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

◆ Serial Number & Capacity Plate

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

Capacity Plate
UL Plate

103808
103446

Manufacturer Name Plate

105017

Lift Truck Serial Number

104906

Engine Serial Number

105031

26 26
KNOW YOUR LIFT TRUCK 27

◆ Electrical Components

! CAUTION

Control valve Input unit Converter, DC/DC
Controller gateway
Control unit (ECU)
Controller, VCM3 (optional)
Operator presence switch
Controller, VCM3
– This system consists of precise com-
ponents. DO NOT attempt to make
adjustment or repair yourself.
Consult your Cat lift truck dealer.
– Moisture is harmful to the con-
troller. When washing, do not splash
water or steam over the VCM
(Vehicle control module), the ECU
and the other controllers.
– The seat has a switch, called opera-
tor presence switch. You are unable
to move the mast and attachments
unless you are seated. When replac-
ing the seat, be sure to select the
genuine Cat lift truck seat with
operator presence switch.

Solenoid valve for transmission

Output unit

104983

27 27
KNOW YOUR LIFT TRUCK 28

◆ Model View

P30000 model Rear combination light

Backup light
Tail/stop light
Overhead guard
Turn signal

Mast Operator’s seat

Engine hood
Lift chain
Rear view mirror
Lift cylinder

Counterweight
Head light Drawbar pin
104909
Rear wheel
Lift bracket

Fork

Fuel tank (left)/

Hydraulic tank (right) Head light

Turn signal light

Front wheel
104910

104984

28 28
KNOW YOUR LIFT TRUCK 29

With FC Lever

Instrument Panel
Turn Signal/Light Switch

Direction Lever •
Starter Switch

Parking Brake Lever

Accelerator Pedal

Steering Tilt Lever

Lift Lever

Inching Pedal Tilt Lever

Attachment Lever

Brake Pedal Emergency Stop Button

•

Operator’s Seat

105019

29 29
KNOW YOUR LIFT TRUCK 30

With MC Lever
Turn Signal/Light Switch

Instrument Panel
Starter Switch
•

Accelerator Pedal
Direction Lever
(Powershift)

Lift Lever
Parking Brake Lever
Tilt Lever

Steering Tilt Lever

Attachment Lever

Inching Pedal
(Powershift)

Brake Pedal
•
Emergency Stop Button

Operator’s Seat

105020

30 30
KNOW YOUR LIFT TRUCK 31

◆ Driving Switches and Controls

Turn signal/light switch • When turning to the right or to the left, light, tail lights, and clearance lights illu-
Head light operate the turn signal switch in the direc- minate. When it is placed to
(Position 2) tion of the arrow as shown on the left. The the position, headlights also illumi-
switch automatically returns when the nate in addition to the above lights.
Left turn
steering wheel is returned, but it can also
be returned manually.
• When the light switch is placed to the
Clearance light Right turn position, the instrument panel
(Position 1)
104221

Position
1 2
Light
Instrument panel
light
Tail lights
Clearance lights Horn switch
Head lights Push to sound

NOTICE: The lights may be turned on by

placing the light switch to position
1 or 2 regardless of the starter 104012
switch position. Turn off the lights
when the truck is not being operat-
Anti-restart starter switch
ed to prevent the battery from dis-
and key
charging.

Parking brake lever

Release
103524
Apply
105019

Push the button Steering tilt lever

to release the lever. 103570
31 31
KNOW YOUR LIFT TRUCK 32

Direction lever
This truck is equipped with a neutral switch.
Be sure to put the transmission in NEU-
TRAL when starting the engine.

Forward (F)

Neutral (N)

Reverse (R)

103569

105019

Inching pedal By varying the position of this pedal, Brake pedal Accelerator pedal
Clutch discs
Released the operator can move the truck Release Idling
start to slip slowly for inching while maintaining
engine speed. Full application of the
pedal puts the transmission in neutral Full throttle
Service brakes
Service brakes and applies the service brakes. start to be applied
start to be applied
100129 100130 100039

32 32
KNOW YOUR LIFT TRUCK
• Anti-restart Starter Switch and Key
Has a built-in mechanical lockout that pre-
vents 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.
Removes all power from instru-
ment panel and electrical circuits
(OFF)
except for horn and lights.
Applies power to all electrical
circuits except for starter circuit.
In diesel models, power is
applied to heater plugs for 1.5 to
10 seconds depending on the
cooling water temperature and
l heater plug indicator glows.
(ON)
OFF ON
102391
Applies power to the starter
motor to crank the engine. A
switch spring returns the key
(START)
switch to the I (ON) position
when the key is released.
CAUTION
! This lever is also used for opening and closing
– 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.
33
33
• Steering Tilt Lever
WARNING
Steering tilt lever
!
– Always adjust the steering column
Lock tilt angle while stopped at a safe
place, as adjustment while driving
Steering column
release lever may lead to accidents.
– Make sure that the steering column
Unlock
is firmly secured.
Lock
Unlock
103572
The steering tilt lever allows the steering col-
umn position to be adjusted to an operator’s
desired driving position.
Adjustment of steering column position
1. Unlock the steering tilt lever.
2. Hold the steering column and adjust it to
an appropriate position.
3. After adjustment, lock the steering tilt
lever.
Steering column release lever
For easy getting on and off, unlock the steering
column release lever and tilt the steering col-
umn toward the front of the vehicle.
After sitting on the seat or leaving the seat, tilt
the steering column toward the driver seat and
make sure that it is automatically locked.
the engine hood.
33
KNOW YOUR LIFT TRUCK 34

◆ Instrument Panel

Hour meter/Display of error codes Fuel gauge Engine coolant temperature gauge
Full
0.1 hour Overheat
(6 minutes)
Normal
Empty

1 hour
103578 103902 103903

Hour meter Indicates the amount of fuel in the tank

when the key switch is turned to the If the needle moves into the red zone, see the
Starts registering the operating hours of the topic. If Engine Coolant Temperature
engine when the key switch is turned to the I (ON) position. To get an accurate gauge
reading, be sure the truck is level. Gauge Needle Moves into Red Zone.
I (ON) position. Periodic maintenance rec-
ommendations are based on these engine
hours.

Display of error codes (display with liquid

crystal) Instrument panel
When minor failures overlap, the relevant When any warning light glows during opera-
warning lights or indicator lights simultane- tion, stop the truck and take corrective
ously flash and error codes are displayed action.
repeatedly.
When a minor failure and major failure
simultaneously occur, the error code for the
major failure alone is displayed.
When the major failure is solved, then the
error code for the minor failure is displayed.
For error codes and their contents, see
“Error Codes and Explanations.”

105021

34 34
KNOW YOUR LIFT TRUCK 35

Bulb check
The following warning lights should glow
when the key switch is turned to the I (ON)
position.
(The lights will go out when the engine is
started; if not, the charging system has a
defect.)

104915

If the lights fail to glow with the key in the

I (ON) position, the bulbs have burnt out.
Consult your Cat lift truck dealer.

35 35
KNOW YOUR LIFT TRUCK 36

• Warning Lights and Indicators

Powershift transmission oil
temperature warning light
Glows when the oil temperature is
high and the danger of overheating
is present.
If this light glows, see the topic,
Powershift transmission oil tem-
perature warning light glows.
Seat belt warning light
Glows when the seat belt is not
worn or when it is not inserted into
the seat belt buckle properly.
A buzzer also sound for 30 sec-
onds.
Multi-purpose warning light
Glows when any of the warnings in the ❋ oval below occurs. Liquid crystal
just below the mark also flickers.
Glows when a minor failure occurs. The error code is also displayed.
Two or more warning lights and indicator lights flicker when a major failure
occurs. The error code is also displayed.
If the error code is displayed, see the topic, Error Codes and Explanations.

Parking brake warning light Mast interlock indicator light

Glows when the parking brake is Flickers and the Presence
applied. Detection System (PDS) discon-
A buzzer will sound when an oper- nects power to the lift and tilt
ator leaves the operator’s seat for levers, when the lift/tilt levers are
approximately 2 seconds without moved and the operator is not sit-
applying the parking brake. ting in the operator’s seat for
❋ approximately 2 seconds with the
key switch is in the I (ON) posi-
Brake fluid level warning light
tion.
(optional)
This function is cleared if the
Glows when the fluid level is
operating control lever is placed to
lower than the specified level. 104973
the neutral position and the opera-
tor sits in the seat.

Engine oil pressure warning light Alternator not charging Heater plug indicator
If this light glows during operation, stop the engine and check the oil level. warning light Glows when the key switch is
Add oil as required. Glows when the charging system turned to I (ON) position and goes
is out of operation. If the light out after heating is completed.
! CAUTION Turn the key switch to the
glows, check the alternator drive
(START) position after the indi-
belt for slippage or breakage.
Do not operate the engine when the oil level is low or when this light is on. cator has gone out.
Engine overheating may result. If the light glows when the oil level is nor-
mal, have the engine checked by your Cat lift truck dealer.
36 36
KNOW YOUR LIFT TRUCK 37

Neutral indicator light

Glows when the direction lever is placed in
Neutral (N) position.
Flickers when the direction lever is placed in
forward or reverse at the time of engine start.

Driving interlock indicator light

Flickers and the PDS disconnects power to
the transmission, when the operator leaves
the operator’s seat for approximately 2 sec-
onds with the direction lever in the forward
or reverse position while the key switch is in
the I (ON) position.

Fuel filter warning light

The liquid crystal of hour
meter just below the mark
flickers, and at the same time
the multi-purpose warning
104222 light glows when water
droplets accumulate in the fuel
filter.
If this light-glows, drain the
water.
! CAUTION
If the truck is operated with this light glow-
ing, engine or injection pump damage could
result.
37
Engine coolant level warning light
(optional)
The liquid crystal of hour
meter just below the mark
flickers, and at the same time
the multi-purpose warning
104223 light glows when the coolant in
the reserve tank becomes less
than the specified amount.
If the light glows, refill the
radiator at the reserve tank.
104974
Air cleaner warning light (optional)
The liquid crystal of hour
meter just below the mark
flickers, and at the same time
the multi-purpose warning
light glows when the air clean-
104224 er element is clogged.
If the light glows, clean or
replace the element.
37
KNOW YOUR LIFT TRUCK 38

◆ Side Instrument Panel

Hazard switch Front working light switch Amber rotating light switch
(optional) (optional)

Powershift transmission oil tem-

perature gauge

High beam indicator (optional) Normal Overheat

(green) (red)
Glows when the head lights are
changed from low to high beams
by and goes out when they are
changed from high to low beams.

100044
104918
The gauge needle is normally in
the green zone. If the needle moves
into the red zone, see the topic,
Rear working light switch Powershift Transmission Oil
! CAUTION
(optional) Temperature Gauge Needle
Be sure to stop completely before Moves into the Red Zone.
turning the selector switch.

Speed Selector Switch

Three speed D
Automatic shift
from 1st to 3rd
1st speed 0 to 6.5 km/h (0 to 4.0 mph)
Automatic D
transmission speed 2nd speed 6.5 to 15 km/h (4.0 to 9.3 mph)
three speed Transmission shifts up and
3rd speed 15 to 33 km/h (9.3 to 20.5 mph)
Select after pulling 2 Automatic shift
down automatically.
from 1st to 2nd Automatic 2 1st speed 0 to 6.5 km/h (0 to 4.0 mph)
the switch. speed two speed 2nd speed 6.5 to 18.5 km/h (4.0 to 11.5 mph)
1 Constant Constant 1 For jobs calling for low travel
1st speed
101709 1st speed 0 to 8 km/h (0 to 5.0 mph) speed and greater drawbar pull.

38 38
KNOW YOUR LIFT TRUCK 39

WARNING Brake lining wear warning Brake air pressure warning

! light
Glows, with the buzzer
sounding (continuously),
when the brake linings are
worn. In such a case, immedi-
ately stop the truck and con-
sult your Cat lift truck dealer.
light
Glows when air tank pressure
is low.
Buzzer will sound intermit-
tently when pressure is low.

101754

If the buzzer sounds

Intermittently Continuously

The brake air tank The brake linings

pressure is low. are worn. 104918

Immediately stop Turn the key

the truck and keep switch to (OFF) Overhead guard open warn- Engine warning light (Red) Engine warning light
on depressing the position to stop the ing light Glows when ECU (electronic (Orange)
accelerator pedal. buzzer. Consult Glows when overhead guard control unit) is abnormal. Glows when ECU (electronic
your Cat lift truck is open. Operate the pump Engine will stop and never control unit) is abnormal.
dealer. with the pump bar to lower restart. Immediately consult Park the truck in a safe area.
the overhead guard until it is your Cat lift truck dealer. Consult your Cat lift truck
in fully lowered position. dealer.

39 39
KNOW YOUR LIFT TRUCK 40

◆ Operating Switches and Controls

FC Lever

Selector switch between fourth Emergency stop button Fore-and-aft adjustment stopper
and fifth attachment (optional) knob
For operation of the fifth attach-
ment, operate the attachment lever
Loosen
B while pressing this switch.
Tighten
Attachment lever B (optional)
This lever is for operating the 103657
fourth attachment.

1. Loosen the knob to unlock.

Attachment lever A 2. Adjust the FC lever box to an
This lever is for operating the third appropriate fore-and-aft posi-
attachment. tion.
3. Tighten the knob to lock.
Tilt control lever 4. Make sure that the box is firm-
Backward
ly secured.

Neutral

Up-and-down adjustment
stopper lever
Forward
1. Raise the lever to unlock.
105460 103564B 2. Adjust the FC lever box to an
appropriate height. The box is
Lift control lever assisted with gas springs.
3. Lower the lever to lock.
Raise
4. Make sure that the box is firm-
ly secured.
Neutral

Lower

105461

40 40
KNOW YOUR LIFT TRUCK 41

MC Lever

Lift Control Lever Tilt Control Lever

Lower Forward

Raise Backward

104956 104957

• •

Emergency stop button 105020

Attachment lever A
This lever is for operating the third
attachment.

Attachment lever B (optional) Selector switch between fourth and

This lever is for operating the
fourth attachment.
fifth attachment (optional)
Switch
For operation of the fifth attachment,
operate the attachment lever B while
pressing this switch.
104958

41 41
KNOW YOUR LIFT TRUCK 42

FC Lever/MC Lever

Tilt control lever Mast interlock system

Tilting speed is controlled by the speed of The following cases, the mast interlock system
the engine (the position of the accelerator disconnects power to the hydraulic control
pedal) and the position of the control lever. valves and the mast and attachment will not
The lever will return to the NEUTRAL posi- operate even if the controls are moved:
tion when released. 1. The operator leaves the operator’s seat for
If the operator leaves the operator’s seat for approximately 2 seconds while the key
approximately 2 seconds while the engine is switch is in the I (ON) position irrespec-
running, the mast will not tilt forward/back- tive of the engine is running or not.
ward even if the lever is tilted forward/back- 2. When the engine is running but the emer-
ward. This is not a failure, the mast interlock gency stop button is in STOP (lock) posi-
system has been activated.
tion (being pushed down).
(Equipped with mast interlock system)
NOTICE:
Lift control lever The mast interlock will work for the lift, tilt
Lifting speed is controlled by the speed of and attachment levers. If the engine is not run-
the engine (the position of the accelerator ning or the key switch is in the (OFF) posi-
pedal) and the position of the control lever. tion, the lift, tilt and attachment levers will not
Lowering speed is controlled only by the operate regardless of whether the seat switch
position of the control lever regardless of the position is ON or OFF.
speed of the engine.
The lever will return to the NEUTRAL posi-
tion when released.
Equipped with mast interlock system
If the operator leaves the operator’s seat for
approximately 2 seconds while the key
switch is in I (ON) position irrespective of
the engine is running or not, the mast will
not lower even if the lever is tilted forward.
This is not a failure, the mast interlock sys-
tem has been activated.
If the operator sits on the seat while the key
switch is in I (ON) position with engine
stopping, the mast can be lowered.

42 42
KNOW YOUR LIFT TRUCK 43

Emergency stop button How to use

Use this button:
– To stop (lock) lift, tilt and attachment – To operate (unlock these actions), turn the
1. When you have to stop mast and attach- button clockwise.
actions, push down on the button. The
ments actions in an emergency—without mast and attachments will not move even
stopping the engine. if the controls are moved.
2. When you get off the truck.

STOP (lock) position OPERATE (unlock)

(The button will remain in position
this position when released.) 103667

104962

43 43
KNOW YOUR LIFT TRUCK 44

◆ Operator’s Seat
• Adjustment
• Fore-and-aft Adjustment • Adjustment of Suspension
! WARNING

Reclining Increase Adjusting lever

lever
Gauge

Adjusting
lever Seat belt Decrease

Slide lever
104862
Adjust the seat before starting the engine.
After adjusting, jiggle the seat to make sure it
is properly locked. DO NOT adjust the seat
while the truck is in motion.
Lever
104863 103956
Lift the lever, slide the seat to one of the eleven Adjust the suspension before sitting in the seat.
positions, and release the lever. Pull out the lever. Then turn the lever until the
gauge indicates the weight of the operator.
Turning the lever clockwise increases the
gauge indication, and turning it counterclock-
! WARNING wise decreases the gauge indication.
Your lift truck comes equipped with a • Backrest Angle Adjustment
Cat lift truck genuine operator restraint
system and an operator presence switch.
Should it become necessary to replace Reclining
lever
the seat for any reason, it should only be
replaced with a Cat lift truck genuine
operator restraint system equipped with
an operator presence switch.

104864

Push the lever and set the backrest to one of

the four positions.

44 44
KNOW YOUR LIFT TRUCK 45

• Pocket for the Manual • Operator Presence Switch

Operator presence
switch

104865 104866

Place the operator’s manual in this pocket. Use
both hands to open/close the pocket.
This switch is built into the seat. The mast and
attachments cannot be moved unless the opera-
tor is seated in the operator seat.
Regardless of the running or stopping of the
engine, the parking brake warning buzzer
sounds and parking brake warning light flick-
ers if an operator leaves the seat without apply-
ing the parking brake.
When leaving the truck during an extended
period of time, apply the parking brake and
turn the key switch to (OFF).

! CAUTION

When replacing the operator seat, be sure

to select a Cat lift truck genuine seat with
operator presence switch.

45 45
KNOW YOUR LIFT TRUCK 46

◆ Seat Belt
The seat belt shall be examined at the regular
! DANGER ! WARNING
service intervals. It is recommended that it be
replaced if any of the following conditions are Seat belts can “jack-knife” drivers—the
found. upper body bends tightly at the waist. If
– Cut or frayed strap you are pregnant or have suffered an
– Worn or damaged hardware, including abdominal disease or injury, consult a
anchor points doctor before using the seat belt.
– Buckle or retractor malfunction
– Loose stitching

105015
! WARNING
The seat belt will help to restrain you in acci-
dents such as a tipover or mast and attachment WARNING If you fasten the belt across your
collisions. If you are unrestrained in a tipover, ! abdomen, the belt will dig into your
you can fall outside of the operator’s compart- abdomen in an accident and may cause
ment and be crushed by the lift truck. If you do serious internal injuries.
not wear your seat belt and have a collision,
you could be thrown from the seat and into the
mast or out of the operator’s compartment.
Wear your seat belt anytime you operate a lift
truck.
NOTICE: It is not necessary to adjust the belt
length.
! WARNING
104945 The belt is designed to fit any body
size.
Also, replace the seat belt assembly if it was
worn during an accident. Tug on it to confirm a tight fit.

104274

If the seat belt is torn causing the pulling

motion to be interrupted during extension of
the belt, or the belt cannot be inserted into the
buckle properly. Replace the seat belt assem-
bly.
46 46
KNOW YOUR LIFT TRUCK 47

To Fasten To Release

Plate

Buckle
104268 104270

1. Grip the plate (connector) of the belt and
pull the belt from the retractor. Then insert
the plate into the slot of the buckle until a
snap is heard.
2. Make sure the belt is not twisted.
Push the button in the buckle to release the
belt. The belt will automatically retract when
released. Hold the plate of the belt and allow
the belt to slowly retract.
IMPORTANT

The following maintenance guidelines detail how to inspect seat belts for “cuts, fraying, extreme or
unusual wear of the webbing, etc., and damage to the buckle, retractor, hardware, or other factors”
which indicate that belt replacement is necessary.
1. Check the web wear at the buckle/latch area. The webbing must be closely examined to deter-
OK
mine if there are any cuts, fraying or extreme wear in the webbing. Cuts, fraying, or excessive
OK
wear would indicate the need for replacement of the seat belt system.
2. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed,
or buckle is damaged or casing is broken.
3. The retractor web storage device, is mounted on the seat. The retractor is the heart of the occu-
pant restraint system and can be damaged if abused, even unintentionally. Check retractor web
104269 storage device operation to ensure that it locks properly and that it spools out and retracts web-
3. Be sure to fasten the belt as low as possi- bing properly.
ble across your hips, not across your 4. Hardware for seat belt mounting points should be evaluated for corrosion, all attachment points
of system should be checked for tightness of bolts and nuts.
abdomen.
5. Check web in areas exposed to ultraviolet rays from the sun or extreme dust or dirt. If the origi-
nal color of the web in these areas is extremely faded, the physical strength of this web may
have deteriorated. If this condition exists replace the system.
6 Check the operation of the seat belt switch.

47 47
KNOW YOUR LIFT TRUCK 48

◆ Presence Detection System

• Mast Interlock System
When the operator leaves the operator’s seat for approximately 2 seconds while the engine is running,
the operator presence switch of the seat is activated to make the mast irresponsive, even if the lift or tilt
levers are operated.

Position of Mast interlock Operating control lever

Engine Operator seat
key switch indicator light Lift Tilt
Seated OFF Not active Not active
(OFF) Stop
Not seated OFF Not active Not active
104975
Seated OFF Lowering only Not active
I (ON) Stop
Not seated Flicker Not active Not active
Lift trucks with this label are equipped with an
operator “Presence Detection System” (PDS). Seated OFF Active Active
(START) Running
This system features an enhanced, integral Not seated Flicker Not active Not active
computer-based feed back system which pro-
vides “certain product intelligence” to the CAUTION NOTICE:
!
operator. The mast interlock will work for the lift, tilt
Be sure to operate the vehicle and system cor- 1. Prior to operating the lift truck, be sure and attachment levers. If the engine is not run-
rectly. Also be sure to properly maintain the to check the mast interlock for opera- ning or the key switch is in the (OFF) posi-
system at all times. tion. tion, the lift, tilt and attachment levers will not
2. This interlock system provides “inte- operate regardless of whether the seat switch
grated” feed back to the operator dur- position is ON or OFF.
ing operation. Always operate the lift
truck correctly with safety in mind.
3. Even when the engine is not running,
while the operator is sitting correctly
in the operator’s seat and with the key
switch at the I (ON) position, it is pos-
sible for the mast to descend. Please be
very careful. (See the table above).
4. When replacing the operator’s seat
assembly, be sure to use Cat lift truck
104628
genuine seat with an operator presence
switch.

48 48
KNOW YOUR LIFT TRUCK
• Driving Interlock System
In normal operation your lift truck will drive in
a creep mode when the direction lever is placed
in the forward or reverse position at engine
idling (not depressing the accelerator pedal). If
the operator leaves the operator’s seat for
approximately 2 seconds, a switch in the seat
activates the driving interlock system, and elec-
trically shifts the transmission to neutral (the
direction lever remains in the forward or reverse
position) to stop the lift truck. In this case, the
parking brake does not synchronize with the
driving interlock and is not automatically
applied the moment the interlock is activated.
If the truck is on a grade and the driving inter-
lock system has been activated, the truck may
continue to move in the direction of the down-
grade. In this case, apply the brakes and sit
securely in the seat.
103888
• Driving Interlock System Functions
Conditions
Key Switch Engine Operator’s Seat
Not Seated
Seated
Seated to Not Seated
ON ON
Seated to Not Seated to Seated
Not Seated to Seated
Not Seated to Seated
49
49
! CAUTION
1. Prior to operating the lift truck, be sure
to check the function of the driving
interlock system.
2. While driving the lift truck, if you lift
your hips above the seat for approxi-
mately 2 seconds, the driving interlock
system will be activated, the same as
in case of engine idling. Always drive
the lift truck correctly with safety in
mind.
3. To restore the lift truck to its normal
driving condition, sit properly in the
operator’s seat and depress the brake
pedal to hold the lift truck. Then,
return the direction lever to the neutral
position once and then shift it back
into the forward or reverse position.
4. When replacing the operator’s seat, be
sure to use Cat lift truck genuine seat
with an operator presence switch.
Direction Lever Function Safety Warning
F/R Driving inoperative Driving Interlock Indicator Light [Flicker]
F/R Driving operative Driving Interlock Indicator Light [OFF]
F/R For 2 seconds driving operative After 2 seconds Driving Interlock Indicator Light [Flicker]
F/R Within 2 seconds driving operative Within 2 seconds Driving Interlock Indicator Light [OFF]
F/R Driving inoperative Driving Interlock Indicator Light [Flicker]
F/R to N to F/R Driving inoperative, Driving interlock indicator [Flicker] then [OFF] after Neutral
then operative after Neutral
49
KNOW YOUR LIFT TRUCK 50

• Neutral System • Seat Belt Warning Light and Buzzer

The lift truck is provided with a risk reduction
device that prevents the engine from being
started when the direction lever is not in the
neutral position.
! CAUTION
The seat belt has a switch that activates a
warning light and a buzzer once you are seat- Before starting the engine, sit properly in
ed. The warning light in the display stays on the operator’s seat and make sure that:
until the seat belt is buckled and a buzzer
– No one is around the lift truck.
sounds for 30 seconds. The seat belt warning is
– The parking brake is applied.
one of the functions of the PDS system
– The direction lever is in the neutral
installed on this truck. The operator display
position.
will let you know when the seat belt is not
buckled or if it is properly buckled.

Seat belt warning light

! CAUTION

1. Prior to operating the lift truck, be sure

to check the function of the seat belt
warning light.
2. This warning light is for reminding the
operator to fasten the seat belt.
Maintain it so that it is always in order.
104016 104974

• Seat Belt Warning Functions

Conditions
Key Switch Engine Operator’s Seat Seat Belt Safety Warning
Not Seated Not Buckled Seat Belt Warning Light [ON]
Buckled Seat Belt Warning Light [OFF]
ON ON or OFF
Seated Not Buckled Seat Belt Warning Light [ON]
Buckled Seat Belt Warning Light [OFF]

• Neutral System Functions

Conditions
Key Switch Operator’s Seat Direction Lever Safety Function
OFF or ON Seated or Not Seated Neutral Engine starts only when the direction lever is in the
Neutral Position.

50 50
KNOW YOUR LIFT TRUCK 51

• Parking Brake Warning Buzzer and Light

The parking brake is a double action type
designed to be released while pressing the top
button and pushing the lever forward. When
leaving the lift truck, always apply the parking
brake! The parking brake is not automatically
applied. Leaving the operator’s seat for
approximately 2 seconds or turning off the key
switch activates the warning buzzer. The light
in the instrument panel stays on when the
parking brake is applied. The parking brake
warning buzzer and light is a function of the
PDS system.
! WARNING
When leaving the machine (lift truck),
apply the parking brake! The parking
brake is not automatically applied.
Alarm will sound if parking brake is not
applied when getting off the lift truck or
turning off the key switch.
Parking brake warning light
! CAUTION
1. Prior to operating the lift truck, be sure
to check the function of the parking
brake warning buzzer and light for
function.
2. The buzzer and warning light are for
Parking reminding the operator to apply the
brake parking brake when leaving the lift
lever
105023
truck. Be sure to maintain them so that
they are always in order.
3. When parking the lift truck:
– Select a place with level and hard
surface.
– Place the direction lever to the NEU-
TRAL position.
– Lower the forks until the fork tips
touch the floor.
– Apply the parking brake.
– Stop the engine and remove the key.
4. When replacing the operator’s seat, be
sure to use Cat lift truck genuine seat
with an operator presence switch.

• Parking Brake Warning Functions

Conditions
Key Switch Engine Operator’s Seat Parking Brake Safety Warning
Seated to Not Applied Parking Brake Warning Light [OFF] Buzzer [ON]
OFF OFF
Not Seated Applied Parking Brake Warning Light [OFF] Buzzer [ OFF]
Not Applied Parking Brake Warning Light [OFF] Buzzer [ON]
Not Seated
Applied Parking Brake Warning Light [ON] Buzzer [ OFF]
Not Applied Parking Brake Warning Light [OFF] Buzzer [ON]
OFF OFF Seated
Applied Parking Brake Warning Light [ON] Buzzer [ OFF]
After 2 seconds
Seated to Not Seated Not Applied Parking Brake Warning Light [OFF]
Buzzer turned [ON]
51 51
KNOW YOUR LIFT TRUCK 52

◆ Raising and Lowering Overhead Guard

• Raising Overhead Guard

! WARNING Pump LOWER

Verify no one is under the overhead

guard when raising the overhead guard.
RAISE

Pump bar

! WARNING
Pump bar
Direction valve
105055 connection 104920A
Perform maintenance in the mainte-
nance position (50° tilted).
Before you place any part of your body 1. Tilt the mast fully forward.
Step
under the overhead guard, always ensure 2. Remove all unsecured items from the over- Pump
that the overhead guard is stopped in the head guard.
maintenance position (50° tilted). 3. Use the pump bar to turn the direction
Remove the pump bar from the pump valve clockwise to RAISE position.
Pump bar Knob
bar connection. 4. Next, insert the pump bar to the pump bar
Do not continue to raise the overhead connection and operate the pump with it.
guard to fully open position (65° tilted). 5. Raise the overhead guard with the pump
until it reaches to the maintenance position
104921
(50° tilted).
Never stop raising before the overhead Located on the rightside frame of the truck.
! CAUTION guard is secured in the maintenance posi-
tion (50° tilted).
Overhead guard damage may occur if the
mast is not completely tilted forward.

! CAUTION Pump bar

Use the pump bar equipped on the lift

truck to raise and lower the overhead
guard.

52 52
KNOW YOUR LIFT TRUCK
• Lowering Overhead Guard
! WARNING
Verify no one is under the overhead
guard when lowering the overhead
guard.
CAUTION
! tilted).
Overhead guard damage may occur if the
mast is not completely tilted forward.
! CAUTION
Use the pump bar equipped on the lift
truck to raise and lower the overhead
guard.
53
53
1. Check that all foreign items/tools are
cleared away.
2. Use the pump bar to turn the direction
valve counterclockwise to LOWER posi-
tion.
3. Next insert the pump bar to the pump bar
connection and operate the pump with it.
4. Lower the overhead guard with the pump
until it stops in partially stop position (25°
5. While pulling out the knob, operate the
pump with the pump bar a few times.
6. Then release the knob and continue to
lower the overhead guard until it is in fully
lowered position. Make sure the knob
returns to the push in position.
53
KNOW YOUR LIFT TRUCK 54

◆ Fuses and Lights

• Lights Won’t Come On

CAUTION Lamp type Capacity

! Check for burned-out or blown fuses first.
Instrument panel lamp 24V-3W
– Always replace fuses with fuses of the Tail/Stop lamp 24V-10W/25W
correct amperage. Head lamp 24V-60W/60W
– If a fuse burns out immediately and
Check the fuses one by one by Turn signal lamp 24V-25W
you cannot locate the cause, have your
Cat lift truck dealer make a circuit operating the light switch and Clearance lamp 24V-12W
check. observing which light comes on. Back-up lamp 24V-25W
– Use a replacement light bulb of the Working lamp (opt) 24V-60W
same wattage.
Lamps may be burned out.
Fuse for engine
Fuse for T/M
Capac-
Code Circuit
ity
100846
F1 15A Head light
Fuse for
F2 10A Horn chassis
F3 10A Stop light
One light of the circuit fails to light.
F4 15A Spare
F5 15A Working light 104985 All lights of the circuit fail to light.
F6 10A DC-DC Convertor
F7 10A Revol light
F8 20A Spare
Check to see if fuse is blown.
F9 15A Spare
F10 20A Spare
F11 10A Air dryer
F12 15A Backup-light
F13 15A Fuel cut
F14 30A Wiper 103614A
F15 10A Warning lamp and buzzer
To remove a fuse, pull the fuse in the direction 100845
F16 10A Spare of the arrow.

54 54
KNOW YOUR LIFT TRUCK 55

◆ Fork Adjustment ◆ Safety Equipment ◆ Battery Cut-Off Switch

WARNING – Overhead guard

!
– Lift bracket
When adjusting the fork spread, be care- ON
ful not to pinch your hand in the lift DO NOT use a lift truck without safety equip-
bracket slot. ment in proper operating order.
OFF

! CAUTION
104905

– Position each fork the same distance Turn on the battery cut-off switch to operate
from the center of the lift bracket. the lift truck or to lift cargo.
– For load stability, always adjust the Turn off the switch before conducting mainte-
forks as wide as possible (as wide as nance work to reduce the risk of an electric
the load will permit). Position the load shock.
evenly on both forks.

Fork
locking
pin

Fork

101984A

1. Lift fork locking pins and slide fork to the

new position.
2. Secure the fork locking pins in the lift
bracket slot. Follow the same procedure
for the other fork.

55 55
KNOW YOUR LIFT TRUCK 56

◆ Drawbar Pin ◆ Assist Grip and Foot Step

! WARNING ! WARNING ! WARNING

DO NOT use the drawbar pin for towing OK OK DO NOT grab the steering wheel or
loads. lever. DO NOT jump on or off the truck.

101262B
Drawbar pin

Precautions for Use of the Drawbar Pin

1. When hitching a cable to the pin, make

sure the pin is inserted safely.
101261A 104967
2. Take up slack slowly – DO NOT jerk.
Use the drawbar pin for: Keep the cable taut. If the cable is slack, Grasp the assist grip with the left hand; the
– Pulling the truck out of a drop-off or ditch. the sudden impact of the load can snap it, seat backrest with the right hand, and use the
– Loading the truck on a hauling truck. resulting in an accident. foot step to get on the truck safely.
3. A helper should stand at a safe distance
and watch the pin. Stop pulling with the
truck, relieve tension, and reduce load if
the pin starts to come out.

56 56
KNOW YOUR LIFT TRUCK 57

◆ Engine Hood

! CAUTION

When closing the engine hood, be careful

not to pinch your hand.

104924
Handle
The engine hood swings up to fully expose the
engine compartment for daily inspection, serv-
icing and lubrication.

Inspection points inside engine 104925

compartment
To open
– Engine oil level
– Engine coolant level 1. Pull the engine hood lever in the direction
– Brake fluid level of the arrow.
– Fan and alternator drive belt 2. Raise the engine hood by using the handle.

To close
1. Push the engine hood down until it is
locked by using the handle.

• Engine Hood Open Switch

The engine will stop if the engine hood is
opened. Once you have closed the engine
hood, turn the key switch to the (OFF) posi-
tion and then turn it to the (START) posi-
tion. The engine will start.

57 57
KNOW YOUR LIFT TRUCK 58

◆ Hydraulic Tank Oil Filler Hole ◆ Fuel Shut-off Valve

! CAUTION

Confirm the engine type before filling the

tank with the recommended fuel.
Close

Open

101542 104868

The oil filler hole is located on the right side of The fuel shut-off valve is located on the left
the truck. side frame of the truck. In an emergency or
when performing maintenance, close this
valve.

◆ Fuel Filler WARNING WARNING

! !

100165A 100989B 101968A

The fuel filler is located on the left side of the
truck. The cap can be removed by turning it
counterclockwise.
Never fill the fuel tank near an open flame or After refueling, close the cap tightly and wipe
when the engine is running. When filling, keep up spillage.
the funnel or fuel hose nozzle in contact with
the tank’s metal. This reduces the risk of an
electric spark igniting the fuel.

58 58