Operation
Unlock
Forward
Reverse
100738B 101622A
1. Depress the inching pedal all the 2. Place the lock knob in the 3. Push the parking brake lever. 4. Gradually depress the accelerator
way. UNLOCK position and move the pedal while releasing the inching
direction lever to the pedal.
FORWARD or REVERSE travel
position.
! CAUTION
DO NOT “ride” the inching pedal during traveling. This produces a partly disengaged
• Changing Speed • Changing Direction
! WARNING ! WARNING
! CAUTION
Before operating the speed selec- tor, BE SURE to come to a com- plete stop.
!
Directional changes faster than stated will cause premature dam- age to the driveline. For greater operator safety and maximu
• Operating Techniques • Steering (Turning)
! WARNING ! WARNING
! WARNING
101067 101068
101066
Turning at high speeds, with or without a load, Be aware of tail swing distance. Be sure the
Turning with the forks elevated, with or with- can also cause a tipover. tail swing area is clear, before turning, to avoid
out a load, can cause a tipover. injury to pedestrians.
• Inching
100747 100748A
The purpose of the inching pedal is to provide 1. Stop ahead of the load platform, lock the 4. When the left foot is slowly taken off the
precise lift truck inching control at very slow parking brake lever, set the direction lever inching pedal, the fork lift will advance
100749A
travel speed and high engine rpm. You can to NEUTRAL, place the mast vertically, slowly.
move your truck slowly while maintaining the and raise the fork to the height of the pallet 5. Insert the fork slowly, taking care it does
engine speed by varying the position of the insertion openings. not hit the pallet.
inching pedal. Use this pedal when approach- 2. Depress the inching pedal all the way, 6. Stop after inserting the fork until the root
ing the load and when loading and unloading. move the direction lever to FORWARD, of the fork comes into light contact with
and release the parking brake. the pallet.
3. Gently depress the accelerator pedal.
! CAUTION
DO NOT “ride” the inching pedal during traveling. This produces a partly disengaged condition that will result in premature clutch plate wear.
◆ Stopping Lift Truck
Lock
! WARNING
Neutral
101623A 101070
1. Release the accelerator pedal. 2. Depress the brake pedal. 3. Move the direction lever to the Avoid sudden stops. This can cause
NEUTRAL position, and place the load to fall off the forks or the
the lock knob in the LOCK posi- truck to tip over.
tion.
◆ Parking Lift Truck (After Stopping)
Lock
(OFF)
l (ON)
Neutral
100885A
1. Move the direction lever to the 2. Pull the parking brake lever all 3. Tilt the mast forward just a little 4. Turn the key switch back to the
NEUTRAL101623A
position, and place the way. and lower the forks to the floor (OFF) position to stop the
the lock knob in the LOCK posi- until the fork tips touch the floor. engine. When leaving the truck,
tion. BE SURE to remove the key.
5. Block th wheels securely.
6. Return the key to a key rack if
! WARNING
specified.
Park safely
lowered to the floor, attach a warning tag to the tip of the fork and position the forks away from pedes- trians.
Stability of the loads depends upon how well the stack is formed.
• Stacking Loads Differing in Size • Stacking Small Identical Loads • Stacking Large Identical Loads
74 69
OPERATING TECHNIQUES
◆ Handling Loads Safely
100856
Not every load can be handled using only the
forks. Some loads will require a special attach-
ment.
75 70
OPERATING TECHNIQUES
◆ Inching into and Lifting the Load
(8 to 12 in.) 20 to 30 cm
10 cm
(4 in.)
! WARNING ! WARNING
101080 100869
76 71
OPERATING TECHNIQUES
◆ Inching into and Lifting the Load
! WARNING
100648
When you pick up loads that extend Center the weight of the load Avoid approaching the load at high
above the backrest extension height, between the forks. speed.
band them together to reduce the risk
of items from falling.
77 71
OPERATING TECHNIQUES
◆ Traveling with the Load
20 to 30 cm
(8 to 12 in.)
15 to 20 cm (6 to 8 in.)
101081 101083
1. Make sure the load is centered Direction lever—REVERSE Direction lever—NEUTRAL Direction lever—FORWARD
on the forks. Then tilt the mast
2. Look behind101082
you. 3. Slowly move the truck 20 to 30 4. Look around 101084
to be sure your
all the way back to cradle the
cm (8 to 12 in.) away from the drive area is clear and then move
load.
stack, then stop the truck. the truck into the working zone.
Lower the load to a position 15 to
20 cm (6 to 8 in.) from the
ground.
! WARNING ! WARNING
101525 100670
78 72
OPERATING TECHNIQUES
! WARNING
101021
Slack lift chains means there is a rail DON’T pick up an off-center load. If the load blocks your view, or when
or lift bracket hang up. Raise the Make sure the weight of the load is you travel down a grade with the
mast before you move. centered between the forks. load, drive in reverse. Always look in
When stacking: the direction of travel.
1. Watch your lift chains.
2. If they go slack, stop; raise the
load and lower it again.
79 72
OPERATING TECHNIQUES
◆ Unloading
20 to 30 cm
(8 to 12 in.)
10 to 15 cm
(4 to 6 in.)
101085 101086
1. Stop the truck 20 to 30 cm (8 to Direction lever—NEUTRAL Direction lever—FORWARD Direction lever—NEUTRAL
12 in.) short of the unloading
2. Lift the load 10 to 15 cm (4 to 6 3. Slowly move the truck forward 4. Tilt the mast forward to the verti-
zone.
in.) higher than the stack. to position the load just above cal position.
the stack.
80 73
101089 101091 101092
5. Carefully lower the load onto the Direction lever—REVERSE 8. When you disengage the forks, 10. Tilt the mast back (6° or more).
stack. stop the truck. Direction lever—REVERSE
7. Look behind you and carefully
6. Lower the forks just enough to Direction lever—NEUTRAL
back the truck away from the 11. Look around to see that it is safe
disengage them.
load. 9. Lower the forks to a position 15 to drive in your work area.
to 20 cm (6 to 8 in.) from the 12. Drive up to your next position.
ground.
! WARNING ! WARNING
EVER 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.
EVER tilt the mast with the load in the elevated position.
EVER leave the lift truck with the load in the elevated position.
101093
6° Tilt back
101071
101026 101074
Travel forward up a grade and in reverse down
a grade when the truck is loaded.
! CAUTION
brake pedal when you have to bring the truck to a stop on a grade. DO NOT hold the truck by depressing the accelerator pedal. This can cause clutch plate wear or torque conv
! WARNING
use the brake pedal only. This can result in brake failure and an accident.
g pedal when traveling down a grade. This pre- vents the engine from acting as a brake.
83 76
OPERATING TECHNIQUES
1. Park the truck in an authorized area. If your lift truck is to be put in storage for any • Hydraulic System
2. Block the wheels securely. length of time, take the following precautions After positioning your truck for storage, retract all
3. Check under the truck for oil or coolant for safety and to reduce the risk of the hydraulic cylinders to minimize rod exposure.
leaks. deterioration of truck components. This will reduce the risk of rusting of the sliding
4. Clean or wash the truck to keep it free of contact surfaces of the rods.
dirt and oil. This will make it easier to spot • Fuel System To prevent rusting of the cylinder interior and
loose or defective parts. – Gasoline engine trucks rods, and deterioration of the seals, periodically
Gasoline evaporates, leaving a sticky gum operate each cylinder for lift, tilt and the attach-
ment to full stroke.
! CAUTION
to rainwater. Take care not to sprinkle water over ECU box when washing your machine.
85 78
||||||||||||||||||||||||||||||||||||||||||||||||| STORING THE LIFT TRUCK ||||||||||||||||||||||||||||||||||||||||||||||
• Engine Cylinders
Over a long storage period, the cylinders
may rust from moisture condensation
within the cylinders. To reduce the risk of
rusting of cylin- der walls, remove the
spark plugs and squirt a small amount of
engine oil into the cylinders. Crank the
engine several times with the starter to
spread the oil uniformly on the cylinder
walls. Replace the spark plugs. Repeat this
pro- cedure prior to starting after storage.
• Battery
Remove the batteries from the truck and
recharge them. Store them in a dry, cool
place.
More precautions may have to be taken
accord- ing to the place of storage, storage
period and season. When you put your
truck in storage, consult your Cat lift truck
dealer.
• Controller
Moisture is harmful to the controller.
When washing, do not splash water or
steam over the ECM inside the right step
and the frequency transducer and the ECU
inside the dashboard.
86 78
||||||||||||||||||||||||||||||||||||||||||||||||| TRANSPORTATION HINTS ||||||||||||||||||||||||||||||||||||||||||||||
◆ Lift Truck Shipping ◆ Machine Lifting and Tiedown
Information
Always block the trailer or rail car wheels NOTICE: Improper lifting or tiedowns may
! WARNING before loading the lift truck. cause a load to shift and cause
Position the lift truck on the truck bed or rail injury and/or damage.
Make sure there is adequate clearance if the vehicle being trans-car.
ported is equipped with a high mast or cab.
from the shipping vehicle and loading dock. 1. Weight and instructions given herein apply
Place the direction lever in NEUTRAL, the to lift trucks manufactured by Mitsubishi
lock knob in lock position and apply the park- Caterpillar Forklift America Inc.
ing brake. 2. Use proper rated cables and slings for lift-
Turn the key switch to the (OFF) position ing. Position the crane so the lift truck is
and remove the key. level when lifted.
Block the wheels and secure the lift truck with 3. Spreader bar widths should be sufficient to
tiedowns. prevent contact with the lift truck.
Do not steer the truck after it has been secured 4. Use the tiedown locations provided for lift
on the truck or rail car. truck tiedown.
Check the state and local laws governing
weight, width and length of a load.
Contact your Cat lift truck dealer for shipping
instructions for your lift truck.
101624
87 79
||||||||||||||||||||||||||||||||||||||||||||||||||||| SPECIAL SITUATIONS ||||||||||||||||||||||||||||||||||||||||||||||||||
◆ Care in Cold Weather
• Fuel Oils and Lube Oils • Battery • Engine Coolant
! CAUTION Float
Electrolyte level
d point should be 6°C (11°F) below the lowest ambient tempera- ture.
engine oil and gear oil to fit the ambient temperature.
Glass tube
Electrolyte
! CAUTION
After distilled water has been added to the battery, run the engine for a while. This mixes the added water w
DO NOT attempt to restore a battery’s charge by pouring boiling water over it. This can break the battery cas
88 80
SPECIAL SITUATIONS
◆ Care in Hot Weather ◆ Care in Severe Dust or Lint
• Fuel Oils and Lube Oils • Engine Coolant Conditions
Be
ry Coolant
evaporates
Use fuel In hot, rapidly and
oil, dry
101104
the engine
101102
engine oil weathe is likely to
and gear r, get
oil to fit check overheated
the the when the
ambient battery truck is
temperatu cells oper- ated
res. for continuous
proper ly or on a
electro grade.
NOTICE: For
lyte During
selection
level such an
of fuel
more operation,
oil,
often observe the
engine oil
than in engine
and gear
cold coolant
oil,
weathe tem-
consult
r. Add perature
your Cat
distille gauge for
lift truck
d water symptoms
dealer.
whene of
ver the overheatin
level is g.
low.
• Batte
89 81
! CAUTION
If the engine coolant temperature gauge needle moves into the red zone, the engine is suspected of getting overheated.
NOTICE: If the
engine
Check and
coolant
service the
tempera
air cleaner
ture
element
gauge
more
needle
frequently.
moves
into the
red
zone, Recommended inspection
Every 200 service
period hours or monthly, whichever comes fir
see the Check the
topic, radiator core
Engine more
Coolan frequently
t for clogging
Tempe or trash
rature build-up.
Gauge Clean or
Needle wash the
Moves truck as
Into necessary.
the
Red
Zone.
90 81
|||||||||||||||||||||||||||||||||||||||||||||||||||||| TROUBLESHOOTING |||||||||||||||||||||||||||||||||||||||||||||||||||
◆ Changing a Tire
! WARNING ! WARNING
101105 101107
! WARNING
Make sure the replacement tire is of the same size, type and load range.
Use the tire recommended by MCFA.
DO NOT attempt to change the tire with the Stop raising the truck when the tire clears the
truck loaded. Injury and/or damage could ground. DO NOT raise the truck more than
result. necessary.
91 82
! WARNING ! WARNING
100832 100833
BE SURE no one is on the truck when raising DO NOT place any part of your body under
the front or rear tires. the truck. SECURELY SUPPORT the truck
with blocks after jacking it up.
! WARNING
Consult your Cat lift truck dealer for proper tire changing procedure.
Changing of tire and adjustment pro- cedure must be made by a trained mechanic
Perform all maintenance in the fac- tory with proper equipment.
92 82
TROUBLESHOOTING
• Single Tire
Wheel nut
100830
2. Prepare tools, jack and wheel blocks.
Jack Capacities
93 83
TROUBLESHOOTING
Other Method
Tilt forward
Tilt backward
Block
100913
94 83
To Raise Rear Tire 4. Remove the wheel nuts (loosened in
step 1). ➀
5. Firmly grip the wheel with both hands and
remove it from the truck. ➅ ➂
➃ ➄
Wheel nut
➁
100836A
Tightening Torque
To Install Tire100835A Unit: N•m (kgf•m) [lbf•ft]
1. Install the wheel and tighten the wheel 4 ton Front 403 (41.1) [297]
nuts finger tight until their clamping models Rear 377 (38.5) [278]
surfaces come into full-face contact with
4.5 to 5 Front 551 (56.2) [406]
the coun- terbores in the rim.
NOTICE: Make sure the clamping sur- ton models Rear 377 (38.5) [278]
faces of the wheel nuts and
counterbores are free of dirt.
! CAUTION
100834
e careful NOT to strip the bolt threads when removing the wheel.
• Dual Tire
101203A
① Extension valve ③ Inner wheel nut 3. Position the jack under the truck at the
② Outer wheel nut specified jacking point.
4. Raise the truck by operating the jack until
To Remove Outer Tire the tire just clears the ground.
1. Remove the outer tire extension valve by 5. Remove the outer wheel nuts by hand.
turning it counterclockwise. 6. Firmly grip the tire with both hands, and
2. Loosen the outer wheel nuts about two remove it from the truck.
turns.
NOTICE: DO NOT remove the wheel
nuts. ONLY loosen them. ! CAUTION
When removing the wheel, be careful not to strip the inner wheel nut threads on the edges of the bolt holes in the rim.
! WARNING
When removing the outer wheel nuts, grasp each nut properly to prevent the wrench from slipping off the nut.
Inner
wheel nut
101205A 101212
! CAUTION
, be careful not to strip the wheel bolt threads on the edges of the bolt holes in the rim.
OTICE:
W
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o
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l
y
,
• Rear Tire
Clamping surface Loosen outer wheel nut.
101210A
101206
100904 100838
101111
Your lift truck uses high pressure tires. When When adding air to the tire using an air com- If the engine stalls, hydraulic pressure is lost in
adding air, check the rim for damage that pressor, make sure the compressor valve is the power steering system. If this happens,
could permit air to leak from the tire. NEVER cor- rectly set. Failure to follow this precaution stop your truck in a safe area and restart the
over- inflate the tire. can damage the tire. Always maintain correct engine.
When adding air to the tire, or checking tire tire pressure. Before restarting the engine:
pressure, BE SURE to keep your body away – Make sure the fuel tank is NOT empty.
from the side. The use of an inflation cage, or – Correct the cause of engine stalling such
some other safety device, helps reduce the risk as overloading.
of serious injury.
◆ Engine Coolant Temperature ◆ Powershift Transmission Oil
Gauge Needle Moves into Red Zone Temperature Warning Light
Glows
! WARNING
NO
104144
104577 104579
YES
ving interlock indicator light is OFF but the truck fails to move. Stop working and move the truck to a safe area. Shut down the engine and consult your Cat lift truck
TROUBLE
104578
◆ Trouble with the LP-Gas Equipment
! WARNING
If you smell gas or notice something wrong There is a possibility of fire after a collision
with LP-Gas equipment during operation, or when a truck turns over. If this happens,
immediately stop the truck in a safe area, close the LP-Gas fuel valve of the LP-Gas
turn tank as soon as possible.
the key switch to the (OFF) position, close Use a dry-chemical (powder) or carbon diox-
the fuel valve of the LP-Gas tank, and try to ide type extinguisher. Never use water. When
find the cause. (It is advisable to have a test possible, however, have large quantities of
kit on hand for detecting gas leakage.) water poured over the LP-Gas tank to cool it
If the internal pressure of the LP-Gas tank down while the fire is being extinguished.
rises too high and causes the relief valve to
open to let out the excess pressure, sprinkle
water over the tank. At the same time, extin-
guish any fire or flame source (such as a pilot
light) and eliminate the possibility of creating
sparks near the truck. Ventilate the work
area.
When gas leakage is evident, close the fuel
valve as soon as possible. Extinguish the fire
or flame sources nearby to prevent spark
conditions.
|||||||||||||||||||||||||||||||||||||||||||||||||||||||||| MAINTENANCE |||||||||||||||||||||||||||||||||||||||||||||||||||||||
◆ General
Open
Follow these rules to help save you from injury
and to service your truck properly.
Close
! CAUTION
or in any way unsafe, or contribute to an unsafe condition, the matter shall be reported immediately to the designated authority, and the truck shall not be oper- ated until it has
10 94
MAINTENANCE
◆ Inspection Precautions
! WARNING
100879
I
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10 95
MAINTENANCE
t
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10 95
MAINTENANCE
e
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10 95
MAINTENANCE
◆ Maintenance Schedule
• Every 10 Service Hours or Daily (Pre-Start),
As the operator, you are responsible for the performance of daily pre-start Whichever Comes First, continued
inspection. You are also responsible for those items listed under Every 50
Service Hours or Weekly, Whichever Comes First to keep your lift truck Item
Item Service
Service Page
Page
in proper working condition. Damaged or pedal
Accelerator faulty operation found Check 100
For periodic inspection and periodic change of rubber parts, however, rely the day before Check 99
on the expert knowledge of the factory-trained servicemen, and the service Brake pedal Check 100
facilities at your Cat lift truck dealer’s workshop. Oil, fuel or coolant leaks Check 99
Inching pedal Check 101
Lights Check 99
One month after delivery of a new truck Parking brake lever Check 101
Every 200 service hours or monthly, whichever comes first Load backrest extension Check 99
Every 400 service hours or 2 months, whichever comes first Seat belt Check 101
Every 600 service hours or 3 months, whichever comes first Tilt cylinder socket bolts Check 100
Seat adjustment Check 101
Every 1200 service hours or 6 months, whichever comes first Overhead guard Check 100
Every 2400 service hours or 1 year, whichever comes first Horn Check 102
Periodic inspection time intervals Assist grip Check 100
Steering wheel Check 102
• Every 10 Service Hours or Daily (Pre-Start), movement
Whichever Comes First Amount of fuel (truck level) Check 102
Stop lights Check 102
OK monitor Check 102
Lift chains Check/adjust 103
Engine Check 104
Service brakes Check 104
Back-up lights Check 104
Engine crankcase Check oil level 105
Engine coolant Check 106
coolant level
Hydraulic oil Check 109
oil level
11 100
• Every 10 Service Hours or Daily (Pre-start), • Every 200 Service Hours or Monthly, Whichever Comes First
Whichever Comes First, continued
Item Service Page
Item Service Page
Wheel nuts Retighten 117
Brake fluid Check level 110
Differential Check oil level 117
Wheel nuts Check 111
Powershift transmission Check oil level 118
Tires and rims Check 111
Alternator drive belt – Gasoline Check/adjust 119
Mast and forks Check 112
Spark plug Check **
Battery Check electrolyte 113
level Vaporizer – LP-Gas Check tar **
Piping and piping joints – LP-Gas Check damage/ 119
gas leakage
• Every 50 Service Hours or Weekly, Whichever Comes First
Engine crankcase – Gasoline and LP-Gas Change oil 120
Item Service Page Engine crankcase – Diesel Change oil 121
Air cleaner element Clean/inspect 114 and filter
Alternator drive belt – Diesel Check/adjust 115 The change intervals for engine oil and filter are depend on the percent-
Mast supports Lubricate 116 age of sulfur in the diesel fuel. Check the following:
• Every 400 Service Hours or 2 Months, Whichever Comes First • Every 2400 Service Hours or 1 Year, Whichever Comes First
Item Service Page
Item Service Page
Engine coolant – Gasoline Change 124
Hydraulic oil Change 136
Brake fluid Change 136
• Every 600 Service Hours or 3 Months, Whichever Comes First
Fuel filter – LP-Gas Change **
Item Service Page
Intake/exhaust valve clearance – Gasoline Adjust ** NOTICE: For the description of ** marked items, refer to the TB45 gaso-
line engine service manual.
Injection nozzle – Gasoline and LP-Gas Inspect **
PCV valve and hose – Gasoline Inspect **
LP-Gas filter Clean **
Engine crankcase – Gasoline and LP-Gas Change filter 127
◆ Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedures.
• Damage or Faulty Operation Found • Oil, Fuel or Coolant Leaks • Load Backrest Extension
the Day Before
– Have repairs been made properly?
Check the daily inspection sheet.
! WARNING
Check on the floor for oil, fuel or coolant – Is the backrest extension free of distortion,
leaks. 102840 cracks and other101400A
defects? Shake the back-
rest to check for excessive rattle.
• Lights
– Are all the lights in safe working condi-
100678A tion?
Fill out a daily inspection sheet. Remember, – Are their lenses clean and not defective?
the complete performance of a daily – Do the tail and head lights come ON prop-
inspection is the best protection against injury erly when you switch them on.
and prop- erty damage.
• Tilt Cylinder Socket Bolts • Overhead Guard • Accelerator Pedal
– Can you depress the accelerator pedal
smoothly without any sign of rubbing?
101049
103201
– Are the bolts tightened properly? 1. Check the front and rear overhead guard
mounting bolts on each side. Tighten bolts
Use a wrench.
to 14.5 N•m (1.5 kgf•m) [10.7 lbf•ft]. 100699
NOTICE: After retightening the bolt, put a 2. Inspect overhead guard for bent or
mark across the bolt and tilt cylin- cracked sections. Contact your Cat lift • Brake Pedal
der socket. This permits you to eas- truck dealer if repairs are needed. – Do you have sufficient pedal travel?
ily notice loosening of the bolt. – Is the free-play adjusted properly?
Tightening Torque for the Bolt • Assist Grip
Correct Free Play:
262 ± 13 N•m (27 ± 1.4 kgf•m) th
[193 ± 9.6 lbf•ft] e
as
si
st
gr
ip
.
102553
Inspect, and if necessary, tighten the screws of
Unit: mm (in.)
4 ton models 4 to 15 (0.2 to 0.6)
4.5 to 5 ton models 5 to 18 (0.2 to 0.7)
• Inching Pedal • Parking Brake Lever • Seat Belt
– Can you pull the lever all the way with – Is the seat belt in safe condition?
rea- sonable effort? Replace the belt assembly if the belt is
– Can you hold your truck on a grade by torn, cut, or if the plate and/or buckle is
pulling the brake lever? defective.
– Lever operating effort:
250 to 290 N (25 to 30 kgf) [55 to 66 lbf]
• Seat Adjustment
Turn the knob clockwise to increase the
Adjustment
lever’s tension; counterclockwise to decrease
– Is the free play correct? it. Adjustment is correct when the lever
100700 effort of 250 to 290 Apply
requires anRelease N (25 to 30 100977
Correct Free Play kgf) [55 to 66 lbf] to snap it over center.
Unit: mm (in.)
All models 5 (0.2)
101437
101726B 103193
– Is the free play 15 to 30 mm (0.6 to 1.2 wheel by rotating the wheel in both direc- tions.
in.)? Check the play at the rim of the – Is wheel installation loose? Check by shaking the wheel up and down.
– D en you depress the brake pedal?
o
a
l
l
s
t
o
p
l
i
g
h
t
s
c
o
m
e
O
N
p
r
o
p
e
r
l
y
w
h
MAINTENANCE
• Lift Chains
Check and To Adjust
Adjust
! WARNING
if they are still in usable condition.
or seized link pins.
se accidents. If some- thing is wrong with the chains, con- sult your Cat lift truck dealer for repair or replacement.
th ne if it
e is still
fol in
- usable
lo conditi
wi on.
1. Chec ng
k the ch Lift Chain
lift art Elongation
chain to Limit:(/20
s for de links)
wear. ter
Use mi
11 105
MAINTENANCE
2. L ht eq justed. 1. L t
i o ua o ③
f n l o to
t th te s adj
t e ns e ust
h ca io n ten
t sio
e rr n.
h n.
f ia 4. If
e 2. Ho
o g th ld
r e e l
o the
k a ch nut
s n c
ai ③
k
h d ns and
n
i c ar tig
u
g h e t hte
h ai lo ① n
e ns os a the
n . e n nut
o 3. C or d ②
u h th t to
h tor
g ec e
e que
h k te
n A.
t to ns Ho
o b io u
t ld
p e n the
u su is ②
. nut
t re no ③
T
t th t and
h
h e eq e tig
e lif ua n hte
i t l, t n
r c ha u the
f h ve r loc
u ai th n kn
ll ns e t ut
①
w h ch h to
e a ai e
tor
i v ns n que
g e ad u
12 105
MAINTENANCE
B ht or
. e qu
ni e:
T n Unit: N•m
i g (kgf•m) [lbf•ft]
g T 4 ton A
49 5 36
models B 147 0
(15 ) [108
0 0
]
4 ton models 518 mm (20.4 in.) 4.5 to 5 A
49 5 36
ton models B 176 0
(18 ) [130
0 0
]
4.5 to 5 ton models 648 mm (25.5 in.)
102708
12 105
• Engine • Service Brakes • Back-up Lights
– Do the brakes apply and stop the truck
! WARNING properly—without dragging, chattering or
closed area, make sure there is adequate ventila- tion. squealing?
n the engine compartment. Know the location of all emergency devices (such as fire extinguisher, first aid kit, etc.) and how to use them.
100712
– Is exhaust smoke normal?
– Listen for abnormal noise or excessive
vibration.
• Engine Crankcase
Check Oil Level Adding Engine Oil
3. Maintain the correct level range on the dip
! WARNING
stick. ! CAUTION
could cause seri- ous injury. Do not allow hot oil or com- ponents to contact your skin. Perform the work on level ground.
Gasoline Clean the filler hole to prevent dirt from dropping into the eng
DO NOT overfill.
Correct level range Clean up spillage.
Park the lift truck with the forks lowered,
park- ing brake applied, transmission in
NEUTRAL, engine stopped and the wheels
blocked. The engine must be cooled down. 1. Remove the oil filler cap.
1. Raise the hood.
103919
2. Remove the dipstick and wipe it clean,
Gasoline
then insert it all the way. Diesel
103924
101304
Diesel
101670
101669
2. Add engine oil as required. 4. Close and tighten the filler cap.
For engine oil, see the topic,
Recommended Fuels and Oils.
Gasoline Gasoline
103929 103919
Diesel Diesel
101671 101304
! CAUTION
Antifreeze/summer coolant (ASC) con- tains rust inhibitors. It is not necessary to add other chemicals.
Recommended concentration range of ASC is 30% to 60% by volume. ASC of less than 30% concentration does not provide sufficient corrosion protecti
Avoid mixing different brands of coolant.
! WARNING
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.
Keep fire away from undiluted antifreeze as it is FLAMMABLE.
! CAUTION
e antifreeze/summer coolant protection and adversely affects the engine. Be sure to pre- mix antifreeze/summer coolant with tap water (soft water). See the topic, Engine Coolin
ave your Cat lift truck dealer check the cooling system.
The lift truck must be level, the forks lowered,
the parking brake applied, the transmission in
NEUTRAL, engine stopped and the wheels
blocked. The engine must be cooled down.
1. Raise the hood.
2. Maintain the coolant level between the
FULL and LOW marks on the reserve
tank.
101465
3. Close and secure the hood.
1. Remove the reserve tank cap and add
coolant to the FULL mark. ! WARNING
2. When adding coolant, maintain the same
concentration of antifreeze solution.
100899
100814
securely. 5. Close and secure the hood.
• Brake Fluid
Check Level
! CAUTION
Before refilling the reservoirs, clean the ports to reduce the risk of dirt from getting inside the reservoirs.
103244
• Wheel Nuts • Tires and Rims
Check – Tighten, when required Check
C
A
103444
– Are the stoppers properly engaged?
2. Check the difference in height of one support of the load and cause Replace one or both forks when the difference
fork tip to the other when mounted problems when entering loads. in fork tip height exceeds the maximum allow-
on the fork carrier. A difference in The maximum allowable difference in fork tip able difference.
fork tip height can result in uneven elevation C is 5 mm (0.2 in.) for pallet forks.
• Battery
Check Electrolyte Level
Specific gravity
corrected to Battery condition
101630 20°C (68°F)
1.260 to 1.280 Fully charged
3. Check the fork blade D. The fork should 1. If the electrolyte level is low, remove the
1.220 to 1.260 Three-fourths charged (to be
be withdrawn from service if the thickness filler caps and add distilled water to the
is reduced to less than the tolerant thick- cells. Before removing the caps, clean the
101403 recharged)
ness. top of the battery. Below 1.220 Completely discharged (to be
Fork blade length may also be reduced by 2. After adding the water, tighten the caps recharged and retested)
wear, especially on tapered forks and platens. securely.
Remove the forks from service when the blade
length is no longer adequate for the intended
loads. ! WARNING
If acid gets in your eyes, FLUSH THEM IMMEDIATELY WITH LARGE AMOUNTS OF WATER AND SEE A DOCTOR AT ONCE.
! CAUTION
Unit: mm (in.) If distilled water has to be often added, have your Cat lift truck dealer check
Tolerant thickness Std. Limit
4 ton models 50 (2.0) 43 (1.7)
4.5 ton model 50 (2.0) 46 (1.8)
5 ton models 60 (2.4) 48 (1.9)
◆ Every 50 Service Hours or Weekly, Whichever Comes First
You must read and understand the warnings and instructions contained in this manual before performing any operating or maintenance procedures.
Element
Wing nut Dust pan
101318
2. Remove the dust pan by releasing the clean the inside of the pan by removing dust.
latches at three places. 5. Clean the inside of the air cleaner housing.
3. Unscrew the wing nut, and remove the ele-
ment by pulling it.
NOTICE:
Never service the air cleaner with the engine
running.
Do not clean the elements by striking them
against another object.
Always inspect the element before and after
cleaning. Use a light inside the element. 101199
Do not use elements with damaged pleats, gas-
kets or seals.
Park the lift truck on a level surface, with the Cover
forks lowered, the parking brake applied, the
transmission in NEUTRAL, engine stopped
and the wheels blocked. 101198
4. Remove the cover from the dust pan, and
7. Insert a light inside a clean, dry
element and check. Discard the
element if tears or rips are found.
8. Put the element back in place.
9. Reinstall the dust cap.
10. Close the hood.
• Alternator Drive Belt – Diesel correct range, readjust the belt.
Check and Adjust Also, check the belt to make sure that
it is not worn, frayed, or has separated
! CAUTION piles.
100696
NOTICE: If the deflection is out of the
3. Loosen the alternator bracket bolts move the alternator out or in.
(indi- cated by the black arrows), and 4. Close and secure the hood.
• Mast Supports
Lubricate
101417
You must read and understand the warnings and instructions contained in this manual before performing
any operation or maintenance procedure.
Lubricate 1 fitting on each support for a total • Engine Crankcase – Gasoline and
of 2 fittings. 102771A LP-Gas
Change filter
– Filter should be changed.
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.
Adding Oil
See the topic, Differential, Change Oil under
Every 1200 Service Hours or 6 Months,
Whichever Comes First.
202983
102565
• Powershift Transmission
Check Oil Level Adding Oil
! WARNING 4. Remove the dipstick. Check the oil level. See the topic, Powershift Transmission,
ents could cause injury. Do not allow hot oil or compo- nents to contact your skin. Change the Oil under Every 1200 Service
Hours or 6 Months, Whichever Comes
First.
102566 101631
• Alternator Drive Belt – Gasoline correct range, readjust the belt.
Check and Adjust Also, check the belt to make sure that
it is not worn, frayed, or has separated
piles.
! CAUTION
nd adjust the rotating part.
racket bolt securely.
resses are placed on the alternator bearing and belt. Such stresses will shorten the service life of both.
o reduce the risk of slipping.
100696
NOTICE: If the deflection is out of the
13 119
3. Loosen the alternator bracket bolts
(indi- cated by the black arrows), and
move the alternator out or in.
4. Close and secure the hood.
14 119
MAINTENANCE
! WARNING
6. Start the engine and allow the oil to fill the
filter and passages.
ents could cause serious injury. Do not allow hot oil or components to contact skin.
7. Check for oil leaks.
8. Stop the engine and measure the oil level.
Maintain the correct level range on the
dip- stick.
1. Operate the lift truck a few minutes to
5. Fill the crankcase. See Refill Capacities
warm the oil.
and Lubrication Specifications charts.
2. Park the lift truck on a level surface with
the forks lowered, parking brake applied,
transmission in NEUTRAL, engine
stopped and the wheels blocked.
3. Raise the hood.
4. Remove the drain plug at the side of the
engine oil pan. Allow the oil to drain.
Clean and put the drain plug back in place. 103918
103924
14 120
MAINTENANCE
103931
9. Close and secure the hood.
14 120
• Engine Crankcase – Diesel
Change Oil and Filter
Whenever the engine oil is changed, the filter must be replaced at the same time with a genuine MCF oil
filter.
! WARNING
ents could cause serious injury. Do not allow hot oil or components to contact skin.
7. Apply a small amount of clean engine oil 10. Check for oil leaks.
to the oil filter element gasket. Install the 11. Stop the engine and measure the oil level.
new filter element. Maintain the correct level range on the
dip- stick.
1. Operate the lift truck a few minutes to
warm the oil.
2. Park the lift truck on a level surface with
the forks lowered, parking brake applied,
transmission in NEUTRAL, engine
stopped and the wheels blocked.
3. Raise the hood.
4. Remove the drain plug at the side of the
engine oil pan. Allow the oil to drain.
Clean and put the drain plug back in place.
101675
8. Fill the crankcase. See Refill Capacities 101669
and Lubrication Specifications charts.
101674 101670
• Lift Bracket Side Rollers total of 2 fittings. 1. Brush a film of engine oil onto the chain links,
Lubricate or spray with chain and cable lubri- cant.
2. Raise and lower the lift bracket a few times to
Lubricate 1 fitting on each side roller for a work lubricant into the chain links. NOTICE:
Lubricate chains more fre-
quently than normal where the
atmosphere can cause corrosion of
components or when the truck must
work in rapid lift cycles.
3. Inspect the chain anchors and individual links
for wear, loose pins or cracked leaves.
102571
• Brake
Pedal
Lubricate
Lubricate 1
fitting.
103458
• Rear Axle Center Pins • Universal Joint – with Grease Nipple
Lubricate Lubricate
102576 103933
Lubricate 1 fitting on each pin for a total of 2 Lubricate 2 fittings.
fittings.
103247
Lubricate 1 fitting on each pin for a total of 4
fittings.
◆ Every 400 Service Hours or 2 Months, Whichever Comes First
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.
103214
3. Open radiator drain valve. Allow the 6. Fill the cooling system with 1 kg (2 lb) 14. Close the drain valve.
coolant to drain. sodium bisulfate per 40 liters (10 gallons) 15. Mix a coolant solution of water and
of water. Most commercial cooling system antifreeze.
cleaners can be used. 16. Fill the cooling system. See Refill
7. Start and run the engine for 30 minutes. Capacities. To avoid air locks, add the
8. Stop the engine and drain the cleaning coolant slowly.
solution.
9. Flush the system with clean water until
the draining water is clear.
10. Close the drain valve. Fill the system with
neutralizing solution, 250 g (1/2 lb)
sodium carbonate per 40 liters (10
gallons) of water.
103216 11. Start and run the engine for 10 minutes.
12. Stop the engine and drain the neutralizing
4. Drain the reserve tank.
solution.
13. Flush the system with clean water until
draining water is clear.
103200
17. Start and run the engine until the coolant
level is stabilized.
18. Stop the engine.
19. Add coolant, if necessary, to maintain the
level to below the bottom of the filler
tube.
101641A
20. Put the radiator filler cap back on.
21. Remove the reserve tank filler cap.
22. Keep the coolant level at the FULL line
on the reserve tank.
101299
101465A
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.
15 127
MAINTENANCE
◆ Every 1200 Service Hours or 6 Months, Whichever Comes First
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.
• Powershift Transmission
Change Oil and Wash Strainer
➃
101631
103275
15 128
• Hydraulic System
Change Return Oil Filter and Wash Strainer
103461
Park the lift truck with the forks lowered on a
level surface, parking brake applied, transmis-
sion in NEUTRAL, engine stopped and the 4. Remove the gasket and strainer ➀.
wheels blocked. 5. Remove the gasket and return oil filter ➁.
1. Raise the hood. Discard the filter element.
2. Remove the battery and tank cover.
100695A
103462
➁
➀ 102580
• Fuel Filter – Diesel
Change
! WARNING
t surfaces or electrical components can cause a fire. Clean up any spillage of fuel. Know the
ices (such as
s, etc.) and how to use them.
changing fuel filters.
101682A
3. Use filter wrench to remove filter element.
4. Clean sealing surface of filter base.
5. Apply
zed refueling area, with the forks low- ered, parking brake applied, a light coat
trans- mission of engine oil
in NEUTRAL, to thestopped
engine gas- and the wheels blocked.
ket of the new filter element.
101681A
6. Install the new filter element by hand until
the gasket contacts the filter base.
7. Start the engine and check for fuel leaks.
101743 8. Stop the engine.
9. Close and secure the hood.
How to Prime the Diesel Fuel System
! CAUTION
Make sure no fuel leaks from the air vent plug.
Clean up spillage.
1. Loosen the air vent plug ➀ on the fuel fil-
ter about 1.5 turns with a wrench.
101338A
2. Unlock priming pump plunger ➁ by turn-
ing it counterclockwise. Operate the prim-
ing pump until the fuel flows free of bub-
bles from the vent.
3. Tighten air vent plug ➀.
• Engine Coolant – Diesel
Change
See the topic, Engine Coolant, Check Level 2. Turn the radiator filler cap slowly to
under Every 10 Service Hours or Daily, ! WARNING relieve the pressure, then remove the cap.
whichever comes first.
! WARNING
r pressure.
orks lowered, park- ing brake applied, transmission in NEU- TRAL, engine stopped and the wheels blocked.
d and the filler cap is cool enough to touch with your bare hand.
100899
h your skin and eyes to reduce the risk of burns and other injuries. Allow cooling system compo- nents to cool before draining.
Antifreeze solution is TOXIC. In case of con- ta
ase of contact with your skin, FLUSH IMMEDIATELY
407181
103210
3. Open radiator drain valve. Allow the 6. Fill the cooling system with 1 kg (2 lb) 14. Close the drain valve.
coolant to drain. sodium bisulfate per 40 liters (10 gallons) 15. Mix a coolant solution of water and
of water. Most commercial cooling system antifreeze.
cleaners can be used. 16. Fill the cooling system. See Refill
7. Start and run the engine for 30 minutes. Capacities. To avoid air locks, add the
8. Stop the engine and drain the cleaning coolant slowly.
solution.
9. Flush the system with clean water until
the draining water is clear.
10. Close the drain valve. Fill the system with
neutralizing solution, 250 g (1/2 lb)
sodium carbonate per 40 liters (10
gallons) of water.
103216 11. Start and run the engine for 10 minutes.
12. Stop the engine and drain the neutralizing
4. Drain the reserve tank.
solution.
13. Flush the system with clean water until
draining water is clear.
103200
17. Start and run the engine until the coolant
level is stabilized.
18. Stop the engine.
19. Add coolant, if necessary, to maintain the
level to below the bottom of the filler
tube.
101641A
20. Put the radiator filler cap back on.
21. Remove the reserve tank filler cap.
22. Keep the coolant level at the FULL line
on the reserve tank.
101299
101465A
You must read and understand the warnings and instructions contained in this manual before performing any operation or maintenance procedure.
• Hydraulic Oil
Change 4. Remove the hydraulic tank drain plug.
Allow the oil to drain. Clean and put the
! WARNING plug back in place.
138 138
• Gasoline (Gas) Specification
Your lift truck must use unleaded gasoline only.
Oxygenated Gasoline
Some gasoline sold at service stations contains oxygenates such as ethanol, methanol, and MTBE
(Methyl Tertiary Butyl Ether), although it may not be so identified. The use of fuels containing
oxygenates is not recommended.
Ethanol (Gasohol)
A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your lift truck pro-
vided the octane rating is at least as high as that recommended for unleaded gasoline.
Methanol
Do not operate your lift truck on gasoline containing methanol (wood alcohol). The use of this type of
alcohol can result in lift truck performance problems and could damage critical fuel system parts.
MTBE (Methyl Tertiary Butyl Ether)
A mixture of 15% or less MTBE and unleaded gasoline may be used in your lift truck provided the octane
rating is at least as high as that recommended for unleaded gasoline.
NOTICE: If you experience driving problems which you suspect are fuel related, try switching to a
different fuel.
SERVICE DATA
13 139
◆ Coolant Information
NOTICE: Clean the cooling system if it is contaminated, The tendency of silicates and phosphates to
Mitsubishi Caterpillar Forklift America Inc. the engine overheats or foaming is observed in precipitate out-of-solution increases with
recommends that the coolant mix contain 50% the radiator. increasing water hardness. Hard water, or
commercially available automotive antifreeze, Old coolant should be drained, the system water with high levels of calcium and magne-
and 50% water. cleaned and new coolant added – as recom- sium ions, encourages the formation of insolu-
To reduce the risk of damage to your engine, mended – using a commercially available ble chemicals, especially after a number of
never add coolant to an overheated engine. auto- motive antifreeze. heating and cooling cycles.
Allow the engine to cool first. Filling at over 20 liters (5 U.S. gallons) per Mitsubishi Caterpillar Forklift America Inc.
Dowtherm 209 full-fill coolant will lower the minute can cause air pockets in the cooling prefers the use of distilled water or deionized
water pump cavitation temperature and system. water to reduce the potential and severity of
cooling boiling point. These lowered After draining and refilling the cooling chemical insolubility.
temperatures will cause overheating at a lower system, run the engine with the radiator cap
ambient tempera- ture than an ethylene glycol off. Run it until the coolant reaches its normal Acceptable Water
and water mix. If Dowtherm is used, follow operating temperatures and the coolant level Water content Limits ppm
the instructions pro- vided and use only the stabilizes. Add coolant as necessary to fill the Chlorides (Cl) 50 maximum
inhibitor package rec- ommended by the system to the proper level. Sulfates (SO4) 50 maximum
Total hardness 80mg/l
supplier. Operate with a thermostat in the cooling sys- Total solids 250 maximum
If the lift truck is to be stored in, or shipped to, tem all year-round. Cooling system problems pH 6.0 to 8.0
an area with freezing temperatures, the cooling can arise without a thermostat.
system must be protected to the lowest ppm = parts per million
expected outside (ambient) temperature. • Coolant Water Using water that meets the minimum accept-
The engine cooling system is protected with a Hard water, or water with high levels of cal- able water requirement may not prevent
commercially available automotive antifreeze cium and magnesium ions, encourages the for- dropout of these chemical compounds com-
when shipped from the factory. mation of insoluble chemical compounds by pletely but should control the dropout rate at
In cold weather, check the specific gravity of combining with cooling system additives such acceptable levels.
the coolant frequently to ensure adequate pro- as silicates and phosphates.
tection.
• Antifreeze
NOTICE: Make Proper Antifreeze Additions.
Mitsubishi Caterpillar Forklift America Inc.
Do not add pure (100%) antifreeze to the cool-
recommends that the coolant mix contain 50%
ing system. Add antifreeze mixed with water
commercially available automotive antifreeze,
using the same freeze protection ratio that is in
or equivalent, and acceptable water to maintain
your cooling system.
an adequate water pump cavitation temperature
for efficient water pump performance.
Premix the coolant solution to provide protec-
tion to the lowest expected outside (ambient)
temperature. Pure undiluted antifreeze will
freeze at -23°C (-10°F).
Use a greater concentration (above 50%) of
commercially available automotive antifreeze
only as needed for anticipated outside (ambi-
ent) temperatures. Do not exceed the coolant-
to-water mix ratio recommendations provided
with the commercially available automotive
antifreezes.
Ambient temperature, °C (°F) -45 (-49) -39 (-38) -30 (-22) -25 (-13) -20 (-4) -15 (5) -10 (14)
Antifreeze solution
Concentration (%) 60 55 50 45 40 35 30
NOTICE: Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when
mixed. It is best to stick with the same brand at successive service intervals.
For refill capacities and measurements, see Specifications in this section.
Below oils are reference only.
• Antifreeze/Summer
• Gear Oils • Greases
Coolant
API service classification GL-4 or GL- NLGI No. 1 NLGI No. 2
5 Full Force
Manufacturer
SAE80W SAE90 Consistency 310 - 340 Consistency 265 - 295
USI Chemical
Mobil Mobilube HD 80W-90 Mobilux EP 1 Mobilux EP 2
Marcus
Shell Shell Spirax HD 80W-90 Retinax HD NLGI 1 Retinax HD NLGI 2
Exxon Gear Oil GX80W-90 Ronex Extra Duty 1 Ronex Extra Duty 2 Peak
NOTICE:
Brands of oil are subject to change without notice. When you buy oil, check
specification. (For example: API service classification CD, SAE10W)
◆ Specifications and Refill Capacities (Standard Models)
Truck model
Item GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K
(Pneumatic) Rear 700 (7.0) [100] 850 (8.5) [120] 700 (7.0) [100] 850 (8.5) [120]
Tightening torque for Front 403 (41.1) [297] 551 (56.2) [406] 403 (41.1) [297] 551 (56.2) [406]
wheel nuts, N•m (kgf•m) Rear 377 (38.5) [278]
[lbf•ft]
Lift chain elongation limit,
518 (20.4) 648 (25.5) 518 (20.4) 648 (25.5)
mm (in.)/20 links
Truck model
Item GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K
Truck model
Item GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K
600 mm (24 in.) — 4000 (9000) 4500 (10000) 5000 (11000) — 4000 (9000) 4500 (10000) 5000 (11000)
Capacity, kg (lb)
500 mm (24 in.) 4000 (8000) — — — 4000 (8000) — — —
Truck weight, Single drive tires 5570 (12300) 5970 (13150) 6530 (14400) 7050 (15500) 5710 (12600) 6120 (13500) 6680 (14750) 7160 (15800)
unloaded kg Dual drive tires 5700 (12550) 6050 (13350) 6610 (14550) 7130 (15700) 5900 (13000) 6250 (13750) 6820 (15050) 7320 (16150)
(lb)
||||||||||||||||||||||||||||||||||||||||||| TO THE CAT LIFT TRUCK OWNER |||||||||||||||||||||||||||||||||||||||||
! CAUTION
genuine parts could cause damage not covered by your Cat lift trucks warranty.
14 147
TO THE CAT LIFT TRUCK
OWNER
◆ Instructions for Ordering Parts
101522
103916
Gasoline and LP-Gas engine models Diesel engine models
102993
14 148
SERVICE REGISTRATION
Delivering Name
dealer
Address
Delivery date
DATE
TRANSFER REPORT
TRANSFER OF OWNERSHIP REPORT
TRANSFERRED TO
CUSTOMER NAME ADDRESS
( ) ( )
15 150
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A C
Accelerator Pedal.......................................................................................28 Capacities, Truck Weight.........................................................................146
Accelerator Pedal, Check (Every 10 Service Hrs.)...................................100 Capacity Chart............................................................................................45
Adding Engine Coolant....................................................................107–108 Capacity, (Weight and Load Center)..........................................................45
Adding Engine Oil............................................................................105–106 Capacity, Changes In..................................................................................20
Adding Hydraulic Oil...............................................................................109 Capacity, Stay Within.................................................................................23
After Starting Engine..................................................................................61 Center of Gravity........................................................................................44
Air Cleaner Warning Light.........................................................................32 Changing Direction....................................................................................64
Air Cleaner, Care in Severe Dust and Lint Conditions...............................81 Changing LP-Gas Tank..............................................................................52
Air Cleaner, Change Element (Every 1200 Service Hrs.)........................130 Changing Speed..........................................................................................64
Air Cleaner, Clean/Inspect (Every 50 Service Hrs.).................................114 Compartment, Operator’s, Cleanliness of...................................................12
Alternator Not Charging Warning Light....................................................32 Controls, Position Correctly.......................................................................24
Alternator, Drive Belt – Diesel, Check-Adjust (Every 50 Service Hrs.)...115 Coolant Information.................................................................................140
Alternator, Drive Belt – Gasoline, Check-Adjust Coolant, Adding Water.............................................................................107
(Every 200 Service Hrs.).....................................................................119 Coolant, Adding................................................................................107–108
Antifreeze Coolant, Recommended..........................................................143 Coolant, Engine Temperature Gauge..........................................................30
Anti-Restart Starter Switch.........................................................................31 Coolant, Engine, Care of in Cold Weather.................................................80
Assist Grip..................................................................................................41 Coolant, Engine, Care of in Hot Weather...................................................81
Assist Grip, Check (Every 10 Service Hrs.).............................................100 Coolant, Engine, Safety While Checking...................................................11
Counterweight, Allowing for Swing Distance............................................18
B
Back-up Buzzer..........................................................................................43 D
Back-up Lights, Check (Every 10 Service Hrs.).......................................104 Damage or Faulty, Operation Found (Every 10 Service Hrs.)....................99
Battery, Check Electrolyte Level..............................................................113 Decals, LP-Gas.............................................................................................4
Before Moving Lift Truck..........................................................................62 Decals, Warning.......................................................................................2–9
Before Starting Engine.........................................................................54–56 Diesel Engine.............................................................................................51
Brake Fluid Level Warning Light...............................................................32 Differential, Change Oil (Every 1200 Service Hrs.).................................130
Brake Fluid, Recommended.............................................................142–143 Differential, Check Oil Level (Every 200 Service Hrs.)...........................117
Brake Pedal................................................................................................28 Direction Lever...........................................................................................28
Brake Pedal, Check (Every 10 Service Hrs.)............................................100 Direction of Travel, Always Look In..........................................................18
Brake Pedal, Lubricate (Every 200 Service Hrs.).....................................122 Disabled Machine, Park Safely..................................................................24
Brake, Service, Change Fluid (Every 2400 Service Hrs.).........................136 Do-It-Yourself Maintenance.......................................................................94
Brakes, Service, Adding Brake Fluid (Every 10 Service Hrs.).................110 Drawbar Pin................................................................................................41
Brakes, Service, Check (Every 10 Service Hrs.)......................................113 Dress, Proper..............................................................................................10
Brakes, Service, Check Fluid Level (Every 10 Service Hrs.)...................110 Driving Interlock Indicator Light...............................................................92
Driving Interlock System......................................................................33–34
15 151
Dual Fuel Type, Gasoline/LP-Gas..............................................................55
15 151
INDEX (continued)
15 152