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◆ Changing a Tire

! WARNING ! WARNING ! WARNING

– Make sure the replacement tire is

of the same size, type and load
range.
– Use the tire recommended by Cat
Lift Trucks.

! WARNING
101105 101107

DO NOT attempt to change the tire with the Stop raising the truck when the tire clears the – Consult your Cat lift truck dealer
truck loaded. Injury and/or damage may result. ground. DO NOT raise the truck more than for proper tire changing procedure.
necessary. – Changing of tire and adjustment
procedure must be made by a
trained mechanic.
– Perform all maintenance with prop-
er equipment.
! WARNING ! WARNING

104772 104773

BE SURE no one is on the truck when raising DO NOT place any part of your body under
the front or rear tires. the truck. SECURELY SUPPORT the side
frames of the truck with Jack stands after jack-
ing it up.

97 97
TROUBLESHOOTING 98

Tire Information NOTICE: When changing tires, change them

in sets, even if only one of the tires
is damaged. If new and used tires
! WARNING
are used on the same axle, tilting
Servicing and changing tires and rims of the mast and rapid tire wear
can be dangerous and should be done will result.
only by trained personnel using proper The mounting faces of the hub,
tools and procedures. If correct proce- wheel nuts and wheels must be
dures are not followed while servicing free of any foreign material and Block Stand Jack
104949
tires and rims, the assemblies could lubricants of any kind. Tighten
burst with explosive force and cause seri- wheel nuts again after 24 hours of (Start by)
ous injury or death. Follow carefully the operation. 1. Park the truck on level ground with the
specific information provided by your Do not reinflate a tire mounted on parking brake applied, transmission in neu-
tire servicing company or dealer. a split type rim that has been driv- tral, forks lowered and engine stopped.
Use a tire inflation gauge and stand en on while flat or underinflated 2. Prepare tools, jack, stands and wheel
behind the tread when inflating a tire without inspecting the rim for block.
and checking tire pressure. damage and checking the lock ring
Proper inflation equipment, and training for proper installation. Jack capacities
in using the equipment, are necessary to
avoid overinflation. A tire blowout or Front Have available two jacks, each having
wheel a capacity of 5 tons (11000 lbf).
rim failure can result from improper or
misused equipment. Rear Have available two jacks, each having
wheel a capacity of 10 tons (22000 lbf).

Weight of wheel 140 kg (308 lb), approx.

3. Block the wheels. When removing a front

wheel, block the right and left rear wheels.
When removing a rear wheel, block the
right and left front wheels.
4. Slightly deflate tires before removing the
wheels from the truck.

98 98
TROUBLESHOOTING 99

• To Raise Front Wheel

To Remove Front Wheel

! WARNING
Spacer
Outer wheel
– DON’T put any portion of your body
Wedge band under the truck being raised.
Extension valve
– After raising the truck, place the
stands under the right and left frame
Extension
bracket members to support the truck.
Inner wheel Wheel nut
101322A
Clamp 3. Raise the truck until the tire just clears the
101545
Jacking ground.
1. Remove the inner tire extension bracket. Position the jack under the frame and raise the
front wheel.

! WARNING
Other method
When removing the outer wheel nuts,
grasp each nut properly to prevent the
wrench from slipping off the nut.
Tilt forward
Tilt backward

2. Loosen the outer wheel nuts about two 104999

rotations.
Block
Next, place the jack stands on both sides under
NOTICE: Only loosen the wheel nuts. DO the frame to support it.
NOT remove them.

101325A

Hydraulic-jacking
Tilt the mast all the way back, put blocks
under the mast, then tilt the mast forward.

99 99
TROUBLESHOOTING 100

! CAUTION

Be careful NOT to strip the threads of the

inner wheel nuts or wheel bolts by the
edges of the wheel disk holes.

Wedge band Drift

200599 101551

5. Remove the band with a hammer and drift 7. Remove the spacer.
as shown. 8. Remove the extension valve to prevent
damage to it during wheel removal.

Clamp Wheel nut

101552 104951

4. Remove the wheel nuts and clamps. 6. Hold the wheel with hoist or a lift truck
and remove it.

Weight of wheel
140 kg (308 lb)
(standard tire)

100 100
TROUBLESHOOTING 101

To Install Front Wheel To Remove Rear Wheel • To Raise Rear Wheel

Tightening sequence 2. Position the jack at the specified jacking

Rear wheel
point.
➀ ➃
3. Raise the truck by operating the jack until
➅ ➆ the tire clears the ground.
➈ ➁ Clamp

Wheel
➂ ➉ nut
➇ ➄ 101546 101547

1. Use the reverse of removal procedure. 1. Loosen the wheel nuts about two rotations.
2. Tighten the wheel nuts evenly to the speci- NOTICE: Only loosen the wheel nuts. DO
fied torque. NOT remove them.
101996

539.4±53.9 N·m 4. Support the truck with rigid racks.

Tightening torque for
(55±5.5 kgf·m)
wheel nuts
[397.8±39.8 lbf·ft]
5. Remove the wheel nuts and clamps.

! CAUTION

Use the same size and brand tire.

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

NOTICE: Even when replacing an outer

wheel tire, make sure the inner
wheel nuts are tightened properly.

101 101
TROUBLESHOOTING 102

105000

! CAUTION

Be careful NOT to strip the bolt threads by

the edges of the rim holes.

6. Hold the rear wheel with a hoist or a lift

truck and remove it.

102 102
TROUBLESHOOTING 103

To Install Rear Wheel

! CAUTION
Tightening sequence
➀
– DO NOT overtighten the wheel nuts.
➇ ➄
– Overtightening will strain the bolts.

➃ ➂

A torque wrench is recommended for tighten-

➅ ➆ ing the wheel nuts. If a torque wrench is not
➁ 101554 available, tighten the nuts with a socket
1. Use the reverse of removal procedure. wrench for wheel nuts by resting the weight on
2. Tighten the wheel nuts evenly to the speci- the handle of the wrench.
fied torque.

539.4±53.9 N·m
Tightening torque
(55±5.5 kgf·m)
for wheel nuts
[397.8±39.8 lbf·ft]

! CAUTION

Use the same size and brand tire.

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

103 103
TROUBLESHOOTING 104

◆ Powershift Transmission Oil

Temperature Gauge Needle Moves
• Inspecting Tire Pressure into the Red Zone
Check the tire pressure and adjust it if neces-
sary. For the tire pressure, see Specifications ! WARNING
and Refill Capacities.
NOTICE: The tire pressure is indicated on the
nameplate attached to the left side
of the hood and seat assembly.

! WARNING
104954

100904A
! CAUTION
Your lift truck uses high pressure tires. When
adding air, check the rim for damage that If the gauge needle remains in the RED
could permit air to leak from the tire. NEVER zone, or if it moves into the RED zone fre-
overinflate the tire. quently, consult your Cat lift truck dealer.
When adding air to the tire, or checking tire
100838
pressure, BE SURE to keep your body away
from the side. The use of an inflation cage, or 1. Park the truck in a safety area.
When adding air to the tire using an air com- some other safety device, helps reduce the risk 2. Place the direction lever in the NEUTRAL
pressor, make sure the compressor valve is cor- of serious injury. position. Allow the engine to run at low
rectly set. Failure to follow this precaution can idle for a while.
When adding air to the tire using, an air com-
damage the tire. Always maintain correct tire 3. After the oil temperature gauge needle to
pressor, make sure the compressor valve is cor-
pressure. move into the GREEN zone, operating the
rectly set. Failure to follow this precaution
may cause personal injury or may damage the truck again.
tire. Always maintain the correct tire pressure.

104 104
TROUBLESHOOTING 105

◆ Stalled Engine ◆ Engine Coolant Temperature Gauge

Needle Moves into the Red Zone

! WARNING

101111A 103594

If the engine stalls, hydraulic pressure is lost 1. Park the truck in a safe area.
100813
in the power steering. This increases your 2. Raise the hood and seat assembly to venti-
steering effort. In such a case, stop your truck late the engine compartment. – DO NOT attempt to remove the radiator
in a safe area and restart the engine. 3. Allow the engine to idle for a while. DO filler cap if the engine is overheated to
NOT attempt to stop the engine. avoid scalding hot coolant and steam will
Before restarting the engine: blow out of the radiator.
4. Stop the engine after the coolant tempera-
– Make sure the fuel tank is NOT empty. – DO NOT add cold water to an overheated
ture gauge needle has moved into the
– Correct the cause of engine stalling such engine. This can cause the engine to suffer
WHITE zone.
as overloading. damage. Wait for the engine to cool, if
5. Check for:
– Lack of coolant. possible. If not, slowly pour water into the
– Loose or broken fan belt. radiator.
– Engine oil level. – Immediately stop the engine if the fan belt
– Dirt buildup in radiator air passages. is broken.

105 105
TROUBLESHOOTING 106

◆ Driving Interlock Indicator Light Flickers or Flashes, and the Truck Stops Moving

The driving interlock indicator Are you properly sitting in the Place the direction lever to the neutral position and sit securely with the
light starts flickering and the operator’s seat ? seat belt fastened.
truck stops moving.

NO

N
103673 104273 105022

YES
The driving interlock indicator Stop working and move the truck to a safe area. Shut down the engine and
light is OFF but the truck fails to consult your Cat lift truck dealer.
move.

TROUBLE

N DO NOT
OPERATE

103674 101463

106 106
TROUBLESHOOTING 107

◆ Mast Interlock Indicator Light Flickers or Flashes, and the Mast Stops Moving

The mast interlock indicator Are you properly sitting in the Place the lift and tilt levers to the neutral positions and sit securely with
light starts flickering and the operator’s seat ? the seat belt fastened.
mast stops moving.

NO

103644 104273 105022

YES
The mast interlock indicator Stop working and move the truck to a safe area. Shut down the engine and
light is OFF but the truck fails to consult your Cat lift truck dealer.
move.

TROUBLE

DO NOT
OPERATE

103646 101463

NOTICE: The mast interlock will work only for the lift and tilt levers. Attachments can be operated
regardless of whether the mast interlock function is operating or not.
Therefore, when the attachment lever is operated, some of the attachments will move, even
though the engine is not running or the key switch is in the (OFF) position, as a result of the
handling load or of its own weight.

107 107
TROUBLESHOOTING 108

◆ The Mast and Attachments Malfunctions

! WARNING
MC Lever FC Lever NEVER attempt to return the emer-
gency stop button to the OPERATE
(unlock) position for operating the truck
before an authorized factory trained
technician arrives to inspect the truck.

104962

If the mast and attachments fails to stop moving although you let go your hold of the control:
1. Push down on the emergency stop button as soon as possible (the engine will not stop).
2. Move the truck to a safe area, turn the key switch to the (OFF) position, and consult your
Cat lift truck dealer.

108 108
TROUBLESHOOTING 109

◆ Error Codes and Explanations

Contact your Cat lift truck dealer when the error code is displayed.

Error Error Error

Explanation Explanation Explanation
code code code
E01 Accel sensor error 1 (Diagnosis code 24) E35 Fuel temperature sensor (Inlet) error (Diagnosis code 41) F22 Tilt lever error
E02 Accel sensor error 2 (Diagnosis code 16) E36 Fuel temperature sensor (outlet) error (Diagnosis code 56) F24 Attach-1 lever error
E03 Accel SW error (Diagnosis code 65) E37 Intake air temperature sensor (upstream) error (Diagnosis code 44) F26 Attach-2 lever error
E04 Camshaft sensor error (Diagnosis code 12) E39 Q adjustment resistor error (Diagnosis code 34) F28 Attach-3 lever error
E05 Common rail pressure error (Diagnosis code 23) E41 Vehicle speed sensor error (Diagnosis code 25) F29 Joystick lever error
E06 Common rail pressure error (Diagnosis code 36) E42 Common rail pressure M/V error (Diagnosis code 63) F31 VCM3 sensor voltage error
E07 Common rail pressure sensor error (Diagnosis code 11) E43 EGR1 error (Diagnosis code 67) F33 VCM3-OP lift oil pressure sensor error
E08 Accel check error (Diagnosis code 58) E44 EGR2 error (Diagnosis code 68) F34 Speed sensor error
E09 Injector M/V 1 error (Diagnosis code 37) E45 EGR3 error (Diagnosis code 69) F36 Tire angle sensor error
E10 Injector M/V 2 error (Diagnosis code 38) E48 Glow relay error (Diagnosis code 26) F39 VCM3-OP tilt angle sensor error
E11 Injector M/V 3 error (Diagnosis code 39) E49 Starter safety relay error (Diagnosis code 48) F40 Steering error
E12 Injector M/V 4 error (Diagnosis code 08) F41 Output unit controller error
E13 Injector M/V 5 error (Diagnosis code 46) F01 VCM3 memory check error F42 Output unit lifecontrol signal
E14 Injector M/V 6 error (Diagnosis code 47) F02 VCM3 battery voltage error F43 Output unit memory error
E15 Flow limit 1 error (Diagnosis code 71) F03 VCM3 communication error F44 Output unit PWM voltage error
E16 Flow limit 2 error (Diagnosis code 72) F04 ECM communication error F45 Output unit communication error
E17 Flow limit 3 error (Diagnosis code 73) F07 MP communication error F46 Input unit controller error
E18 Flow limit 4 error (Diagnosis code 74) F08 TMS communication error F47 Input unit lifecontrol signal
E19 Flow limit 5 error (Diagnosis code 75) F10 Lift lever neutral error F48 Input unit memory error
E20 Flow limit 6 error (Diagnosis code 76) F11 Tilt lever neutral error F49 Input unit communication error
E24 Engine revolution sensor (Diagnosis code 15) F12 Attach-1 lever neutral error F50 Lift up solenoid error
E25 Engine overrun error (Diagnosis code 07) F13 Attach-2 lever neutral error F52 Lift down solenoid error
E26 Boost pressure sensor error (Diagnosis code 32) F14 Attach-3 lever neutral error F54 Lift solenoid leak
E28 Common rail pressure error (Diagnosis code 22) F15 ECU communication error F55 Tilt forward solenoid error
E29 Atmosphere pressure sensor error (Diagnosis code 19) F16 Shift lever error F57 Tilt backward solenoid error
E30 CAN communication error F17 Speed error F59 Tilt solenoid leak
E32 Water temperature sensor error (Diagnosis code 21) F18 ECU KWP2000 communication error F60 Attach-1A solenoid error
E33 ECU system error (Diagnosis code 33) F19 ECU speed sensor error F62 Attach-1B solenoid error
E34 Injector circuit error (Diagnosis code 82) F20 Lift lever error F64 Attach-1 solenoid leak

109 109
TROUBLESHOOTING 110

Error Error Error

Explanation Explanation Explanation
code code code
F65 Attach-2A solenoid error P03 VCM3 communication error
F67 Attach-2B solenoid error P04 ECM/ECU communication error
F69 Attach-2 solenoid leak P07 MP communication error
F70 Attach-3A solenoid error P08 TMS communication error
F72 Attach-3B solenoid error P22 Shift lever error signal
F74 Attach-3 solenoid leak
F75 Unload solenoid error
F79 Unload solenoid leak
F80 Knob position solenoid error
F81 VCM3-OP tiltlock solenoid error
F83 VCM3-OP tiltlock solenoid leak
F84 Knob position solenoid leak
F85 T/M forward solenoid error
F87 T/M backward solenoid error
F89 T/M solenoid leak
F90 VCM3-OP sensor voltage error
F91 VCM3-OP memory error
F92 VCM3-OP battery Voltage error
F93 VCM3-OP changemission solenoid 1 error
F94 VCM3-OP changemission solenoid 2 error
F95 VCM3-OP changemission solenoid leak error
F96 VCM3-OP EAT setting error
F97 VCM3-OP communication error

L03 VCM3 communication error

L04 ECM/ECU communication error
L07 MP communication error
L08 TMS communication error

110 110