GP15N GP35N IC Pneumatic Trucks Electronic Sales Manual

Page 1
LIFT TRUCK ELECTRONIC SALES MANUAL
GP15N-GP35N/DP15N-DP35N
3,000 lb. 7,000 lb. Capacity IC Pneumatic
Forklifts
Last updated on 15 December 2014
Copyright 2013. All rights reserved. All registered trademarks
are the property of their respective owners, including Cat Lift Trucks and its
logos. Some products may be shown with optional equipment.
Page 2
TABLE OF CONTENTS
NOTE: Each word in the Table of Contents is hyperlinked. Click on the word to jump to the related page.
ABOUT THIS LIFT TRUCK SALES MANUAL ................................................................................................... 8
Your Single Source For All Model-Related Selling Information ........................................................................ 8
Your Participation To Improve This Document & Who To Contact ................................................................. 8
How To Find Information.................................................................................................................................. 9
SPECIFICATIONS ...................................................................................................................................... 10
Line Art ........................................................................................................................................................... 10
Primary Specifications .................................................................................................................................... 11
Mast Tables..................................................................................................................................................... 14
GP15N Single Drive .................................................................................................................................. 14
GP15N Solid Drive .................................................................................................................................... 15
GP18N Single Drive .................................................................................................................................. 16
GP18N Solid Drive .................................................................................................................................... 17
GP20CN Single Drive ................................................................................................................................ 18
P20N Single Drive .................................................................................................................................... 19
GP20N Solid Single Drive ......................................................................................................................... 20
GP20N Dual Drive .................................................................................................................................... 21
GP20N Solid Dual Drive ........................................................................................................................... 22
GP25N Single Drive .................................................................................................................................. 23
GP25N Dual Drive .................................................................................................................................... 25
GP28N Single Drive .................................................................................................................................. 27
GP28N Dual Drive .................................................................................................................................... 29
GP30N Single Drive .................................................................................................................................. 31
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GP30N Dual Drive .................................................................................................................................... 33
GP33N Single Drive .................................................................................................................................. 35
GP33N Dual Drive .................................................................................................................................... 37
GP35N Single Drive .................................................................................................................................. 39
GP35N Dual Drive .................................................................................................................................... 41
INTRODUCTION ....................................................................................................................................... 43
Market Focus .................................................................................................................................................. 43
Class V Market Opportunity ....................................................................................................................... 43
Class V by Product Type.............................................................................................................................. 44
SICP by Fuel Type ........................................................................................................................................ 45
Target Industries/Applications ................................................................................................................... 46
Product Configuration .................................................................................................................................... 47
Models and Capacities................................................................................................................................ 47
Standards Compliance ................................................................................................................................ 48
COMPETITIVE COMPARISON.................................................................................................................... 50
Ramp Performance ..................................................................................................................................... 51
Top Travel Speed ........................................................................................................................................ 53
Lift Speeds .................................................................................................................................................. 54
Fuel Consumption and Productivity Cycles ................................................................................................ 55
PRODUCTIVITY ........................................................................................................................................ 56
K21 and K25 Engines................................................................................................................................... 56
4EG Diesel Engine ....................................................................................................................................... 57
Emissions Compliant Fuel System .............................................................................................................. 58
Powershift Transmission ............................................................................................................................ 59
RELIABILITY ............................................................................................................................................. 62
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Durable Steel Frame ................................................................................................................................... 62
Mast and Carriage ...................................................................................................................................... 63
Overhead Guard ......................................................................................................................................... 64
Low Profile Counterweight ......................................................................................................................... 65
Engine Protection System........................................................................................................................... 66
3-Section Hydraulic Control Valve with Cowl Mounted Levers ................................................................. 67
Vehicle Control Module .............................................................................................................................. 68
Electrical System ......................................................................................................................................... 69
Hydraulic System ........................................................................................................................................ 70
Air Intake Process ....................................................................................................................................... 75
Drive Axle .................................................................................................................................................... 76
Steer Axle .................................................................................................................................................... 77
Hydrostatic Power Steering System ........................................................................................................... 77
Cooling System ........................................................................................................................................... 78
Cooling Fan ................................................................................................................................................. 78
Two Pedal Brake System ............................................................................................................................ 79
Inching Pedal .............................................................................................................................................. 79
Parking Brake System ................................................................................................................................. 80
Tires ............................................................................................................................................................ 81
Easy Maintenance ...................................................................................................................................... 82
500 Hour Service Intervals.......................................................................................................................... 83
SUPERIOR OPERATOR COMFORT ............................................................................................................. 84
Full Suspension Vinyl Seat .......................................................................................................................... 84
Orange Seatbelt .......................................................................................................................................... 84
Noise Reduction Features .......................................................................................................................... 85
Tilt Steer Column with Mechanical Quick Return ...................................................................................... 86
Electronic Direction Control ....................................................................................................................... 86
Three Point Entry System ........................................................................................................................... 87
Floor Mat .................................................................................................................................................... 88
INCREASED OPERATOR AWARENESS........................................................................................................ 89
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Premium LCD/LED Display Panel ................................................................................................................ 89
Meter Panel Indicator Lights ...................................................................................................................... 90
Mast Visibility ............................................................................................................................................. 91
LED Forward Work Lights ........................................................................................................................... 92
Rear Combination LED Lights ..................................................................................................................... 92
ADDED OPERATOR PROTECTION ............................................................................................................. 93
Presence Detection System (PDS) .............................................................................................................. 93
Parking Brake .............................................................................................................................................. 94
Ground Speed Control ................................................................................................................................ 94
Electronic Backup Alarm............................................................................................................................. 94
OPTIONS ................................................................................................................................................. 95
Custom Shop Modifications (CSMs) ........................................................................................................... 95
Fork Options ............................................................................................................................................... 95
UL Safety Rated Chassis Options ................................................................................................................ 96
Optional Wide Carriages............................................................................................................................. 98
Sideshifters ................................................................................................................................................. 99
3- & 4- Section Control Valves with Levers and Fingertip Control Options ............................................. 100
Single Function Internal Hosing ................................................................................................................ 101
Dual Function Internal Hosing .................................................................................................................. 101
Hydraulic Steel Supply Lines ..................................................................................................................... 102
Hydraulic Lift Line Accumulator ............................................................................................................... 103
Load Bearing Clamp Lockout .................................................................................................................... 104
Bottlers Tilt .............................................................................................................................................. 104
Tilt Cylinder Boot Kit ................................................................................................................................. 105
Overhead Guard Options.......................................................................................................................... 105
Martin Cab ................................................................................................................................................ 106
Martin Cab Accessories ............................................................................................................................ 107
Harris Stolper Cab ..................................................................................................................................... 108
Harris Stolper Cab Accessories ................................................................................................................. 109
Tire Options .............................................................................................................................................. 110
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Seat Options ............................................................................................................................................. 112
Foot Direction Control .............................................................................................................................. 113
Reverse Drive Packages ............................................................................................................................ 114
Steering Wheel Knob ................................................................................................................................ 114
Rear Grab Bar With Horn Button.............................................................................................................. 115
Swing Down LP Tank Bracket.................................................................................................................... 115
Underbelly Screen .................................................................................................................................... 116
High Pass Through Radiator ..................................................................................................................... 116
Radiator Screen ........................................................................................................................................ 117
High Speed Fan ......................................................................................................................................... 117
Cotton/Fiber Protection Package ............................................................................................................. 118
Dust Proof Hydraulic Tank Breather Kit ................................................................................................... 118
Dust Proof Front Axle Breather Kit ........................................................................................................... 118
Dual Element Air Cleaner ......................................................................................................................... 119
Elevated Air Intake Pre-cleaner ................................................................................................................ 119
Transmission Fluid Filter ........................................................................................................................... 120
Foundry and Brick Protection Package..................................................................................................... 121
Exhaust Options ........................................................................................................................................ 122
Sealed Alternator...................................................................................................................................... 122
Engine Block Heater.................................................................................................................................. 123
Rear LED Working Light ............................................................................................................................ 123
Premium Working Light Package.............................................................................................................. 124
LED Turn Signals........................................................................................................................................ 124
Amber Strobes .......................................................................................................................................... 125
Blue Spotlights .......................................................................................................................................... 126
Additional Indicators ................................................................................................................................ 127
Engine Shut Down System ........................................................................................................................ 128
Seat Belt Ignition Interlock ....................................................................................................................... 129
Dual Panoramic Rear View Mirror Kit ...................................................................................................... 130
Adjustable Armrest ................................................................................................................................... 130
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Operator Fan ............................................................................................................................................ 131
Keyless Ignition ......................................................................................................................................... 131
Thermoformed Overhead Guard Covers .................................................................................................. 132
Fire Extinguisher ....................................................................................................................................... 133
Drawbar Pin .............................................................................................................................................. 133
Lifting Eyes ................................................................................................................................................ 134
Special Paint Options ................................................................................................................................ 135
Language Markings ................................................................................................................................... 136
Customer Service ...................................................................................................................................137
Customer Support Programs ........................................................................................................................ 137
Warranty Information .............................................................................................................................. 137
Dealer Network ........................................................................................................................................ 138
Forklifts Are Not Commodities................................................................................................................139

Back to Table of Contents
Page 8
ABOUT THIS LIFT TRUCK SALES MANUAL

Your Single Source For All Model-Related Selling Information
This document is your SINGLE SOURCE of all data needed to support your efforts to sell this product. It
combines all sales technical data from available Price Pages (excluding prices), Sales Brochures, Mast
Tables, and any other product-related information into this sole document.
IF YOU CANT FIND YOUR DESIRED INFORMATION IN THIS DOCUMENT, THEN THE INFORMATION:
Has not been published elsewhere or does not exist (and/or)
Has not yet been analyzed and created for publication (and/or)
Is of a proprietary nature (and/or)
Has not been identified as relevant or missed due to human error (see below )
At the time of this publication, there are 30+ model families that either have or will have Lift Truck Sales
Manuals associated with them. They are constantly being updated to provide you with the most
comprehensive information for our products and improved to enable faster location of the information
you seek.
Please note that this models Operation & Maintenance Manual (OMM), Service Manual (SM), and Parts
Manual (PM) will have additional information relating to their respective subject matter.
Your Participation To Improve This Document & Who To Contact

MCFA NEEDS YOUR HELP to make this the best single source of product selling information available to
you and your fellow sales associates.
If there is information you consistently need to enable you to sell lift trucks and you have not been able
to find it in this document, please let MCFA know!
The MCFA Product Marketing group is responsible for creating this publication. You can contact them in
the following ways:
e-Mail mailto:[email protected] (click on address to create e-mail)
Phone Via MCFA LiftCentral at (877) 543-6757
The MCFA Product Marketing group thanks you in advance for your active participation!
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How To Find Information

We realize that finding information FAST is the key for you to address your customers needs or
questions.
This document has been converted to .pdf file. As such, please consider the following methods:
Table of Contents (at the beginning of this document)

This will probably be the easiest way to find information. Consider the category or name of the
feature and simply click on the item in the Table of Contents to jump to that page.
Using the Find search box (via the Adobe Reader or Acrobat program)
Type the relevant word in the Find search box at the top of the Adobe Reader window then press
ENTER on your computer keyboard. Each time ENTER is pressed, it will search and jump to the
next instance of the word occurring in the document.
This same Find command can be found under Edit / Find from the top menu bar or by pressing
CTRL + F at the same time (doing these steps will highlight the Find search box and be ready to
accept your typing of the relevant search word.
NOTE: Some data has been inserted

as a picture, so words within such an
image are not searchable.

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SPECIFICATIONS
Line Art

Page 11
Primary Specifications

Page 12

Page 13

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Mast Tables
GP15N Single Drive
* Contact CSM Group to obtain capacities.

** Capacity based on model equipment with MCFA OEM integral sideshifter
NOTE: These specifications assume the use of drive axles, tires and tilt angles specified. Any modification
to specifications or other combination of specifications made after the shipment of the truck requires
prior written approval from Mitsubishi Caterpillar Forklift America Inc. (MCFA). (See ANSI/ITSDF B56.1
Part II 4.2.)

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GP15N Solid Drive

Part II 4.2.)

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GP18N Single Drive

Part II 4.2.)

Page 17
GP18N Solid Drive

Part II 4.2.)

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GP20CN Single Drive

Part II 4.2.)

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P20N Single Drive

Part II 4.2.)

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GP20N Solid Single Drive

Part II 4.2.)

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GP20N Dual Drive

Part II 4.2.)

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GP20N Solid Dual Drive

Part II 4.2.)

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GP25N Single Drive

Part II 4.2.)

Page 24

Part II 4.2.)

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GP25N Dual Drive

Part II 4.2.)

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Part II 4.2.)

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GP28N Single Drive

Part II 4.2.)

Page 28

Part II 4.2.)

Page 29
GP28N Dual Drive

Part II 4.2.)

Page 30

Part II 4.2.)

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GP30N Single Drive

Part II 4.2.)

Page 32

Part II 4.2.)

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GP30N Dual Drive

Part II 4.2.)

Page 34

Part II 4.2.)

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GP33N Single Drive

Part II 4.2.)

Page 36

Part II 4.2.)

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GP33N Dual Drive

Part II 4.2.)

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Part II 4.2.)

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GP35N Single Drive

Part II 4.2.)

Page 40

Part II 4.2.)

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GP35N Dual Drive

Part II 4.2.)

Page 42

Part II 4.2.)

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INTRODUCTION
Market Focus
Class V Market Opportunity
According to ITA information, class V is one of the larger of the lift truck classes as can be seen in the
chart below. Because of this, it is imperative that Cat lift trucks offers a premium lineup of strongly
competitive IC pneumatic, sit down, counterbalance lift trucks to gain even more presence in the market
than it has built over the years. The data is tracked back all the way through 2004 in order to show more
than just how the market has fared since the economic troubles that came in the late 2000s.
Over the last 10 years (even with the improvement of electric lift truck technology and stringent federal
emissions regulations), the number of trucks sold has fluctuated greatly. Even with this fluctuation, the
percentage of all lift trucks sold in the market that are class V has hovered around the same level, at 1/4
of all trucks sold.
Year
Total Class V ITA

Factory Orders
Total ITA Factory

Orders Across All
Classes
Class V As a Percentage
of All Orders
2004
65915
233935
28.17%
2005
70714
246539
28.68%
2006
72142
260500
27.69%
2007
72697
244440
29.74%
2008
51722
190318
27.17%
2009
21285
112519
18.92%
2010
43535
174967
24.88%
2011
59482
214057
27.79%
2012
58856
223002
26.39%
2013
57158
236613
24.15%
TOTAL
573506
2136890
26.83%

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Class V by Product Type

So lets get a little more specific, as this manual is not about ALL of Class V. How do the trucks that will be
described in this manual fit into the marketplace? How much of the 1/4 of all trucks consists of the small
IC pneumatic trucks that are described in the following pages? Here you go:
The numbers below suggest that of the one quarter of ALL lift truck factory orders according to the ITA
(total Class V sales determined above), around 75% of those orders have been small IC pneumatic
capacity trucks. These are the trucks that are a huge population in the market and will be discussed in
detail in this manual.
.
Year
SICP Truck Factory

Orders
Total Class V Factory

Orders
SICP Trucks as a
Percentage of All Class
V Orders
2004
48314
65915
73.24%
2005
50648
70714
71.62%
2006
51885
72142
71.92%
2007
54518
72697
74.99%
2008
37860
51722
73.20%
2009
16431
21285
77.20%
2010
33637
43535
77.26%
2011
45906
59482
77.18%
2012
44536
58856
75.67%
2013
43899
57158
76.80%
TOTAL
427634
573506
74.56%

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SICP by Fuel Type

The small IC pneumatics are available in diesel, gasoline and LP configurations. Market data below (from
2004-2013) shows that a vast majority of the trucks in the market at this size are LP trucks, coming in at
74.39% of all SICP factory orders. At 318,116 actual orders over the time frame listed, these might be the
single most important truck offering that you have at your disposal.
Gas
LP
Diesel
Fuel Type
Total Factory Orders
Percentage of Total
SICP Orders
Gas
47804
11.18%
LP
318116
74.39%
Diesel
61714
14.43%
TOTAL
427634
100%

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Target Industries/Applications
Obviously, there is a more than adequate market for IC pneumatic lift trucks, but where should you start?
Below are some of the most common applications and industry segments that have regular use for the
family of trucks that are covered in this manual. They represent the heaviest usage of IC lift trucks in the
market today.
Industry
Description
Building Materials and Garden

Supplies
This industry segment is a key player for class V. It ranks in the top 10 as far as ITA ranked
market segments go. It is the most ripe retail market there is for these size trucks and
includes the wood and lumber industry where they are extremely popular.
Fabricated Metal Industries
Prone to economic volatility, the fabricated metal products industry is consistently in the
top 15 among ITA ranked industry groups. While vulnerable to economic fluctuation, it is
also among the first to benefit from economic recovery. Due to its industrial nature, it
favors class V trucks.
Stone, Clay, and Glass
While this industry is impacted by both seasonal and cyclical volatility, this group
ranks top 20 among ITA industry groups. There is high demand for IC trucks,
particularly class V, and there is a favorable long-term forecast for the industry
segment.
Industrial Machinery and

Equipment
This group is also prone to economic volatility but has consistently ranked in the top
10 of ITA industry groups. While the industry handles a lot of different materials and
has a good spread across all five classes, it has a heavier concentration on class V lift
trucks.
Miscellaneous Durable Goods
Wholesale trade and durable goods consists of a broad array of establishments that
buy bulk merchandise in order to sell into the retail market.

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Product Configuration
Models and Capacities
Model
Capacity
(Pounds)
Wheelbase
(Inches)
Engine
Fuel Type
GP15N
3,000
55.1
K21
Gas/LP
GP18N
3,500
55.1
K21
Gas/LP
GP20N
4,000
55.1
K21
Gas/LP
GP20CN
4,000
55.1
K21
Gas/LP
DP20N
4,000
63.0
Tier 4 Final 4EG
Diesel
GP25N
5,000
63.0
K25
Gas/LP
DP25N
5,000
63.0
Tier 4 Final 4EG
Diesel
GP28N
5,500
63.8
K25
Gas/LP
DP28N
5,500
63.8
Tier 4 Final 4EG
Diesel
GP30N
6,000
66.9
K25
Gas/LP
DP30N
6,000
66.9
Tier 4 Final 4EG
Diesel
GP33N
6,500
66.9
K25
Gas/LP
DP33N
6,500
66.9
Tier 4 Final 4EG
Diesel
GP35N
7,000
66.9
K25
Gas/LP
DP35N
7,000
66.9
Tier 4 Final 4EG
Diesel

Page 48
Standards Compliance
In addition to relevant global and national health and safety standards, this family of lift trucks is
designed according to the highest standards using the latest technologies.
ANSI/ITSDF
All trucks are manufactured in accordance with the American
National Standards Institute/Industrial Truck Standards
Development Foundation B56.1. These are the safety
standards for low lift and high lift trucks.
NFPA 505
All trucks are manufactured in accordance with National Fire Protection
Association (NFPA) 505, Fire Safety Standard for Powered Industrial Trucks,
including type designations, areas of use, maintenance, and operation.
UL 558
All trucks listed in the standard price list for North American sale are
manufactured in compliance with UL 558, Standard for Industrial Trucks,
Internal Combustion Engine-Powered. Please note that some options
ordered through the Custom Shop Modifications (CSM) group may void UL
listing. Please inquire within the CSM group to determine the specific UL
position on CSM options ordered. UL LPS and DS type ratings are available
as price list options. These ratings provide additional safeguards against fire
hazards compared to those required for the types LP and D. To determine
what classification your customer's application requires, refer to the Powered Industrial Trucks, Type
Designations, Areas of Use, Maintenance and Operations, NFPA 505.

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OSHA
All trucks are labelled in accordance with
Occupational Safety and Health Administration
(OSHA) Section 1910.178.
EMISSIONS: EPA & CARB

EPA stands for the U.S. Environmental Protection Agency (EPA), which
measures and sets performance emission regulations for air, water and
land pollution for the United States. EPA has adopted mandatory
regulations with regards to engine emissions. These regulations require
manufacturers of forklifts to certify that the engines meet a minimum
standard for HC+NOx - hydrocarbon plus nitrogen oxides and carbon
monoxide (CO) emissions. The California Air Resources Board (CARB) is
a long-standing organization that oversees the activities of 35 local and
regional air pollution control districts within California. These districts
regulate industrial pollution sources and set mandates within the
state.

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COMPETITIVE COMPARISON
In 2013, Cat Lift Trucks brought competitive
trucks in house to be tested against the Cat
2P5000 (the same model as the GP25N in
every aspect other than nomenclature) in as
many different tests as possible. Knowing the
importance of the 5,000 lb. pneumatic tire
trucks in our lineup, we were pleased to see
that we have quite a story to tell in many
categories. As part of the analysis of the
competitive testing, we have drastically
extrapolated the numbers in outrageous
examples to help show just how much our
product can be differentiated over time given some of the advantages that we found through the testing.

Page 51
Ramp Performance
When tested for ramp performance, the Cat truck had a
clear advantage in speed up the ramp. This is a blatant
advantage that can be exploited any time the end user
has an application that either utilizes ramps to enter
/exit warehouses or any time the environment that the
truck will be working on has inclines or declines. The
benefits of improved ramp performance can be sold to a
number of potential purchase influencers such as the
operator, operations managers and purchasing
managers. This can be done by showing how the job can
be made easier, productivity levels can be increased and
the way that increased productivity can justify up front purchase prices to the decision makers listed
above, respectively.
It is possible to calculate the amount of productivity that can be had with these speed advantages with
the specifics of the application site. Below are the test results at a 10% grade and also on a 14% grade.
10% Grade
Test
Units
Cat Lift Trucks
Hyster
Toyota
Km/h
13.30
12.30
11.70
mph
8.31
7.69
7.31
Km/h
9.70
9.10
9.00
mph
6.06
5.69
5.63
Speed (Unloaded)
Speed (Loaded)
These test results show that the Cat GP25N is 8% faster unloaded and 6.5% faster loaded than the
comparable Hyster truck on a 10% grade. Compared to the comparable Toyota truck, the Cat lift truck
was 13.6% faster unloaded and 7.7% faster loaded than their truck these are substantial differences.
14% Grade
Test
Units
Cat Lift Trucks
Hyster
Toyota
Km/h
10.90
10.90
9.50
mph
6.81
6.81
5.94
Km/h
7.70
7.30
6.90
mph
4.81
4.56
4.31
Speed (Unloaded)
Speed (Loaded)
This chart shows substantial differences as well. The GP25N was the same speed unloaded and 5.4%
faster loaded than the Hyster and 14.6% faster unloaded and 11.6% faster loaded than the Toyota truck
on the 14% grade.
Page 52
Exaggerated Example:
So what do these numbers
mean to our customers? Lets
take a look at these values
extrapolated out into an
example that can really show
the kind of difference that
this advantage can make over
time.
Lets pretend for a moment
that these lift trucks were
required to make the greatest
climb that there is to the
peak of Mt. Everest at 29,029 ft. of altitude all while carrying a rated load. So of course we know that Mt.
Everest is not at a 10% grade, but using trigonometry, we can find that if it was, the total travel distance
required to reach the peak would be 293,222 feet of travel. At the speeds tested in the first chart above,
this would mean that in the time that it took the Cat truck to travel all the way to the peak, the Hyster
truck would only be able to travel to 273,162 feet and the Toyota truck would only be able to travel to
270,643 feet. That is only 93% and 92% of the total climb, respectively. So whenever it comes to ramp
performance, who is the king of the mountain?

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Top Travel Speed

Top travel speed can directly impact productivity levels. When testing these trucks head to head, the Cat
truck was clocked at a higher top speed than the competition. This can make a major difference in
applications that have longer cycle times or a longer distance to travel when moving loads.
Test
Units
Cat Lift Trucks
Hyster
Toyota
Km/h
19.30
18.70
18.30
mph
12.06
11.69
11.44
Km/h
19.20
18.80
18.10
Mph
12.00
11.75
11.31
Top Travel Speed (Unloaded)
Top Travel Speed (Loaded)
The above chart tells us that when loaded, the Cat truck was 2.1% and 6% faster than the Hyster and
Toyota comparable trucks respectively. Whenever unloaded, the truck was 3% and 5% faster than the
Hyster and Toyota, respectively.
If we expand the numbers again to find out just how much more ground the Cat Lift Truck can cover than
the leading competition, lets think about marathons. In the time that it would take our truck to cover the
distance of a marathon (26.2 miles), the Hyster and Toyota trucks would only be able to travel 25.6 and
24.6 miles each. Doesnt sound like a huge advantage? What if during the course of a week, your lift truck
travels one marathon while loading and unloading materials? That would mean that over the course of a
year, the Cat GP15N would be able to travel more than 2 marathons more than the competition. Think
about that that means that while the competition is maxing out over the course of a year (based on
26.2 miles of travel a week), the Cat truck would be able to travel 57 more miles. Thats a lot of ground
covered, and a lot of product moved. How can a Cat lift truck carry your customers and their product
across the finish line in first place?
Page 54
Lift Speeds
When testing for lift speeds, Cat had an advantage again over Hyster and Toyota as can be witnessed by
the chart below. You may be starting to notice a trend that is leading to our next comparison that is the
most important of all.
Test
Condition
Cat Lift Trucks
Hyster
Toyota
Unloaded
118.31
96.85
101.38
Loaded
118.11
86.02
93.70
Unloaded
131.30
109.65
113.58
Loaded
130.71
98.23
107.28
Lift Speed 1st stage (fpm)
Lift Speed 2nd Stage (fpm)
As you can see, there are pretty substantial differences when tested head to head. That being said, lets
look at another drastic example.
Lift speed can directly affect the number of cycles that your
truck can run in a regular day to day application, but just how
much of a difference can it make? If we pretend that we had all
three of these trucks and they had an imaginary one stage
mast that rose at a rate that is the average of the test results
above (for 1st and 2nd stage), then the Cat truck would easily
reach the top of the Willis Tower in Chicago (at 1,451 feet tall)
first with or without a load and by quite a margin. If the load
was at the top of the tower, and the truck was getting it down,
it would take the Cat truck 11 minutes to reach the top based
on average lift speed while it would take the Hyster 14.08
minutes and the Toyota 13.5 minutes. Thats quite a
difference. What about it the truck was lifting the load to the
top of the tower? The Cat truck would take 11.7 minutes as
compared to 15.75 minutes and 14.43 minutes of the Hyster
and Toyota, respectively.

Page 55
Fuel Consumption and Productivity Cycles

You may have noticed as mentioned in the above sections, all of the side by side performance testing
leads up to one thing, which might be the single most important test of all overall productivity. Some of
our competitors have been harping on fuel efficiency for the last few years, and to be perfectly honest,
they are good at talking about it. They often speak in straight fuel efficiency, which is determined by
finding how much fuel is burned over a set amount of operation of the truck. We also tested this through
the use of a standard VDI cycle and found the following:
Test
Cat Lift Trucks
Hyster
Toyota
9.05
9.60
8.65
42
36
38
Straight Fuel Consumption (lb/hr)

VDI Cycle
Productivity Cycles
So what exactly does the chart above mean? Quite
simply it means that the Cat lift truck can get more
work done in an hour than the competition. The 42
cycles may not seem to have a drastic advantage over
the 36 and 38 cycles that Hyster and Toyota ran in the
same amount of time respectively, but whenever you
extend it over the course of time it makes a huge
difference. For example, if you consider that the Cat
truck can run 42 cycles in an hour, over a 10 hour shift,
5 days a week, for 52 weeks the Cat truck can run
109,200 cycles, versus 93,600 by Hyster or 98,800 by
Toyota. That is a difference of over 10,000 cycles over
the course of a year whenever you do the math. Sure,
whenever we ran the test the Toyota used less fuel in
an hour, but the reality is that the Cat truck moved
more than enough product to compensate for the slight
difference in straight fuel consumption. It is time to
stop asking how much fuel was burned and start
discussing how much product was moved.

Page 56
PRODUCTIVITY
K21 and K25 Engines
The LP and gasoline configurations in this model family are equipped with the K21 or K25 engines that
have an existing track record of performance and durability and have been engineered to meet the needs
of the lift truck industry. The K21/K25 are designed for high performance, low noise and vibration,
excellent fuel economy for the production provided and low emissions to meet the CARB/EPA
requirements that were instituted in 2010.
The models and engines are as follows:
Model
Engine
HP
Torque
53 @ 2,700 RPM
110 lb-ft @ 2,000 RPM
61 @ 2,700 RPM
129 lb-ft @ 1,600 RPM
GP15N
GP18N
K21
GP20N
GP20CN
GP25N
GP28N
K25
GP30N
GP33N
GP35N
These engines are equipped with two computers, the Engine Control Module (ECM) which delivers a
precisely calculated mixture of air and fuel to the cylinders of the engine, and the Vehicle Control Module
(VCM) which controls the Engine Protection System (EPS).
These engines use an overhead valve design in which a rocker shaft located in the cylinder block controls
the valves and push rods transfer the movement to the valves. This design helps to reduce premature
wear on the valve train. A velocity governor is pre-set at the factory to control engine speed and benefit
by helping prevent the hydraulic pump and fan drive from being over-sped and providing controlled
speed in applications that are high traffic or require limitations in operating speeds.
With these engines, there are three fuel configuration options the end user can select the Gasoline, LP
or dual fuel configuration. The dual fuel configuration includes a dash toggle switch that allows the user
to switch between using gasoline or LP as the fuel source of the truck.
Page 57
4EG Diesel Engine

These trucks are equipped with a tier 4 final, water cooled 4 stroke cycle diesel engine. The inline 4cylinder 4EG uses a direct injection system with an overhead valve type mechanism. It is a 3.3L engine
that has been tested to provide the performance and efficiency needed to provide productivity in even
the harshest applications.

Page 58
Emissions Compliant Fuel System

The fuel system of the truck is designed to meet stringent tier 4 final emissions standards. There are a
number of ways that it is able to accomplish this without the use of a diesel particulate filter (DPF) or a
selective catalyst reduction (SCR) system.
Common rail systems are a modern
variant of direct fuel injection systems.
The common rail, which can be seen
near the center of this diagram is
controlled by the ECM of the engine
which opens each fuel injector in the
given cylinder. This process helps to
ensure that fuel/air mixture used for
combustion in the engine is precisely
tuned for minimal harmful emissions.
There are also two ways by which the

exhaust of the engine is manipulated in
order to minimize harmful emissions. The
first is the utilization of a diesel oxidation
catalyst (DOC). A diesel oxidation catalyst
is a chamber through which exhaust
leaving the truck will pass through.
Whenever it does, the carbon monoxide,
hydrocarbons and particulate matter (all
harmful emissions) go through an
oxidation process and are reduced to
carbon dioxide and water, which are
harmless.
The second way that exhaust is manipulated is that it is returned to the engine compartment for use in
the combustion phase through a process called exhaust gas recirculation (EGR). As you can see in the
diagram above, part of the engine exhaust is recirculated through a cooler, and then released through a
valve to combine with air coming in from the air intake cleaner and is reused in the combustion process.

Page 59
Powershift Transmission
The powershift transmission of the truck consists of one forward gears and one reverse gear. The
changeover is accomplished with a powershift mechanism that employs hydraulically controlled multidisc clutches. The transmission is equipped with a Power Take Off (PTO) that transmits power to the
hydraulic pump and the parking brake circuit, without losing any power to the drive gear.
Clutch Drums
The transmission utilizes four hydraulically-actuated oil cooled clutch

drum assemblies; two for forward direction, one for reverse, and one
for the parking brake. They consist of six carbon fiber mating plates
and five friction plates that transmit torque and motion from the
input to the output shaft.
These drums help to dissipate frictional heat during normal
operation.
Helical Gears
The angled teeth engage more gradually than common

spur gear teeth, causing them to run more smoothly and
quietly, as well as reducing stress from the high power
transmission.

Page 60
Transmission Control Valve
The flow to the clutch packs is controlled by a solenoid valve or an electro-hydraulic shift employed by
the drive by wire system of the lift truck. The signal to this solenoid valve is controlled by the Vehicle
Control Module of the truck, directing the truck to travel forward, in reverse, or disengage.
This transmission interlock is a key component to the PDS system because a signal will not be sent to
engage the transmission unless the operator is properly seated in the truck.
Inching Valve
This valve controls the oil inflow to the

clutch drum by the amount of force applied
to the inching pedal. Half-clutch operation
of the powershift transmission model is
created as a result which allows the
operator to inch while moving loads.

Page 61
Transmission Oil Cooler
The transmission oil cooler is located in the radiator itself. The continuous circulation of the fluid allows
for easy dissipation of the heat that can build in the clutch packs, which is transmitted into the radiator.
Torque Converter
The torque converter smoothly transfers the power from the engine and multiplies the torque sent to
the transmission which can provide increased power on demand. These benefits are provided by the fluid
connection of the converter, which is located between the engine and the transmission. It connects the
engine flywheel to the transmission input shaft.

Page 62
RELIABILITY
Durable Steel Frame
The robust steel frame of the truck is first designed using Finite Element Analysis (FEA) in which
computers are able to model the truck frame and analyze where the stress will affect the frame the most
whenever the truck is loaded. With the help of the FEA system, the frame is adjusted to help minimize, or
in some cases, eliminate these stress points altogether so that whenever the frame is then built it is as
strong as possible. More steel in the frame means more durability and a lower center of gravity which
helps to provide higher residual capacity for the truck as well.

Page 63
Mast and Carriage

The masts of these trucks incorporate modern engineering
and design practices that allow them to provide the high
rigidity, while maintaining excellent visibility. Engineers
designed the masts to have more narrow flanges, in order to
increase that visibility. To provide more strength however,
they made the webs deeper and six load rollers provide more
strength and support for forward and backward loading of
the carriage, respectively. The specially shaped channels
allow for the load rollers to contact them at two points,
which increases the ability to handle side thrust forces
between the mast channels. There are also two side thrust
rollers to help maintain alignment with the mast.
If a tilt cylinder is not properly aligned, it can lead to eventual
leaks and possible failure. Because of this, the cylinder rod
ends mount to the mast of these trucks using spherical
bushings which prevent misalignment. Each lift cylinder is
also equipped with an internal drain that permits a controlled
amount of hydraulic oil to flow above the piston, preventing
corrosion of the cylinder rod.
Chains and hoses are canted at 45 so that the operator has a
better view from their seat in a normal operating position.
The diameter of the lift cylinders in the mast were also made
smaller for visibility purposes as well.
The carriage was designed to increase visibility as well with square fork bars rather than rectangular, and
more space in-between the fork bars.

Page 64
Overhead Guard
The overhead guard of the truck is also designed
using the Finite Element Analysis. The modern
computational design process helps to ensure
that the stress points on the overhead guard are
kept to a minimum. The guard is one of the most
vital parts of the truck whenever it comes to
operator comfort and security because it encases
the operator in the operator compartment.
Because of this, it is imperative that it does not
obstruct the vision of the operator during use of
the truck. Keeping that in mind, the overhead
guard was designed so that it does not use any
horizontal stability bars that might block vision when the operator is looking up at a load on his forks
through the top of the overhead guard.
The overhead guard is also constructed using a welded, one-piece design instead of a bolt together
system. Through rigorous testing, it was found that this helps to reduce wear down of the joints of the
overhead guard over time and extensive use.

Page 65
Low Profile Counterweight

The counterweight of the truck is a simple but crucial part of the integrity of the truck. It has many
purposes and was designed specifically to best meet the needs of the truck.
1. Design provides for shorter turning radius (see specs)
2. Provides truck with maximum residual capacity due to strategic weight positioning
3. Provides housing for the muffler and radiator while providing airflow to the cooling system which
is critical in high shuttle, dusty or dirty applications
4. Low profile allows for good visibility behind the truck from the operator compartment
4
1
3
1
2
1
1
1

Page 66
Engine Protection System

The Engine Protection System (EPS) is controlled by the Engine Control Module. It is invaluable, standard
feature on Cat lift trucks because it immediately notifies the operator if there is a failure or something
wrong with the way that the truck is running. The operator maintenance crews can quickly see to the
issue reducing the chance for further damage to be done by continued usage, which immediately results
in less downtime and cost of ownership on more expensive repairs. The EPS is capable of:
Monitoring engine oil pressure, coolant temperature and transmission temperature
Lowering max engine speed if coolant temperature reaches critical levels
Slowing travel and hydraulic speeds if the truck is not performing at acceptable levels
Notifying the operator of issues by way of display panel lights and diagnostic trouble codes (DTCs)

Page 67
3-Section Hydraulic Control Valve with Cowl Mounted Levers

The standard configuration of the truck consists of three ergonomically shaped levers that are designed
to match the natural swing of the arm of the operator. They are located in close proximity to the steering
wheel so there is little movement required to move the right hand from the steering wheel while driving
to the required lever. Each knob has a soft touch urethane cover for excellent grip.
As mentioned, there are three knobs, but in the standard configuration, only two are used, with the third
lever available for use if there are added hydraulic functions or attachments.
The lever closest to the steering wheel is the lift lever.
Lifting speed is controlled by the speed of the engine
(position of the accelerator pedal) and the position of
the lift lever and lowering speed is controlled only by
the position of the lift lever regardless of engine speed.
In order to lower the forks, the lever should be pushed
forward (away from the operator) and to raise the
forks, the lever should be pulled back (towards the
operator). The lever will return to the neutral position
when released.
The second lever is the tilt lever. The tilt speed is

controlled by the speed of the engine (position of the
accelerator pedal) and the position of the tilt lever. The
lever will automatically return to the neutral position
when released.
Both of the above levers can be directly affected by the mast interlock system. In order to deactivate the
mast interlock system, the operator must sit on the operator seat while the key switch is in the (ON)
position regardless of whether the engine is running or not, and then operate the tilt lever.

Page 68
Vehicle Control Module

The Vehicle Control Module (VCM) is the computer of the truck that controls a number of input and
output signals from the truck in order to make sure that everything is operating properly. It is easy to
access and troubleshoot by way of laptop of your authorized Cat dealers service technician. Below are
the signals that the VCM can get through communication with the truck.
Principle Functions of the VCM
No.
Item
Function
Transmission Control
Engine Control
Idle- up solenoid output is turned on to prevent engine stall when hydraulic

pressure (main) exceeds preset level
Ground Speed Control
Computes vehicle speed from vehicle pulse signal and transmits output
Buzzer Output
Issues a buzzer control signal to the instrument panel when the seat belt is not
fastened or operator leaves the normal operating position without applying
parking brake.
User Setting and Self-Diagnosis
VCM sensors input values can be checked.
Fail-Safe and Error Archiving
When a fault is detected in the VCM itself or any peripheral device, the VCM
takes appropriate action. An error due to a detected fault is indicated through
the warning lamp in the controller etc. and recorded in the EEPROM with hour
meter reading at the same time. The error is also communicated to a possible
connected laptop of the dealers service technician.
Diagnostic Software
When the diagnostic software tool is connected by the authorized dealer,

sensor signal status and past errors archived in the EEPROM can be
monitored. Also, optional functions and various parameters can be monitored.
Inter-Controller Communicator
CAN communication exchange of sensor signals, control signals, fault

information, etc. is possible with instrument panel and other devices
throughout the truck.
Power to the transmission forward and reverse solenoid is controlled by the

Vehicle Control Manager (VCM) output according to the position of the FNR
lever input to the VCM.
When the operator leaves the normal operating position the VCM interrupts
power output to the forward and reverse solenoid placing the transmission in
the neutral position.

Page 69
Electrical System
These trucks operate using a 12V electrical system. The battery is maintenance free and is conveniently
located on the left hand side of the chassis along with the relays and fuses. The fuses that are used are
automotive style standard fuse that are grouped and conveniently located in boxes in close proximity to
the battery and have labels for each fuse underneath the cover of the fuse box.

Page 70
Hydraulic System
The hydraulic system works in such a way that it sucks up hydraulic oil from the hydraulic tank and
distributes pressurized oil to work equipment and the steering system with the priority valve.
Pressurized oil is fed to each cylinder through the control valve of the system.
Hydraulic Tank
The hydraulic tank is located in the
middle of the right side of the frame of
the truck and is part of the frame
structure itself. There are three pipes
that are welded onto the tank cover,
which are the suction pipe, pipe for the
return line and the pipe for level gauge.
At the top of each of these three pipes
are a suction strainer, return filter, level
gauge and a cap. This is done so that the
parts of the tank can be removed as an
assembly if the tank cover is removed.
The filter can be replaced or the strainer
cleaned easily once the tank cover is removed.
The hydraulic tank cap has two air holes that serve as a vent for
the air trapped inside the tank, which will fluctuate depending on
the level of oil. There is also a filter element installed in the cap to
serve as an air filter to prevent debris from entering the tank.
At the end of the return pipe is a return filter which is a cartridge type of 15 m with a built in relief
valve. When that filter is clogged, the relief valve activates to divert unfiltered oil into the tank. Periodic
replacement is needed.
Oil filter replacement is recommended once a month after the purchase of the lift truck or after
conducting a major overhaul that includes replacing parts. The suction strainer is 100 mesh screen gauze
and should be cleaned at every oil replacement.
There is also a drain plug at the bottom of the tank.

Page 71
Gear Pump
The gear pump is a circumscribed gear pump that sends the hydraulic oil required to activate the
hydraulic cylinder.
Priority Valve
Of the working oil that is discharged from the gear pump, only the amount that is required for steering
operation is supplied to the steering control valve. The rest is forwarded for use by other equipment.
Whenever the truck is in neutral, almost all of the work of the fluid is routed to the other equipment
mentioned above.
Hydraulic Control Valve
The hydraulic control valves of the standard truck move mechanically. When one of the control levers is
operated, the spool valve starts to move up and down and exchanges pressure oils with the
corresponding hydraulic cylinders.
If a truck is equipped with fingertip controls, the hydraulic control is a solenoid valve. As the valve spools
move in proportion to control input of the FC control box operated by the operator, the controller and
electromagnetic proportional pressure control valve are used.
Because it is a sectioned valve, it is easy to upgrade to allow for more auxiliary functions. The most basic
valve is a 3 section valve, which would consist of the tilt, lift, and one auxiliary function. All trucks come
standard with these three basic functions. It is also possible to create a 4-way, or 5-way valve by adding
the appropriate attachment valves and associated parts.
Lift Cylinders
Second Lift Cylinder For Simplex and Triplex MastThis lift cylinder has a check valve in the piston instead of a return pipe and is called an internal drain
type cylinder. The bottom of the piston is provided with a cushion mechanism for soft landing.

Page 72
Action During Piston Descent
The picture below shows a condition in which the piston rod assembly (2) is descending. The cushion
bearing (5) is pushed upward by entrapped oil(A) and the piston and cushion bearing make surface
contact (B). This blocks passage A in the diagram. The only outflow passage for entrapped oil is
clearance (b) between the cushion bearing and the outside of the pipe. This passage (b) becomes
narrower as the piston descends further. Therefore, the descending speed of the piston becomes
gradually slower and impulsive contact is avoided.
Action During Initial Stage of Piston Ascent

The illustration below shows what happens to the piston immediately after the assembly ascends. Oil
that flows in acts on the center of the piston rod assembly slightly. At the same time, the cushion
bearing (5) descends by being pushing by the inflowing oil. This action opens up area (B) causing
passage (a) to open. Oil from passage (a) and passage (b) which open from the beginning, flow in the
piston bottom, acting on the entire bottom surface of the piston and pushing the assembly upward.

Page 73
First Cylinder for Duplex and Triplex Mast
This cylinder is mounted on the center of the mast and is the first to act during the ascending stroke
of the forks. The piston rod extends from the cylinder tube by pressure oil acting on the piston
bottom.
For prevention of an impulsive approach of the piston and the cylinder head at the last stage of its
ascent, cushion oil is always filled in space (B) between the cylinder tube and the piston rod. When
the piston rod ascends, it ascends while pushing out cushion oil out to air chamber A at its last stage.
This is how the last stage becomes smooth.
In the descending stroke of the piston rod, cushion oil in air chamber A is sucked into space B. The air
chamber, stand tube and check valve are all involved in the cushioning action. Extra oil which leaks
from around the piston and enters space B returns from the stand tube (10) to the cylinder bottom
by way of the check valve (9) at the last stage of the cylinders ascension. The stand tube always
retains a certain amount of oil as cushion oil.

Page 74
Flow Regulator Valve (For trucks with Fingertip Control Valve Only)
This is an adjustable valve that is located between the lift cylinders and the lift control valve. Its purpose
is to limit the amount of return hydraulic fluid that is allowed to flow. The valve can be adjusted by an
authorized service technician with an easily reachable screw on the valve. The end user is thus able to
customize the lowering speed of the truck based on application if necessary.
Flow regulator valve should NEVER be adjusted to allow the forks to lower faster than the standard
factory setting (which is the industry standard). This adjustment should only be made by an authorized
Cat lift trucks dealer.
Tilt Cylinder
The tilt cylinder is a double action type and has the rod end threaded for adjusting the balance between
the right and left sides when the mast is mounted. The tilt angle can be modified with an optional
adjustment of the collar and socket.

Page 75
Air Intake Process

The air intake is vital to the performance and efficiency of the engine as contaminated air will rob power
and eventually damage an engine causing extremely costly repairs. Because of this, great attention was
paid to provide the engine with clean air, free of debris with the system used.
The air intake vents were positioned high on the

rear overhead guard levels in an attempt to reduce
the potential for contaminants like dust and debris
kicked up from the ground to enter the system.
Once the air enters the truck, it then travels through

the second step of the air intake process, which is the
air cleaner located on the right side of the engine
compartment. Vanes around the filter element create
a cyclone effect causing the larger dust particles to
drop to the bottom of the air cleaner canister. Then, a
dry paper element filters the remaining, finer particles
from the air. This element is easily replaceable
without the use of any tools.

Page 76
Drive Axle
The drive axle on these trucks is the front axle. Designed for durability, it is a full-floating, banjo shaped
design that can carry more weight than a semi-floating or non-floating axle assembly because the hubs
have two bearings riding on a fixed spindle. The axle shaft itself does not carry any weight; it serves only
to transmit torque from the differential to the wheels.

Page 77
Steer Axle
The steer axle of the truck is one solid unit, which gives it superior strength and rigidity. It allows the
truck to perform in the most strenuous environments because the solid steel unit withstands the stress
that is exerted on the axle and the chassis of the truck. The design makes it extremely suitable as a
connection piece between the two knuckles and the steering cylinder.
Hydrostatic Power Steering System

Directly related to the steer axle housing unit, the hydrostatic
steering system is powered by hydraulic oil flow, which
minimizes the effort needed for the operator to easily and
smoothly steer the truck. Any kickback from the steer wheels
into the steering wheel is eliminated by the system. It also
removes the need for any mechanical linkage in the steering
process which lowers the amount of maintenance needed. The
precise steering control of the truck allows the operator to easily
turn the steering wheel regardless of truck speed which aids with
control and maneuverability in various scenarios and
applications.
When the steering wheel is turned, hydraulic oil flows into a
small oil pump inside the steering valve. At the core of the pump is a pump rotor called a gerotor which
rotates coaxially with the steering wheel. Because of this, when the steering wheel is turned, the pump
rotor also turns, which delivers pressure oil from the left or right port of the steering valve to the steering
cylinder. At the same time, the steering cylinder return passage to the hydraulic control valve is opened
to allow return flow. As this pressure and return oil flows back and forth from one side to another, the
steering cylinder rod extends to the right or left, which activates the tie rod to turn the knuckle, which
turns the rear wheels of the truck and alters the direction of travel.
The Kingpin layout of the hydrostatic steering is supported by needle bearings and a thrust bearing. Each
of these has a function as the needle bearings are capable of handling radial forces (forces incurred when
turning), and the thrust bearing helps to handle the axial forces (forces caused by the weight of the
truck). It is an easy system to maintain as there is no special tooling required to pre-load the bearings.
The Kingpin does require greasing as it helps to reduce the risk of premature wear by water and dust.
The steering control valve is also equipped with a solenoid valve that compensates deviation of the
steering wheel knob position from the correct forward drive position. Whenever there is a difference, the
valve is opened to allow drainage of some part of the supplied oil to return it to a correct forward drive
position.
Page 78
Cooling System
One of the biggest challenges with internal combustion lift trucks is making sure that the engine stays
cool. These trucks are equipped with a corrugated, aluminum core radiator that provides excellent
cooling because of the large surface area exposed on the fins.
As mentioned above, the core of the radiator is aluminum
which horizontal flow. This aluminum core is more
resistant to galvanic corrosion in the cooling system. It has
also proven over time that it is more effective at
transferring heat than traditional copper or brass
radiators.
The side tanks of the radiator are plastic. One of these
tanks includes a heat exchange unit for the powershift
transmission.
Cooling Fan
The truck is equipped with a pusher that is directly coupled
to the engine itself. Its purpose is to pull air from under the
truck and out of the back of the counterweight helping to
keep constant airflow through the engine compartment.
The fan is also covered with a plastic guard for safety
reasons and to help minimize the chances of large debris
from becoming tangled in the fan itself.

Page 79
Two Pedal Brake System

Located directly to the left of the accelerator pedal of the truck are two brake pedals that activate the
dual brake pedal system. One is a standard brake pedal (it is the middle pedal) and the inching pedal (on
the far left) is intended to allow the operator to apply the brake without disengaging the transmission
while using hydraulic functions. Remember, as mentioned in the hydraulic system section, some
functions (lift, tilt forward and backwards) are directly affected by not only the lever being activated, but
also by the engine output affected by the accelerator pedal.
The brake assembly is a large 12.2 inch (10 inch on GP15N-GP20CN) for high lining to drum contact area.
The brake shoes are made of non-asbestos material with very good cold and warm frictional
characteristics. This is to help ensure consistent brake feel throughout the shift. Whenever the brakes
are applied, a self- energizing mechanism transfers turning force from the leading shoe to the training
shoe. This presses both shoes against the drum with greater strength and provides more breaking force.
The self-energizing shoes help reduce the amount of force needed to be applied to the pedal, which can
help reduce the amount of operator fatigue over the course of a shift.
When travelling in reverse, there is a self-adjusting mechanism as well that is activated. As the clearance
between the shoes and the drum increases, an adjustment screw is turned one notch by the lever of the
adjuster to reposition the shoes closer to the drum.
Inching Pedal
As mentioned before, the inching pedal is to the left of the standard brake pedal. It simultaneously
applies the brakes without disengaging the transmission. It does this by disengaging the clutch, or
inching by letting the clutch slip as the brakes are released. This can give advantages such as slow,
controlled acceleration where it is needed most, such as when working on a grade or in tight areas that
require high maneuverability.
*It is important to note that if the inching pedal is

continuously ridden while travelling, there will be
damage to the transmission and/or premature wear of
brake components.
Inching Pedal
Page 80
Parking Brake System
The parking brake lever is conveniently located to the left of

the steering column. It is a dual action parking brake, which
means that the operator must depress the button on top of the
lever in order to release the brake. This helps minimize the
chances that the operator might accidentally release the brake
unintentionally. There is also a sensor in the parking brake that
communicates with the PDS system.

Page 81
Tires
This family of trucks comes standard with air filled

pneumatic tires. They provide good traction and added
operator comfort by cushioning the overall ride for the
operator. The only exception to this is the 2 ton compact
model (GP20CN) that comes standard with solid
pneumatics. Solid pneumatics for the rest of the lineup
are available as optional upgrades.
Tire Size
Models
Drive Tires
Steer Tires
GP15N-GP18N
6.5x10-10PR
5.0x8-8PR
GP20CN (Solid Pneumatics Standard)
6.5x10/5.00
6.0x9-10PR
GP20N-GP25N
7.0x12-14PR
6.0x9-10PR
GP28N-GP30N
28x15-14PR
6.5x10-10PR
GP33N-GP35N
250x15-16PR
6.5x10-12PR

Page 82
Easy Maintenance
These trucks are designed to perform with maximum productivity and efficiency for the end user. In
order to accomplish this, it is important that the truck is given every opportunity to do so. To ensure this
peak performance, as with any machine, maintenance is a vital step. These trucks are designed to allow
for regular maintenance to be completed with relative ease minimizing down time and saving the owner
money.
Daily Checks Daily checks are made that much easier and less time consuming because of the
ease of gaining access to all of the major components of the truck. The engine cover opens wide
and allows access to check fluid levels and carry out the visual inspections needed before the daily
shift.
1. Move the steering column using the yellow lever on the left of the column.
2. Move the seat forward as far as
possible and fold the seat down
using the spring-loaded locking pin
located near the left side hip
restraint. NOTE: It is not necessary
to fold down the seat on diesel and
gasoline models (unless they are
equipped with a cab) because there
is no obstruction by way of propane
tank.
3. Raise the engine cover by pulling the latch located on the front left side of the
cover. A single gas-assisted spring permits the cover to be raised with minimal
effort and keeps it in a raised position.
4. For even more access, there are NO TOOLS REQUIRED to remove the floor plate
and the steel side covers. They can be quickly and easily removed and replaced if
needed.
5. The brake master cylinder reservoir is made of translucent molded plastic which
makes it possible to verify fluid levels with a quick visual check.
6. These trucks use fuses that are easily accessible. Inside the fuse box, there is also a
tool to remove them as well as a labeled guide with an explanation of the function
of each fuse.

Page 83
500 Hour Service Intervals

Extended service intervals mean that this truck will have less down
time and less money spent on the planned maintenance of the
truck over its lifetime.
* This may vary based on application.
Preventative
Maintenance
Interval
Number of
Preventative
Maintenance
Sessions
Labor @ $80
Parts @ $20
Estimated Total
Preventative
Maintenance
Expense
200
50
$4,000
$1,000
$5,000
250
40
$3,200
$800
$4,000
500
20
$1,600
$400
$2,000

Page 84
SUPERIOR OPERATOR COMFORT

Full Suspension Vinyl Seat
The standard vinyl seat* for this model provides adjustment in numerous planes to allow the operator to
put himself in an extremely comfortable position.
1. Front and Back Adjustment Lever
positioned on the front right side of
the seat can adjust the seat forward
and backwards up to 6.5 to
accommodate operators at various
heights
2. Suspension Adjustment Knob
located on the front of the seat can
be turned (clockwise to increase
support, counterclockwise to
decrease support) to adjust the
suspension of the seat
2
4
1
3. Lumbar Support Adjustment Knob on the left side of the seat can adjust the lumbar support to
the preference of the operator
4. Fold Down Pin Pin located on the left side of the seat just to the rear of the steel wrapped hip
restraint allows the seat to fold down
*Seat shown in picture is cloth version of standard seat.
Orange Seatbelt
The standard orange seat belt allows for easier visible confirmation that the belt is being used properly
during operation of the truck.

Page 85
Noise Reduction Features

There are a number of standard features that are built into the truck that limit noise and vibration. This
helps to keep the operator comfortable, thus increasing his efficiency and output. They include:
1. Rubber mounted key components isolate noise and vibration transfer to the steel frame
a. Hydraulic control valves, transmission, engine, radiator, exhaust system, and secondary lift
cylinders on the mast
2. Fully insulated steel engine hood limits the amount of noise and vibration directly under the
operators compartment
3. Helical transmission gears reduce drivetrain noise
4. Closed wheel wells reduce noise from the engine
5. Hydraulic accumulator in the transmission control valve promotes smooth shifts and direction
changes up to 2.5 mph, reducing shocks in the powertrain
2
3
4
5

Page 86
Tilt Steer Column with Mechanical Quick Return

The tilt steering column is equipped with a two lever system that is designed to adjust and lock with a
wide range. The forward position allows for extra clearance when opening and closing the engine cover.
After daily inspections (or any other reason to open the hood), the operator can return the steering
column to the pre-set position customized to their comfort level using the memory function.
1. Black release lever provides desired position within 12 to be locked (pull down to position, push
up to lock
2. Yellow release lever allows column to move 13 forward (lift)
Electronic Direction Control

The electronic directional control lever on the left side of the steering column allows the operator to easily
shift between forward and reverse travel without ever having to lose contact with the steering wheel. A
change in direction is as simple as a flick of the finger.

Page 87
Three Point Entry System

The three-point entry system of all Cat lift trucks IC sit down forklifts allows the user to easily access the
operators compartment. The driver of the lift truck can be in and out with little effort and a consistent
method of entry and exit that is more conducive to productivity.
1. Elongated Grab Bar
a. 18 long to allow easy
reachability for operators
of all heights
b. Mounted inside operator

compartment to reduce
chance of damage
2. Low Entry Step with Anti-slip

Step Plates
a. Open step frame allows

for easy entry
b. Natural step height
provides a proper step-up
and step-down
3. Wrapped Steel Hip Restraint
a. Offers third point of contact for secure entry/exit while climbing into truck
b. Provides multiple points to hold onto while climbing into truck

Page 88
Floor Mat
The raised, 4 mm thick floor mat of the truck is designed to provide traction in the operators
compartment and channels water or any other spills away from the feet of the user. It also is one of the
many features that help to isolate the vibration and noise of the truck.

Page 89
INCREASED OPERATOR AWARENESS

Premium LCD/LED Display Panel
The light emitting diode (LED) and liquid crystal display (LCD) meter panel provides a number of
important indicator lights and information to the operator. These indicators are crucial to the operator
whenever it comes to knowing how the truck is currently running (speedometer, travel direction
indicator, etc.), what problems need to be addressed with the truck (maintenance requirement indicator
icons), and general reference points (fuel level indicator and clock).
1. Travel Direction
2. Service Interval
3. Warning Icons (See
Next Page)
4. Operator Button
5. Clock Time/ Hour
Meter
6. Water Temperature
Gauge
7. Speedometer
8. Fuel Gauge

Page 90
Meter Panel Indicator Lights
Symbol
Name
Illuminated Condition and Models Applicable*
Low Coolant Level Warning
When coolant level is low. (Optional)
Clogged Air Cleaner Element

Warning
When air cleaner is clogging. (Optional)
Low Fuel Level Warning
When diesel levels are low.
Parking Brake Warning/Brake Fluid

Level Warning
When parking brake is activated/ When brake fluid is low.
Seat Belt Warning
When seat belt is not fastened.
Battery Charge Warning
When battery charging system is not working properly.
Multi-Purpose Warning
When a minor fault occurs or operating cautions are being

issued.
Torque Converter Fluid

Temperature Warning
When torque convertor fluid temperature is not normal.

(Only available on models with ProShift)
Low Engine Oil Pressure Warning
When engine oil pressure is low.
Engine Warning (Check)
When the engine has experienced a fault.
ProShift
When protective function against sudden travelling

direction change is activated. (Optional)
Mast Interlock Indicator
When PDS is activated.

Page 91
Mast Visibility
Narrow mast channels provide the

large window of vision for the
operator while in normal operating
position. The 3 canted rollers
provide stability of the load on these
narrower mast channels. The cross
members of the truck are designed to
make sure that the operator has
good visibility through the mast. The
carriage is designed with square fork
bars instead of rectangular ones,
providing more space, and therefore
more visibility, between the bars.

Page 92
LED Forward Work Lights

Light emitting diode (LED) work lights are mounted on the
mast of the truck. LED lamps provide the truck with the
latest development in light technology. Benefits of the LED
lamps include brighter light, longer life, and a cooler light
source than traditional bulbs used by forklift manufacturers.
There is no filament in these lights which eliminates the
typical weak point of ordinary lamp breakage.
The vertical pattern of the light emission projects where the
operator needs it; illuminating the forks of the truck as well
as the racks in front of the truck. The LED light also
minimizes glare off of the mast.
The standard lights of this series of trucks further minimize
cost of ownership in a number of ways:
Longer bulb life
Durable aluminum die cast housing minimizes damage
Steel outer guard to protect entire housing
Coverage under the standard warranty terms of the truck
Rear Combination LED Lights

Rear combination LED stop/tail/backup lights and turn signals come included with the standard offering
of this truck. They are located on rear of the overhead guard and help to inform pedestrians and the
other operators what the current and intended movements of the lift truck are.

Page 93
ADDED OPERATOR PROTECTION

Presence Detection System (PDS)
Cat Lift Trucks has a PDS system that is equipped with an integral computer-based feedback system. This
system was introduced as the industrys first in 2004 and remains the premier presence detection
system. It is activated whenever the operator does not fasten their seat belt during operation or exits the
truck without activating the parking brake. It uses visual and audible cues to notify the operator if they
are not in the normal operating position with seat beat fastened:
1. Electronically stops powered travel movement of the truck (transmission) and stops activation
of load handling functions (hydraulics)
2. Seat belt warning indicator (both buzzer and icon)
3. Parking brake reminder (both buzzer and icon)
2
1
3

Page 94
Parking Brake
The parking brake of the truck is a dual action lever that is
located to the left of the steering column on the dash. The
operator must press the button at the top of the lever in order
to release the parking brake in order to move the truck. As
noted above in the PDS section, an alarm will sound if the
operator has left the normal operating position without setting
it.
Ground Speed Control

The ground speed control feature allows the trucks top travel speed to be set at one of four options: 5.5
mph, 6.5 mph, 7.5 mph or 8.5 mph. Software and sensors limit the max travel speed of the truck without
limiting lift performance. This could be helpful in areas where lift trucks and pedestrians work in close
proximity, where fragile materials are handled or in locations where stricter policies are being enforced.
Electronic Backup Alarm

This family of trucks comes standard with an electronic backup alarm that sounds any time the truck is in
reverse. This allows pedestrians who are working within close proximity of the lift truck to know that it is
the intention of the operator to move backwards, and react accordingly if necessary.

Page 95
OPTIONS
Custom Shop Modifications (CSMs)
The following section of this manual will describe the options that are immediately available by way of
the price pages, but we certainly understand that there are a number of other options that a customer
might need for their specific application that are not listed. This does not, by any means, mean that the
needs of the customer cannot be accommodated. For any option that you cannot find in the price pages,
you will need to submit a CSM request that will go directly to our engineering department that
specializes in providing the solutions to the customers in option form. This department will gladly help to
determine pricing and availability, as these specialized options will take some time to design and
implement. Many times, however, there is a good chance that they have done something in the past that
might be able to help you and your customer.
In the LiftNet 2.0 quoting tool, you will see some SPI part numbers that you can select. SPIs are
previous CSM parts that have been built into the system for your convenience in ordering. There is also a
spreadsheet that is on the portal of SPIs from the past that you can search through to find a price for
the option that your customer needs.
Fork Options
Order Code
DP100N-DP160N
Description
Reference the Price Pages for the complete listing of forks styles and part numbers available.
Description
Hook and shaft type forks are available for order in various sizes.
Lumber forks are thinner than most forks and allow the operator to pick up stacked product easier.
Different fork sizes might be needed for different kinds of material handling

Page 96
UL Safety Rated Chassis Options

Order Code
Description
ULGSP15I
UL Rated Gas
ULLPSP15I
UL Rated LPS
ULDSP15I
UL Rated Diesel
Description
For applications that require safety rated chassis, these
model families are available with a UL safety rated chassis
designation. These chassis are designated with an S in
their nomenclature (LES,DS, GES) and include certain
standard components that are replaced with specifically
designed components that help reduce the possibility of
spark ignition. Battery disconnect switches, sealed wiring
connectors and additional labels are added to aid the
operator in applications that might require this kind of
upgrade.
Componentry changes include an enclosed alternator,
spark resistant muffler, battery disconnect switch, self
closing lockable fuel caps, silicone sealed wiring and the UL label to designate safety rated trucks.
In order to receive a safety rating, there is an intense review and testing process. It is important to note
that although you may add the components listed above, it is not considered safety rated unless it has
been deemed as such by the manufacturer and is an officially rated UL safety rated truck.
While the LP, Gas and diesel options are available through the price pages, there is no dual fuel
configuration that is listed in the price pages. It is available however through CSM.

Page 97
Applications where this might be common include chemical and chemical processing, petroleum
processing, fine dust (paper) and any application where spark ignition could pose a problem. Refer to
Powered Industrial Trucks, Type designations, Areas of Use, Maintenance and operations, NFPA 505. The
chart below can be used in reference to applications in which safety rated trucks might be needed.

Page 98
Optional Wide Carriages

Order Code
GP20N-GP25N/DP20NDP25N
CARR55P25I
Description
55 Wide ITA Class II Hook Type Carriage
CARR59P30I
59 Wide ITA Class III Hook Type Carriage
Description
These trucks can be fitted with optional wide carriages in order to accommodate the various attachments
that an application might require. All carriage widths include a 48 high load backrest. When installing
attachments with optional width carriages, be sure to verify compatibility between the attachment and
the carriage. Please note that:
These carriages are NOT AVAILABLE with quad masts.
Make sure to add 1 to carriage and/or attachment width when determining width over the load
backrest

Page 99
Sideshifters
Order Code
GP15N-GP20CN
ISS36P15I
Description
36 Wide ITA Class II Integral Sideshifter
ISS39P25I
39.5 Wide ITA Class II Integral Sideshifter

ISS39P30I
ISS55P25I
39.5 Wide ITA Class III Integral Sideshifter
55 Wide ITA Class II Integral Sideshifter

ISS59P30I
SSHO36P15I
55Wide ITA Class III Integral Sideshifter
36 Wide ITA Class II Hang-On Sideshifter

SSHO39P25I
39.5 Wide ITA Class II Hang-On Sideshifter
SSHO39P30I
39.5 Wide ITA Class III Hang-On Sideshifter
Description
Neither type of side shifter is compatible with quad mast options. Both require single function
internal hosing at a minimum.
When the integral carriage options are ordered, they replace the standard carriage that is on the
mast.
The hang-on sideshifters mount to the standard carriage on the mast of the truck and are not
compatible with optional wide carriages.

Page 100
3- & 4- Section Control Valves with Levers and Fingertip Control Options
Order Code
GP15N-GP35N/DP20NDP35N (Fingertip Controls)
Description
VLV3-STD
HVLV3FCP15I
3 section control valve
VLV4P15I
HVLV4FCP15I
4 section control valve
Description
In the standard configuration, the standard relief valve for lift, tilt
and 3rd section is set at 2,650 psi. When ordering the 4-section
control valve with cowl mounted levers, the 3rd and 4th sections are
set at 2,250 psi.
The addition of the fingertip control armrest is preferred by some customers as it provides an
ergonomic armrest and the ability to control the hydraulic functions of the truck with the ease of
ones fingertips, but it is important to know the requirements and limitations of some other options
when ordering fingertip controls.
On the 3,000 lb. to 4,000 lb. compact models, fingertip controls require a swing down LP tank
bracket on dual fuel or LP chassis, because of interference with the LP tank whenever the
hood is opened. The fire extinguisher option is also not available with fingertip controls on this
sized chassis for similar reasons.
Fingertip controls in general ARE NOT for use with the following options: UL safety rated
trucks, swivel seat, enclosed cabin, operator convenience tray, accumulator or enclosed cab
options.
Fingertip controls require a full suspension seat.

Page 101
Single Function Internal Hosing

Order Code
Description
3VSIMP15I
For use with simplex masts
3VDUPP15I
For use with duplex masts
3VTRIP15I
For use with triplex masts
TC3VQUAP15I
For use with quad masts
Description
Single function internal hosing is required for some options and includes one pair of #6 hoses and
fittings that terminate at the back of the carriage bottom plate.
Dual Function Internal Hosing

Order Code
Description
4VSIMP15I
For use with simplex masts
4VDUPP15I
For use with duplex masts
4VTRIP15I
For use with triplex masts
TC4VQUAP15I
For use with quad masts
Description
Single function internal hosing is required for some options and includes one pair of #6 hoses and fittings
that terminate at the back of the carriage bottom plate. It requires 4-section valve at a minimum.

Page 102
Hydraulic Steel Supply Lines

Order Code
Description
SFSSL3P15I
Single function steel supply lines
SFSSL4P15I
Single function steel supply lines 4 way

valve
DFSSL4P15I
Dual Function Steel Supply Lines
Description
These steel supply lines replace the normal supply lines of hydraulic fluid to attachments.
The first option above (SFSSL3P15I) is for use with single function, carriage mounted hydraulic
attachments. The line terminates at the right hand side of the carriage top plate. These ARE NOT for
use with factory-installed sideshifters or optional carriage widths.
The second option above (SFSSL4P15I) is for use with a single function, sideshifter mounted
attachment and the line terminates in the same place, at the right hand side of the carriage top plate.
The third option above (DFSSL4P15I) is for use with dual function, carriage mounted hydraulic
attachments. The 3rd function line terminates at the right hand side of the carriage top plate and the
4th function line terminates at the left hand side of the carriage top plate. This option is NOT for use
with the factory ordered sideshifter either.

Page 103
Hydraulic Lift Line Accumulator

Order Code
Description
TC-1060I
Hydraulic Lift Line Accumulator
Description
This 1 Liter diaphragm type lift line accumulator
helps to provide shock dampening to the load and
front end components of the truck. It should be
offered and considered for applications in which
the loads tend to be fragile or there is potential
from damaging during hydraulic activity of the
truck.
This option is NOT for use with fingertip control
options.

Page 104
Load Bearing Clamp Lockout

Order Code
Description
TC-7100I
Load Bearing Clamp Lockout
Description
This option requires the operator to depress a button that is on the
side of one of the cowl mounted levers in conjunction with the
rearward movement of the lever in order to unclamp a load with
clamp attachments. It is required for all trucks with clamp
attachments to have this option to remain in compliance with ANSI
B56 Standards.
This option is NOT for use with fingertip control options.
Bottlers Tilt
Order Code
Description
BTLTP15I
9 Forward/6 Backward Bottlers Tilt
Description
This is an option that is referred to as Bottlers Tilt for its common existence in the beverage
industry. The reason for this customization is that many times the pallets in the beverage industry are
kept in a rack or in trucks that require the mast to tilt forward more in order to get them out of the
racks. If the customer is in the beverage industry, this is something to offer.

Page 105
Tilt Cylinder Boot Kit

Order Code
Description
BOOTTLTP15I
Covers for tilt cylinders
Description
Tilt cylinder boots are an accordion-like rubber
covering that is mounted over the tilt cylinders that
help reduce the risk of damage from debris or dust
getting into the cylinder. This option does limit the
back tilt to 6.
Overhead Guard Options

Order Code
Description
TC-2045I
Lowered OHG
TC-2040I
Raised OHG
Description
The lowered overhead guard option lowers the OHG 3 lower than the standard OHG of the truck.
Because of this, it includes the change to a vinyl comfort (non-suspension) seat. It is NOT for use with
thermoformed OHG cover options or enclosed cabin options.
The raised overhead guard option raises the OHG 3 higher than the standard OHG and is NOT for use
with enclosed cabin options either.

Page 106
Martin Cab
Order Code
Description
TC-3260I
Martin Cab
Description
This fully enclosed cab includes the following: Front and splitrear laminated safety glass windshields with wiper and washer,
top clear, modified acrylic panel, right and left steel doors with
modified, acrylic sliding windows, headliner with a dome light,
front window defogger, rear combination stop/tail/backup
lights and a heater.
Important notes with this cab include:
The overall height from the ground to the top of the

enclosed cabin increases approximately 1 as
compared to the standard OHG.
Cab may increase the sound level at the operators ear.
This option is NOT compatible with optional OHGs,

thermoformed OHG cover options, foot direction control or fingertip controls.
The mast will be restricted to 6 back tilt with this cabin equipped.
Please contact CSM department regarding the use of OHG mounted accessories and options.
Please contact the cab manufacturer (Martin) for any warranty or product support.

Page 107
Martin Cab Accessories

NOTE: All electrical cab accessories are 12 volt.
NOTE: Cab accessories are NOT for use with Warning/Light options (except for Service Indicator
Package, Engine Shut Down and Seat Belt Ignition Interlock.
Order Code
Description
Notes
TC-2120I
Vertical Exhaust
For use with gas or diesel options and standard

muffler
TC-3190I
Rear Window Defogger

Fan
Defogger fan for rear windshield
TC-3200I
Inside Rearview Mirror
Automobile style center mounted rearview

mirror
TC-3210I
Rear Work light
One work light mounted outside the cab
TC-3220I
Turn Signals
Front and rear turn signals
TC-3230I
Amber Rotating Beacon
Rotating beacon mounted behind the cab that

continuously operates with the keyswitch on
TC-3240I
Amber Strobe
Flashing strobe mounted behind the cab that

TC-3270I
Foundry and Brick

Package for Cab
Includes: Radiator coolant level warning light,

air cleaner service indicator, dust proof
hydraulic tank breather kit, dust proof front
axle breather, air intake pre-cleaner (modified
for Martin Cab), transmission oil filter, dual
element air cleaner and tilt cylinder boot kit.
TC-3275I
Foundry and Brick

Package with elevated
exhaust

NOT for use with vertical exhaust options.

Page 108
Harris Stolper Cab

Order Code
Description
TC-3265I
Harris Stolper Cab
Description
This fully enclosed cab includes the following: Front and
split-rear laminated safety glass windshields with wiper
and washer, top clear, modified acrylic panel, right and left
steel doors with modified, acrylic sliding windows,
headliner with a dome light, front window defogger, rear
combination stop/tail/backup lights and a heater.
Important notes with this cab include:
The overall height from the ground to the top of the

enclosed cabin increases approximately 1 as
compared to the standard OHG.
Cab may increase the sound level at the operators

ear.
This option is NOT compatible with optional OHGs, thermoformed OHG cover options, foot
direction control or fingertip controls.
The mast will be restricted to 6 back tilt with this cabin equipped.
Please contact CSM department regarding the use of OHG mounted accessories and options.
Please contact the cab manufacturer (Martin) for any warranty or product support.

Page 109
Harris Stolper Cab Accessories

NOTE: All electrical cab accessories are 12 volt.
NOTE: Cab accessories are NOT for use with Warning/Light options (except for Service Indicator
Package, Engine Shut Down and Seat Belt Ignition Interlock.
Order Code
Description
Notes
TC-2125I
Vertical Exhaust
For use with gas or diesel options and standard

muffler
TC-3195I
Rear Window Defogger

Fan
Defogger fan for rear windshield
TC-3205I
Inside Rearview Mirror
Automobile style center mounted rearview

mirror
TC-3215I
Rear Work light
One work light mounted outside the cab
TC-3225I
Turn Signals
Front and rear turn signals
TC-3235I
Amber Rotating Beacon
Rotating beacon mounted behind the cab that

TC-3245I
Amber Strobe
Flashing strobe mounted behind the cab that

TC-3255I
Foundry and Brick

Package for Cab

TC-3280I
Foundry and Brick

Package with elevated
exhaust

NOT for use with vertical exhaust options.

Page 110
Tire Options
Order Code
GP15N-GP20CN
Description
SPTP15I
Solid Pneumatic Single Drive and Steer Tires.

Drive 6.5x10; Steer 5x8.
TC-3175I
Non-Marking Solid Pneumatic Single Drive and Steer Tires.

For use with 3,000-4,000 lb. and 5,500-7,000 lb. models.
Drive 6.5x10; Steer 5x8
GP20N-GP25N
Description
SPT1D1SP25NI

Drive 7x12; Steer 6x9.
TC-3180I

Drive 7x12; Steer 6x9.
TC-3450I
Large Pneumatic Single Drive Tires.

Tires are 28x9-15. Increase chassis width to 46.7. Not for
use with steel supply lines.
TC-3460I
Large Solid Pneumatic Single Drive Tires.

Tires are 28x9-15. Increases chassis width to 46.7. Not for
use with steel supply lines.
DRP28DP25I
Air-Filled Pneumatic Dual Drive and Single Steer Tires.

Drive Tires are 7x12-14PR.
SPT2D1SP25I
Solid Pneumatic Dual Drive and Single Steer Tires.

Drive 7x12; Steer 6.5x10.

Page 111
GP30N-GP35N
Description
SPT1D1SP30NI

5,500-6,000 lb. capacity: Drive 28x9-15; Steer 6.5x10.
6,500-7,000 lb. capacity Drive 250x15; Steer 6.5x10.
TC-3185I

Drive 28x9-15; Steer 6.5x10.
DRP28DP30I
Air-Filled Pneumatic Dual Drive and Single Steer Tires.

Drive Tires are 28x9-15-14PR.
SPT2D1SP30I
Solid Pneumatic Dual Drive and Single Steer Tires.

Drive 28x9x15; Steer 6.5x10.
Description
There are a wide array of different tires that are in the price pages for this model family. This is
however, only a fraction of the tires that you can get on Cat Lift Trucks. If there is something that the
customer needs but is not in the price pages, be sure to consult the CSM department.
All trucks come standard with air-filled pneumatics, but if
the application is one that is traditionally tough on the
tires and might result in excessive damage, then the
customer should consider solid pneumatics.
Also, dual drive tires can add stability when lifting a load
by providing a wider base on the front of the truck, where
the load is being lifted.

Page 112
Seat Options
Order Code
GP15N-GP35N
Description
SEATVI
Comfort (non-suspension) Vinyl Seat. Not for use

with fingertip controls or adjustable armrest.
Automatically included with lowered OHG option.
SEATCI
Comfort (non-suspension) Cloth Seat. Not for use

with fingertip controls or adjustable armrest.
Automatically included with lowered OHG option.
SEATFSCCI
Full Suspension Cloth Seat
SEATFSVSI
Full-Suspension Fold Down Vinyl Swivel Seat.

Provides 18 of swivel to the right with a latch at the
end of travel. Reduces torso clearance to the OHG by
approximately 1.25. Not for use with the
convenience tray, adjustable armrest or fingertip
controls. If this is ordered in combination with
armrest TC-1870, please contact CSM.
SEATFSCSI
Full-Suspension Fold Down Cloth Swivel Seat.

Provides 18 of swivel to the right with a latch at the
end of travel. Reduces torso clearance to the OHG by
approximately 1.25. Not for use with the
convenience tray, adjustable armrest or fingertip
controls. If this is ordered in combination with
armrest TC-1870, please contact CSM.
TC-8100I
Full-Suspension Vinyl Seat with Back Adjustment.

Back of seat can adjust 6 forward and 8 backward.
Not for use with fingertip controls and armrest
options.
TC-8110I
Full-Suspension Cloth Seat with Back Adjustment.

Back of seat can adjust 6 forward and 8 backward.
Not for use with fingertip controls and armrest
options.

Page 113
Foot Direction Control

Order Code
Description
FDCP15I
Foot Direction Control
Description
This option removes the electronic direction control lever
from the steering column and adds the pictured direction
control lever that is operated using the foot by the
operator. Often referred to as Monotrol, this is simply
preferred by some operators that are used to using it.

Page 114
Reverse Drive Packages

Order Code
Description
RDPCP15I
Reverse Drive Package Cloth Seat
RDPVP15I
Reverse Drive Package Vinyl Seat
Description
The reverse drive package includes the following accessories in order to make it easier and more
comfortable for an operator that is in an application that is travelling in reverse a large portion of the
time:
1. Swivel Seat Base Allows for 12 swivel in either direction.
2. Reverse Hand Grip with Horn Button Mounted on the rear OHG leg and allows the operator to
have something to hold onto while turned facing backwards and a horn to use without having to
use the conventional forward facing horn on the steering wheel.
3. Steering Wheel Knob Allows for easier turning of the steering wheel.
Reverse drive packages are not for use with fingertip control options due to interference when swiveling.
Steering Wheel Knob

Order Code
Description
STKNB15I
Steering Wheel Knob
Description
The steering wheel knob provides the operator with a smooth knob used for
turning the steering wheel with ease. It is a plastic knob attached to the steering
wheel.

Page 115
Rear Grab Bar With Horn Button

Order Code
DP100N-DP160N
Description
RGHP15I
Rear grab bar with horn button
Description
The rear grab bar is mounted to the overhead guard on its back, right leg and has a
yellow button to activate the horn of the truck.
This option is not for use on the 3,000-4,000 lb. compact models.
Swing Down LP Tank Bracket
GP20N-GP35N
Description
SDBKTP15I
Swing-Down LP Tank Bracket
Description
This patented swing down bracket allows more convenience to the
operator whenever changing the LP tank of the truck. For some
operators the idea of changing the tank at the top of the
counterweight can be a daunting task, so this bracket swings the tank
out, and then down to a more manageable height.
It is important to keep in mind that this swing down LP bracket does
cause the tank to sit a little higher than normal and as a result might
limit some rearward visibility, especially visibility to the area directly behind the counterweight.
This option is obviously only available on LP trucks and the brackets are for use with both 33.5 lb and
43.5 lb. LP tanks.
Page 116
Underbelly Screen
GP20N-GP35N
Description
UBSP15I
Underbelly Screen
Description
This optional underbelly screen was designed to fully cover the underside of the truck with perforated
metal. The natural operation of a forklift sucks air up into the engine compartment in order to cool it.
This underbelly screen might inhibit some of the cooling capability of the truck, but at the same time will
prevent debris from being sucked up into the engine compartment. This is commonly used to avoid large
debris such as shrink-wrap from getting sucked into the engine where it can cause damage to
components if it gets tangled.
High Pass Through Radiator
GP20N-GP35N
Description
HPTRADP15I
Square Fin Radiator
Description
This high pass through radiator is a square fin design, as opposed to the serpentine fin design of the
standard radiator. It is commonly used in applications with a lot of dust and debris as the square fin
design allows for more dust or fiber to pass completely through a radiator rather than being stuck on the
front end and possibly clogging it up. This is very common in cardboard or paper applications.

Page 117
Radiator Screen
GP20N-GP35N
Description
RADSCRP15I
Radiator Screen
Description
Another option to help prevent the clogging of the radiator would be too add
this option. This is a slide in screen that protects the front of the radiator
from debris. The screen can then be removed and cleaned whenever
necessary.
High Speed Fan
GP20N-GP35N
Description
HSFP15I
High Speed Fan Upgrade
Description
Heat balance and overheating are one of the major challenges that forklift manufacturers face. If there is
an application where the customer is consistently experiencing overheating or where it might be a
problem, this option provides a higher speed fan to pull hot air from the engine and expel it from the
engine compartment at a higher rate than the standard cooling fan.

Page 118
Cotton/Fiber Protection Package
GP20N-GP35N
Description
LINTPROTP15I
Cotton/Fiber Protection
Description
This package is put together for ease of order for applications that are particularly exposed to fiber or
particles. The components included in the package include the few previously listed options:
Square Fin Radiator- Allows debris to pass through the radiator more easily to prevent clogging.
Radiator Screen Blocks heavier debris from entering into the radiator
High Speed Fan Pushes hot air out of the engine compartment
Dust Proof Hydraulic Tank Breather Kit
GP20N-GP35N
Description
HTBP15I
Hydraulic Tank Breather Kit
Description
Dust Proof Front Axle Breather Kit
GP20N-GP35N
Description
FABP15I
Front Axle Breather Kit
Description
This breather kit is attached to the drive axle (front axle) of the truck and can help reduce the possibility
of contamination of the gear oil from dust and debris in dirtier applications. This is part of the
Foundry/Brick Protection Package.
Page 119
Dual Element Air Cleaner
GP20N-GP35N
Description
AIRCLDEP15I
Dual Element Air Cleaner
Description
This option adds a secondary filter element inside of the standard
primary air cleaner element. It helps to reduce the chances of dust or
debris from entering into the engine system and is part of the larger
Foundry/Brick Protection Package.
Elevated Air Intake Pre-cleaner
GP20N-GP35N
Description
PRECLNRP15I
Elevated Air Intake Pre-cleaner
Description
This moves that air intake of the truck to an elevated location mounted to the rear OHG leg. It helps to
further reduce the chance of contamination of the engine by way of dust particles taken in through air
intake because the entry point is higher from the ground, where many of the contaminants originate. It
reduces the load on the air filament itself.
This option is not for use with cabin options or with the elevated exhaust option.

Page 120
Transmission Fluid Filter
GP20N-GP35N
Description
TFFP15I
Transmission Fluid Filter
Description
This is an external filter that is added to one of the transmission lines to help trap any debris that might
contaminate the transmission. It is often added in applications with excessive dirt or dust and is part of
the Foundry/Brick Protection Package.

Page 121
Foundry and Brick Protection Package
GP20N-GP35N
Description
DUSTPROTP15I
Foundry/Brick Protection Package
TC-1315I
Foundry/Brick Protection Package for use with

Elevated Exhaust
Description
This is a compiled package of options that is designed to help trucks perform at an optimal level in
applications that are particularly dirty and/or dusty. This package is not for use with cabin options or
elevated exhaust (unless option TC-1315I is ordered) and comes with the following options:
Service Indicator Package Additional icons added to monitor air cleaner and radiator coolant
levels
Dust Proof Hydraulic Tank Breather Kit Hydraulic tank protection from contamination
Dust Proof Front Axle Breather Kit Drive axle protection from contamination
Dual Element Air Cleaner Provides more efficient filtration system during air intake process
Elevated Air Intake Pre-Cleaner Elevates air intake to lessen chance of contaminant entry into
the engine.
Transmission Fluid Filter Fluid to increase protection from contamination of the transmission
fluid
Tilt Cylinder Boot Kit- Covers for the tilt cylinders to help protect from dust or debris
contamination

Page 122
Exhaust Options
GP20N-GP35N
Description
EXHSELEP15I
Elevated Exhaust
TC-6715I
Wrapped Exhaust
Description
The elevated exhaust option re-routes the exhaust of the truck from
underneath it, to the rear right hand overhead guard leg of the truck.
This blows the exhaust fumes from below the truck to above the truck
as to allow for less release of exhaust where it might irritate pedestrians
or product.
Sealed Alternator
DP20N-DP35N
Description
TC-3610I
Sealed Alternator
Description
This is an option that is commonly used in excessively dirty/dusty applications and is a 35 amp sealed
alternator. It comes included with the UL Safety rated trucks.

Page 123
Engine Block Heater
GP20N-GP35N
Description
TC-6720I
Engine Block Heater
Description
This is an engine block heater that could help in cold start environments.
Rear LED Working Light
GP20N-GP35N
Description
RLWLP15I
Rear Facing Working Light
Description
A rear facing LED work light is mounted to the rear
left OHG leg. This option might benefit a customer
who uses the lift truck in a lowly lit environment and
often works in reverse. This rearward illumination
can drastically increase visibility behind the truck.

Page 124
Premium Working Light Package
GP20N-GP35N
Description
RLMRLP15I
Premium Light Package
Description
This is a package intended to help increase operator awareness
by combining the following options:
Rear View Mirror Kit Mirrors mounted to increase

rearward visibility
Rear Work Light Increases rearward visibility and view

of area behind truck in dimly lit areas
LED Turn Signals
GP20N-GP35N
Description
LTSP15I
Turn Signals
Description
LED turn signals can be added to the truck and are OHG mounted. They
allow the operator to utilize them to notify pedestrians or other operators
what the intended path of the truck is going to be.

Page 125
Amber Strobes
GP20N-GP35N
Description
BUHASP15I
Amber Strobe Mounted Above OHG
BULASP15I
Amber Strobe Mounted Below OHG
Description
An amber strobe can be mounted above or below the overhead
guard based on customer preference or need. Whenever the key
switch is activated, the strobe will flash to visually notify
pedestrians and other operators that the truck is in the area.
Applications with low lighting, high ambient noise levels and high
pedestrian and vehicle traffic might benefit from having trucks
equipped with this option.
It is important to keep in mind that when mounted above the
OHG, this option increases overall height clearance of the truck
and when mounted below, it can affect rearward visibility by way
of physically being in the line of sight and by flashing brightly.

Page 126
Blue Spotlights
GP20N-GP35N
Description
TC-3370I
Rear Activated Rear Facing Blue Spotlight
TC-3375I
Forwarded Activated Forward Facing Blue Spotlight
Description
These blue spotlights are used to announce the presence
of the truck by projecting a blue spotlight onto the ground
either in front or behind the truck on the ground,
dependent on the direction of travel of the truck. The
spotlights are mounted on the overhead guard of the
truck. The forward facing option shines through the mast
and the rearward facing option shines to the ground
behind the counterweight.
These allow pedestrians around corners or away from the
lift truck to know that it is coming because the arrival of
the truck is preceded by the shining blue light. These
options are not for use with lowered OHG options or fully
enclosed cabin options.

Page 127
Additional Indicators
GP20N-GP35N
Description
ACSIP15I
Air Cleaner Service Indicator
RCWLP15I
Radiator Coolant Warning Light
SRVCINDP15I
Service Indicator Package: Includes Air Cleaner

Service and Radiator Coolant Warning Lights
Description
These are added service indicators on the in dash display. The air cleaner service indicator makes the
operator aware whenever the air intake is clogging and the radiator coolant warning light lets the
operator know if they radiator coolant level is low.
Air Cleaner Service Indicator

Radiator Coolant Warning Icon
Page 128
Engine Shut Down System
GP20N-GP35N
Description
TC-1020I
Engine Shut Down System
Description
The engine shut down system is an option which shuts down the engine if any of the following
occur:
High transmission temperature (>230 F)
High coolant temperature (>225 F)
Low engine oil pressure (<3.5 psi)
If any of the above occur, an audible alarm will sound and a dash light will illuminate. This will
happen for 30 seconds and if the engine isnt shut down by the operator, then the engine will
shut down on its own. Once this happens, the engine can be restarted by cycling the key switch,
but if the condition that cause the shutdown still exists, the engine will shut down after 30
seconds again.
Appropriate sensors are added to the truck and the wiring harness for the system is installed
through the frame of the truck. Also, the buzzer that sounds whenever the system is activated
must be installed. Everything is routed through a relay box which tells the engine if any of the
trigger conditions are occurring.
The benefits here are that the operator cannot continue to operate the truck if there one of any
of a number of fluid conditions that could cause expensive and time consuming repairs. If the
truck is automatically shut down, there is a better chance of diagnosing the issue and fixing it with
less money spent by the end user.

Page 129
Seat Belt Ignition Interlock
GP20N-GP35N
Description
TC-2020I
Seat Belt Ignition Interlock
Description
Seat belt ignition interlock is an option that adds sensors and wiring to mandate that the operator
is using the seat belt and parking brake during operation of the truck.
If the operator has not fastened the seat belt, the

ignition of the truck will not start.
If the operator is running the truck and removes

the seat belt, then the engine will stop running in
2.5 seconds.
If the operator leaves the seat without setting the

parking brake, the engine will shut down within
2.5 seconds as well.
Wiring is added to the truck that communicates whether the critical components are being used
correctly. The seat belt and seat sensor work hand in hand so that the engine knows if the
operator is in the seat and the seat belt is fastened. The wiring is also connected to the parking
brake and will shut the engine down if the operator leaves the seat (warning the engine by way of
the seat sensor) without setting the brake.
The benefit here is added security to the operator. If the engine cannot run without these major
components being used, then it could help reduce the chances for improper use. This takes the
PDS system a step further and completely shuts the engine down instead of a lockout of hydraulic
and transmission functions.

Page 130
Dual Panoramic Rear View Mirror Kit
GP20N-GP35N
Description
RVWMIRRI
Rearview Mirror Kit
Description
This option adds to adjustable rear view mirrors that are mounted to the
front legs of the OHG to increase operator visibility behind the truck without
having to actually turn to face in a rearward direction. This option is part of
the premium working light package.
This mirror is not for use with enclosed cabin options.
Adjustable Armrest
GP20N-GP35N
Description
TC-1870I
Armrest
Description
This adjustable armrest mounts to the right side of the seat and
conveniently adjusts in numerous ways in order to reach the
position that is most comfortable for the operator. This low cost
option is a great way to increase the ergonomics of the operator
compartment during operation.

Page 131
Operator Fan
GP20N-GP35N
Description
TC-6700I
Operator Compartment Fan
Description
This is a small fan that is mounted (usually in the upper right hand corner
of the operators compartment) to blow air on the operator. This option
comes included with the cabin options of this model family.
Keyless Ignition
GP20N-GP35N
Description
TC-2015I
Keyless Ignition
Description
As suggested in the name of the option, this allows the truck to be started without the need of a key.
Usually this adds a keypad where the operator will enter a passcode and the engine of the truck will start
automatically. The difference between this and the standard trucks passcode capabilities is that a key is
still required to start the truck with the standard offering.

Page 132
Thermoformed Overhead Guard Covers
GP20N-GP35N
Description
TC-1930I
Tinted Overhead Guard Cover
HGCP15I
Clear Overhead Guard Cover
Description
These acrylic OHG covers are built to form fit
the top of the overhead guard and is held
securely in place with Velcro straps so that the
cover is easily to remove and replace. It can
help protect the operator from the elements
and small falling objects without restricting
the visibility through the top of the operators
compartment. There is a drain hose that runs down the
left front OHG leg to prevent water from gathering on
top of the cover.
Applications that could benefit from the use of this
option include those where the truck is regularly
operated outdoors or where the customer has covered
the OHG regularly with other materials that might
affect visibility such as cardboard, plywood, or other plastic materials.

Page 133
Fire Extinguisher
GP20N-GP35N
Description
FIREEXTP15I
Fire Extinguisher
Description
This option adds an ABC-type 2.5 lb. fire extinguisher to the right rear OHG leg of
the truck. This extinguisher meets the UL rated requirements of the US market
and some countries or customers might require a fire extinguisher that meets
other requirements.
Because it is mounted on the rear OHG leg, there is a chance that it might slightly
affect rearward visibility and this option is not available with certain options.
Benefits of this option include increased fire safety and possible compliance with
insurance policies required on certain sites. The end user is responsible for the
training of the operator whenever it comes to use of the extinguisher.
Drawbar Pin
GP20N-GP35N
Description
DRWPINP15I
Drawbar Pin
Description
The drawbar pin is the steel pin that is located on the back of the
counterweight. It is important to note that lift trucks are not intended to
tow anything with this pin. The pin is intended for the loading and
unloading of the truck onto trailers.

Page 134
Lifting Eyes
GP20N-GP35N
Description
LFTEYECP15I
Counterweight Mounted Lifting Eyes
LFTEYEMP15I
Mast Mounted Lifting Eyes
Description
Lifting eyes are used whenever an end user needs to move the lift
truck with the use of a crane. The counterweight mounted lift eyes
consist of a lifting eye that is forged onto a rod and fitted into the
appropriate holes in the counterweight. Secured with a nut and a
pin, a rubber socket prevents the eyes from damaging the paint of
the counterweight. These eyes can be used to remove the
counterweight if it is ever needed. When combined with the mast
mounted lift eyes, the truck can be completely hoisted using a crane.
This option is commonly used in stevedoring to lift a truck onto the deck of a ship for deck loading.
It is important to note that counterweight mounted lift eyes are not compatible with LP models due
to inference with the LP tank mounting.

Page 135
Special Paint Options
GP20N-GP35N
Description
9999-72110I
Red Paint; RAL: 3002
9999-72120I
Blue Paint; RAL: 5015
9999-72130I
Bright Yellow; RAL: 1023
9999-72140I
Gray Paint; RAL: 7001
9999-72150I
Green Paint; RAL: 6024
9999-72160I
White Paint; RAL: 9016
9999-72170I
Orange Paint; RAL: 2011
Description
Special paint can be ordered by the end user. The RAL codes of the
various price page option colors are listed above. If a custom color is
desired, it can be done through the CSM department (inquire for
pricing as there is a minimum amount of powder that must be
ordered for custom colors) with RAL code.

Page 136
Language Markings
GP20N-GP35N
Description
LANGENGEUI
European English Language Markings
LANGDFREEUI
French Language Markings
LANDSPAAMI
Spanish Language Markings (North/South America)
LANGPORAMI
Portuguese Language Markings (South America)
Description
These options change the language of all of the decals are changed to the language requested. The
languages listed above are the most frequently ordered, but in the future there are a number of other
languages that will be available. See the price pages for available options.

Page 137
Customer Service
Customer Support Programs
Cat Lift Trucks has an extremely strong dealer network that is able to provide its customers with the most
comprehensive support system possible. There are a number of ways that this is accomplished.
Warranty Information
Standard Warranty Program

o 1 Year / 2,000 Hour Standard Warranty
o 2 Year / 4,000 Hour Powertrain Warranty
Optional Extended Warranties

o Lift Plus Extended Warranty Program
2 year / Unlimited hour, 3 year / 6,000 hour , 4 year / 8,000 hour and 5 year /
10,000 hour options for carriage to counterweight coverage extension options
3 year / 6,000 hour, 4 year / 8,000 hour and 5 year / 10,000 hour options for
Powertrain coverage extension options
o Lift Truck Advantage Warranty Extensions
3 year / 6,000 hour , 4 year / 8,000 hour and 5 year / 10,000 hour options for
carriage to counterweight coverage extension options
4 year / 8,000 hour and 5 year / 10,000 hour options for Powertrain coverage
Parts Fast or Parts Free Guarantee (U.S. and Canada Only)

o This guarantee ensures next day business delivery of parts to the dealership or they are
free, freight included.
Separate Extended Warranty for Emission Parts (U.S. and Canada Only)

Page 138
Dealer Network
Supported by the most extensive dealer network in the industry, Cat Lift Trucks is driven and committed
to keeping the end users fleet up and running. If anything goes awry, help is always a phone call away.

Page 139
Forklifts Are Not Commodities

The Cat lift trucks brand is well known
around the globe for being a premium
brand. It leads the industry in its three
core beliefs of quality, reliability, and
customer service. As with its counterparts
on the earth moving side, these products
have a reputation for being tough,
durable, and backed by an extremely
strong dealer network.
As a salesman, it is important to
remember that this purchase is an
investment, and a large one at that. As
you discuss the needs and desires of the end user, do not forget to take time to remind them of the
features that are listed in this manual that make these lift trucks stand out. A lift truck is not a
commodity. It is not something that you purchase to run until it dies and then just toss it in the dump and
get a new one. There is a very good and clear reason that there are so many premium features that are
standard on Cat lift trucks while competitors might only offer them as options that add to the baseline
price, or not at all.
These lift trucks are meant as an investment. They are meant to be sold on the premise that the unique
features it has and the presence of your dealership will provide a wide array of benefits that will HEAVILY
outweigh the relatively minor lifetime cost of the truck.


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Page 1

LIFT TRUCK ELECTRONIC SALES MANUAL

Copyright 2013. All rights reserved. All registered trademarks

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ABOUT THIS LIFT TRUCK SALES MANUAL

Has not been published elsewhere or does not exist (and/or)

Is of a proprietary nature (and/or)

Your Participation To Improve This Document & Who To Contact

e-Mail mailto:[email protected] (click on address to create e-mail)

Phone Via MCFA LiftCentral at (877) 543-6757

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How To Find Information

Table of Contents (at the beginning of this document)

NOTE: Some data has been inserted

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* Contact CSM Group to obtain capacities.

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GP15N Solid Drive

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GP18N Single Drive

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GP18N Solid Drive

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GP20CN Single Drive

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P20N Single Drive

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GP20N Solid Single Drive

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GP20N Dual Drive

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GP20N Solid Dual Drive

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GP25N Single Drive