CAT Lift Truck GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K Operation & Maintenance Manual # 1

Operation & Maintenance Manual 99730-85141 Keep this manual in your lift truck as a ready reference. GP40K AT29C-00011-20230 AT29C-20231-up GP40KL AT29C-50011-70230 AT29C-70231-up GP45K AT29C-80001-89999 AT29C-R0231-up GP50K AT33B-50001-70230 AT33B-70231-up DP40K AT19C-00011-20230 AT19C-20231-up DP40KL AT19C-50001-70230 AT19C-70231-up DP45K AT19C-80001-89999 AT19C-R0231-up DP50K AT28B-50001-70230 AT28B-70231-up

i i The Occupational Safety and Health Administration (OSHA) is now mandating operator training for all lift truck operators. SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness of the operator. To develop the skill, the operator should: 1. Know the working capabilities and limitations of the lift truck. 2. Know the make-up of the lift truck. 3. Read and understand the safe driving and load handling procedures con- tained in this manual. And, most important, a qualified person experienced in lift truck operation should guide new operators through several driving and load handling opera- tions before they attempt to operate the lift truck on their own. It is the responsibility of the employer to make sure the operator can see, hear and has the physical and mental ability to operate the lift truck safely. This manual contains information necessary for the operation and “do-it-yourself” maintenance of standard lift trucks. Optional equipment is sometimes installed; it can change some operating characteristics described in this manual. Before operating such a lift truck, make sure the necessary instructions are available and understood. Lift truck operator training is provided through your Cat lift truck dealer. They will be glad to help you and answer any questions you may have about operating your new lift truck. The lift trucks are NOT intended for use on public roads. FOREWORD 100588A 99730-85141

ii ii The following safety signs and NOTICE are used in this manual to emphasize important and critical instructions. Be sure to read these precautionary instructions and all safety related decals installed on your truck before you operate it. Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by MCFA is used, you must satisfy yourself it is safe for you and others. You should also ensure the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the most complete and current information from your Cat dealer before starting any job. Cat dealers have the current information available. Additional manuals are available from your Cat dealer. Directional terms: The directions “left,” “right,” “front” and “rear” are given from the view- point of the operator facing forward. 101582C HOW TO USE THIS MANUAL Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a potentially hazardous situation 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 moderate injury, or damage to your machine. DANGER ! WARNING ! CAUTION ! !

iii iii TABLE OF CONTENTS Know What Lift Truck Stability is ...................................................... 44 Center of Gravity (CG) ........................................................................ 44 Stability and Center of Gravity ............................................................ 44 Lift Truck Stability Base ...................................................................... 43 Capacity (Weight and Load Center) .................................................... 45 Capacity Chart ..................................................................................... 46 Do’s and Don’ts to Avoid Tipover ....................................................... 47 How to Survive in a Tipover ................................................................ 49 HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE New Lift Truck Break-In ..................................................................... 54 Before Starting Engine......................................................................... 54 Starting Gasoline Engine ..................................................................... 57 Starting Diesel Engine ......................................................................... 58 Engine Won’t Start ............................................................................... 59 Starting with Jumper Cables ................................................................ 60 Starting LP-Gas Engine ....................................................................... 61 After Starting Engine ........................................................................... 61 Before Moving Lift Truck.................................................................... 62 Lift Truck Operation ............................................................................ 63 Stopping Lift Truck .............................................................................. 67 Parking Lift Truck (After Stopping) .................................................... 68 OPERATION In General............................................................................................. 1 Warning Decals, Location .................................................................... 2 Decals for LP-Gas Only....................................................................... 4 Warning Decals, Description ............................................................... 5 Safety Rules ......................................................................................... 10 Operating Precautions .......................................................................... 17 Working Precautions ............................................................................ 20 LP-Gas ................................................................................................. 25 SAFETY RULES FOR LIFT TRUCK OPERATORS Serial Number and Capacity Plate ....................................................... 26 Model View .......................................................................................... 27 Operator’s Compartment ...................................................................... 28 Instrument Panel .................................................................................. 30 OK Monitor (Warning Lights and Indicators) ..................................... 32 Driving Interlock System ..................................................................... 33 Operator’s Seat ..................................................................................... 35 Seat Belt ............................................................................................... 36 Fuses and Lights .................................................................................. 39 Fork Stoppers ....................................................................................... 40 Changing Forks .................................................................................... 40 Additional Warning Devices ................................................................ 40 Drawbar Pin ......................................................................................... 41 Assist Grip ........................................................................................... 41 Hydraulic Tank Oil Level/Filler Hole .................................................. 42 Fuel Filler ............................................................................................. 42 Fuel Shut-off Valve .............................................................................. 42 Engine Hood ........................................................................................ 43 KNOW YOUR LIFT TRUCK Gasoline and Diesel Engine Equipped ................................................ 51 LP-Gas Equipment ............................................................................... 52 REFUELING Stacking Methods................................................................................. 69 Handling Loads Safety......................................................................... 70 Inching Into and Lifting the Load........................................................ 71 Traveling with the Load ....................................................................... 72 Unloading ............................................................................................. 73 Working on Grades .............................................................................. 75 OPERATING TECHNIQUES

iv iv Care in Cold Weather ........................................................................... 80 Care in Hot Weather............................................................................. 81 Care in Severe Dust or Lint Conditions............................................... 81 SPECIAL SITUATIONS TO THE CAT LIFT TRUCK OWNER General ................................................................................................. 94 Inspection Precautions ......................................................................... 95 Maintenance Schedule ......................................................................... 96 Every 10 Service Hours or Daily (Pre-start), Whichever Comes First....... 99 Every 50 Service Hours or Weekly, Whichever Comes First ..............114 One Month After Delivery of a New Truck .........................................116 Every 200 Service Hours or Monthly, Whichever Comes First ..........117 Every 400 Service Hours or 2 Months, Whichever Comes First ........124 Every 600 Service Hours or 3 Months, Whichever Comes First ........127 Every 1200 Service Hours or 6 Months, Whichever Comes First ......128 Every 2400 Service Hours or 1 Year, Whichever Comes First ............136 Parts to be Changed Periodically .........................................................137 MAINTENANCE Fuel Information ..................................................................................138 Coolant Information .............................................................................140 Recommended Fuels and Oils .............................................................142 Specifications and Refill Capacities (Standard Models) .....................145 Capacity and Truck Weight (Standard Models) ...................................146 SERVICE DATA The Importance of Genuine Parts ........................................................147 Instructions for Ordering Parts ............................................................148 Service Registration .............................................................................149 Transfer of Ownership Report .............................................................150 End of Each Shift Storage.................................................................... 78 Long Term Storage............................................................................... 78 STORING THE LIFT TRUCK Lift Truck Shipping .............................................................................. 79 Machine Lifting and Tiedown Information ......................................... 79 TRANSPORTATION HINTS Changing a Tire .................................................................................... 82 Stalled Engine ...................................................................................... 90 Engine Coolant Temperature Gauge Needle Moves Into Red Zone ....................................................................... 91 Powershift Transmission Oil Temperature Warning Light Glows ....... 91 Driving Interlock Indicator Light Flickers or Flashes, and the Truck Stops Moving ............................................................ 92 Trouble with the LP-Gas Equipment ................................................... 93 TROUBLESHOOTING INDEX Index.....................................................................................................151

1 1 |||||||||||||||||||||||||||||||| SAFETY RULES FOR LIFT TRUCK OPERATORS ||||||||||||||||||||||||||||| The safety rules and regulations in this section are representative of some, but not all rules and regulations that apply to lift trucks. Rules are paraphrased without representation they have been reproduced verbatim. Your lift truck was manufactured in accordance with the National Fire Protection Association (NFPA) No. 505 and the American National Standards Institute, Inc./Industrial Truck Standards Development Foundation (ANSI/ITSDF) B56.1, Safety Standard for Low and High Lift Trucks. Operate this lift truck in accordance with local regulations. See www.ITSDF.org web site for more information on the B56.1 Safety Standard for Low and High Lift Trucks. The most effective way of preventing serious injuries, or even death, to you and others, is for you to know how to operate the truck properly. Drive alertly and avoid maneuvers or conditions 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. Continuing improvement and advancement of product design may have caused changes to your lift truck which are not included in this publication. Whenever a question arises regarding your lift truck, or this publication, please consult your Cat lift truck dealer for the latest available information. All lift truck users should be familiar with their Local, Regional, and National regulations. United States users should be familiar with the Occupational Safety and Health Administration (OSHA), and American National Standards Industrial Forklift Trucks. You should also be familiar with areas of use of different types of lift trucks as specified in the National Fire Protection Association (NFPA). ◆ In General

2 2 You must replace a decal if it is damaged, missing or cannot be read. If a decal is on a part that is replaced, make sure a new decal is placed on the new part. Contact your Cat lift truck dealer for new decals. There are several specific warning decals on your lift truck. Their exact location and description of the potential hazard are reviewed in this section. Please take the time to familiar- ize yourself with these decals. Be sure you can read all warning and instruc- tion decals. If you cannot, clean or replace them. Use a cloth and soap and water to clean them. SAFETY RULES FOR LIFT TRUCK OPERATORS ◆ Warning Decals, Location Hoist Point decal Inspection/Lubrication chart No One On Forks decal No One Under Forks decal Precautions for Handling E.C.U. decal No Access with Engine Running decal 105363 Tire Pressure decal Deflate Air Before Loosening Nut Engine Coolant decal Radiator Cap Warning decal Fuel decal Parking Brake Adjustment decal Operator Restraint System decal No One Between Mast and Body decal (Inside of Right Step)

3 3 SAFETY RULES FOR LIFT TRUCK OPERATORS Direction Lever decal Impact Test Rating decal No Riders decal Capacity decal With Backrest Extension decal Operator Restraint System decal No Contamination decal UL Plate Operation Warning decal Back-up Buzzer decal Fasten Seat Belt decal Survive in Tipover decal 105364 Requirement Tires Authorized Pinch Point decal

4 4 SAFETY RULES FOR LIFT TRUCK OPERATORS ◆ Decals for LP-Gas Only Fuel decal Dual Fuel System decal Fuel Gauge decal (For L.P. Gas Only) Maintenance decal Location decal L.P.G. decal 105365 G/LPG Changeover decal

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CAT Lift Truck GP40K GP40KL GP45K GP50K DP40K DP40KL DP45K DP50K Operation & Maintenance Manual # 1

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