CAT Forklift GP40 Service, Operation & Maintenance Manual

CAT Forklift GP40 Service, Operation

& Maintenance Manual
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**CAT Forklift GP40 Service, Operation & Maintenance Manual** Size: 47.8 MB
Format: PDF Language: English Brand: CAT Caterpillar Type of Machine: Forklift
Type of Manual: Service Manual, Operation & Maintenance Manual Model: CAT
GP40 Forklift Date: 2010 Content: Main Harness S15G Fuel System Schematic
99719-34130-00 Engine: 4G15, 4G63, 4G64, 6G72: Foreword 99719-34130-01
Engine: 4G15, 4G63, 4G64, 6G72: Structure and Function 99719-34130-02
Engine: 4G15, 4G63, 4G64, 6G72: Operating Instructions 99719-34130-03
Engine: 4G15, 4G63, 4G64, 6G72: Troubleshooting 99719-34130-04 Engine:
4G15, 4G63, 4G64, 6G72: Disassembly and Reassembly 99719-34130-05 Engine:
4G15, 4G63, 4G64, 6G72: Inspection and Adjustment 99719-34130-06 Engine:
4G15, 4G63, 4G64, 6G72: Wiring Schematic 99739-84110-00 Engine: 6G72
Gasoline: Foreword 99739-84110-01 Engine: 6G72 Gasoline: General Information
99739-84110-02 Engine: 6G72 Gasoline: Engine Proper 99739-84110-03 Engine:
6G72 Gasoline: Lubricating System 99739-84110-04 Engine: 6G72 Gasoline: Fuel
System 99739-84110-05 Engine: 6G72 Gasoline: Cooling System
99739-84110-06 Engine: 6G72 Gasoline: Intake and Exhaust System
99739-84110-07 Engine: 6G72 Gasoline: Electrical System 99739-88100-01
Chassis and Mast: General Information 99739-88100-02 Chassis and Mast:
Cooling System 99739-88100-03 Chassis and Mast: Electrical System
99739-88100-05 Chassis and Mast: Transmission 99739-88100-06 Chassis and
Mast: Front Axle and Differential SENB8531-00 1.4 Liter (4G33), 2.0 Liter (4G63),

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2.4 Liter (4G65), 3.0 Liter (6G72) LP Gas Supplement: Foreword SENB8531-01
1.4 Liter (4G33), 2.0 Liter (4G63), 2.4 Liter (4G65), 3.0 Liter (6G72) LP Gas
Supplement: LP Gases SENB8531-02 1.4 Liter (4G33), 2.0 Liter (4G63), 2.4 Liter
(4G65), 3.0 Liter (6G72) LP Gas Supplement: Structure and Function
SENB8531-03 1.4 Liter (4G33), 2.0 Liter (4G63), 2.4 Liter (4G65), 3.0 Liter (6G72)
LP Gas Supplement: Actions To Be Taken In the Event Of An LP-Gas Fuel System
Failure SENB8531-04 1.4 Liter (4G33), 2.0 Liter (4G63), 2.4 Liter (4G65), 3.0 Liter
(6G72) LP Gas Supplement: Troubleshooting SENB8531-05 1.4 Liter (4G33), 2.0
Liter (4G63), 2.4 Liter (4G65), 3.0 Liter (6G72) LP Gas Supplement: Model J
Repair Kit Installation Instructions SENB8531-06 1.4 Liter (4G33), 2.0 Liter (4G63),
2.4 Liter (4G65), 3.0 Liter (6G72) LP Gas Supplement: Electrical Circuit Testing
SENB8531-07 1.4 Liter (4G33), 2.0 Liter (4G63), 2.4 Liter (4G65), 3.0 Liter (6G72)
LP Gas Supplement: Model CA50, CA100 Carburetor Adjustment SENB8538-00
Gas and Diesel Pneumatic Tire Lift Truck Introduction SENB8542-01 Lift Truck
Vehicle Systems; Cooling System SENB8542-02 Lift Truck Vehicle Systems:
Electrical System SENB8542-02a Lift Truck Vehicle Systems: Electrical System
SENB8542-03 Lift Truck Vehicle Systems: Rear Axle SENB8542-04 Lift Truck
Vehicle Systems: Brake System SENB8542-05 Lift Truck Vehicle Systems:
Steering System SENB8542-06 Lift Truck Vehicle Systems: Hydraulic System
SENB8542-07 Lift Truck Vehicle Systems: Masts and Forks SENB8542-08 Lift
Truck Vehicle Systems: Trouble Shooting SENB8542-09 Lift Truck Vehicle
Systems: Service Data 99730-88100-00 Operation & Maintenance Manual:
Foreword 99730-88100-01 Operation & Maintenance Manual: How To Use This
Manual 99730-88100-02 Operation & Maintenance Manual: Safety Rules For Lift
Truck Operators 99730-88100-03 Operation & Maintenance Manual: Know Your
Lift Truck 99730-88100-04 Operation & Maintenance Manual: How To Avoid A
Tipover; How To Survive One 99730-88100-05 Operation & Maintenance Manual:
Refueling 99730-88100-06 Operation & Maintenance Manual: Operation
99730-88100-07 Operation & Maintenance Manual: Operating Techniques
99730-88100-08 Operation & Maintenance Manual: Storing The Lift Truck
99730-88100-09 Operation & Maintenance Manual: Special Situations
99730-88100-10 Operation & Maintenance Manual: Transportation Hints
99730-88100-11 Operation & Maintenance Manual: Troubleshooting
99730-88100-12 Operation & Maintenance Manual: Maintenance 99730-88100-13
Operation & Maintenance Manual: Service Data 99730-88100-14 Operation &
Maintenance Manual: Service Data Cat Pub List Publication List (Service,
Operator, & Parts Manuals) Mast Tilting Angles Mast Tilting Angles REF-18-0001C
How To Determine Correct Mast Rails Lift Cylinders And Mast Hosing
REF-18-0001C How To Determine Correct Mast Rails Lift Cylinders And Mast
Hosing (Spanish) REF-18-0002C How To Locate Fluid Capacities REF-18-0002C
How To Locate Fluid Capacities (Spanish) REF-18-0003C How To Use A Pick List
REF-18-0003C How To Use A Pick List (Spanish) REF-18-0007C Abbreviations
And Acronyms List REF-18-0008C Diagnostic Trouble (Error) Codes This part
manual inlcude all spare parts number you need inside this model, for you easier in
fixing your forklift replace new spare part hight performance. This service manual is
a guide for servicing Cat Lift Trucks. For your convenience the instructions are
grouped by systems as an easy reference. This Original Instructions (Operator's)
Manual describes operating procedures, daily checks and simple maintenance for
safe usage of your Cat lift truck. SERVICE MANUAL CHAPTER 1 GENERAL
INFORMATION 1.1 Model View 1.2 Models Covered 1.2.1 Lift Truck
Nomenclatures and Definitions 1.3 Serial Number Locations 1.4 Dimensions 1.5
Technical Data 1.6 Performance CHAPTER 2 COOLING SYSTEM 2.1
Specifications 2.2 Structure 2.3 Removal and Installation 2.3.1 Fan Belt Removal
2.3.2 Suggestions for Removal 2.3.3 Installation 2.4 Inspection and Adjustment
2.4.1 Fan Belt Inspection 2.4.2 Fan Belt Tension 2.4.3 Connecting Hoses 2.4.4
Coolant 2.4.5 Radiator Cap CHAPTER 3 ELECTRIC SYSTEM 3.1 Chassis
Electrical Devices Wiring Outline 3.1.1 Harnesses Layout 3.1.2 Components
Layout 3.2 Structure 3.2.1 Console Box 3.2.2 Major Electrical Components 3.2.3
Table of Lamps 3.3 Console Box 3.3.1 Disassembly 3.4 Battery Maintenance 3.4.1
State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment 3.4.2 Specific
Gravity Reading and State of Charge 3.4.3 Charging Precautions 3.5 Instrument
Panel 3.5.1 Instrument Panel Screen Element 3.5.2 Basic Screen Display 3.5.3
Basic Operation 3.5.4 When An Error Occurs 3.5.5 Warning Lamps 3.5.6 Optional
Functions 3.5.7 Hour Meters 3.5.8 Troubleshooting 3.6 Wire Color 3.6.2 List of
Wire Colors 3.7 Troubleshooting 3.7.1 Starter System 3.7.2 Gauges 3.7.3 Lighting
System 3.8 Electrical Schematic CHAPTER 4 CONTROLLERS 4.1 Outline 4.2
Main Functions 4.2.2 Instrument Panel 4.2.3 VCM (Vehicle Control Module)1-M
4.2.4 ECM (Gasoline Engine Control Module) 4.2.5 Remote Input/Output Units
4.2.6 GSE Connector 4.3 Service Tool Functions 4.3.1 Service Tool Menus 4.3.2
Service Tool Box 4.4 Mast Interlock System 4.4.1 Function 4.4.2 VCM1-M
Controller, Mast Interlock System Checking Procedure 4.4.3 Active Test Inspection
Procedure 4.5 Driving Interlock System 4.5.1 Function 4.5.2 Driving Interlock
System Checking Procedure for Powershift T/M Lift Trucks 4.5.3 Active Test
Inspection Procedure 4.6 Seat Belt Warning Lamp 4.6.1 Function 4.6.2 Seat Belt
Warning Lamp Checking Procedure 4.7 Parking Brake Warning Buzzer and Lamp
4.7.1 Function 4.7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure
4.7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in OFF
Position 4.8 Harness Codes 4.9 Controller Details 4.9.1 VCM1-M Controller 4.9.2
Seat Switch/Seat Belt Switch 4.9.3 Parking Brake Switch 4.9.4 Direction Lever
4.9.5 Speed Sensor 4.9.6 T/M Solenoid 4.9.7 Unload Solenoid 4.9.8 Lift Lock
Solenoid 4.9.9 Warning Buzzer 4.9.10 Warning Buzzer Relay 4.9.11 Warning
Buzzer Circuit 4.9.12 Instrument Panel 4.10 Error Codes and Troubleshootings
4.10.1 Error Code Display 4.10.2 Diagnosis Table (F Code) 4.10.3 Error Codes
and Troubleshooting 4.11 Locations of Sensors and Switches CHAPTER 5
POWER TRAIN 5.1 Removal and Installation (MC Models) 5.1.1 Removal of
Engine and Transmission Assembly 5.1.2 Removal of Engine and Transmission
Assembly (for Gasoline-Engine Lift Trucks) 5.2 Removal and Installation (FC
Models) 5.2.1 Removal of Engine and Transmission Assembly CHAPTER 6
POWERSHIFT TRANSMISSION 6.1 Structure and Functions 6.1.1 Transmission
6.1.2 Torque Converter 6.1.3 Control Valve 6.1.4 Hydraulic System Schematic of
Powershift Transmission 6.2 Removal and Installation 6.2.1 Removal 6.2.2
Installation 6.3 Control Valve 6.3.1 Disassembly 6.3.2 Reassembly 6.4 Input Shaft
Assembly 6.4.1 Disassembly 6.5 Oil Pump Assembly 6.5.1 Disassembly 6.5.2
Reassembly 6.6 Inspection and Adjustment 6.6.1 Oil Pressure Measurement 6.6.2
Clutch (Inching) Pedal Adjustment 6.6.3 Inching Cable, Adjustment 6.7
Troubleshooting 6.8 Tightening Torque 6.9 Service Data CHAPTER 7 FRONT
AXLE AND REDUCTION DIFFERENTIAL 7.1 Structure 7.1.1 Front Axle 7.1.2
Reduction Differential 7.2 Removal and Installation 7.2.1 Front Wheels 7.3 Front
Axle 7.3.2 Reduction Differential 7.4 Disassembly and Reassembly 7.4.1 Front
Axle 7.4.2 Reduction Differential 7.5 Troubleshooting 7.6 Service Data CHAPTER
8 REAR AXLE 8.1 Structure and Functions 8.1.1 Rear Axle in General 8.1.2
Structure of Each Component 8.1.3 Steering Cylinder 8.2 Removal and Installation
8.2.1 Rear Wheel and Rear Axle Assembly 8.3 Disassembly and Reassembly
8.3.1 Wheel Hub, Disassembly and Reassembly 8.3.2 Knuckle (King Pin),
Disassembly and Reassembly 8.3.3 Steering Cylinder, Disassembly and
Reassembly 8.3.4 Tie Rod, Disassembly and Reassembly CHAPTER 9 BRAKE
SYSTEM 9.1 Structure 9.1.1 Brake System 9.2 Disassembly and Reassembly
9.2.1 Master Cylinder 9.2.2 Wheel Brakes 9.2.3 Wheel Cylinder 9.3 Inspection and
Adjustment 9.3.1 Automatic Adjuster Test 9.3.2 Manual Adjustment 9.3.3 Parking
Brake Cable Adjustment 9.3.4 Brake Pedal Adjustment 9.3.5 Brake Lines Bleeding
9.3.6 Braking Performance Test 9.3.7 Parking Brake Lever 9.4 Troubleshooting 9.5
Service Data CHAPTER 10 STEERING SYSTEM 10.1 Structure and Functions
10.1.1 Steering System 10.1.2 Steering Valve 10.1.3 Steering Column 10.2
Disassembly and Reassembly 10.2.2 Steering Wheel and Steering Valve,
Removal and Installation 10.2.3 Steering Wheel 10.2.4 Steering Valve 10.2.5 Tilt
Lock Lever 10.3 Steering Valve 10.3.1 Disassembly 10.3.2 Reassembly 10.4
Troubleshooting 10.5 Service Data CHAPTER 11 HYDRAULIC SYSTEM 11.1
Structure and Functions 11.1.1 Outline 11.2 Hydraulic Circuit Diagram (For Models
With MC Control Valve) 11.3 Hydraulic Circuit Diagram (For Models With FC
Control Valve) 11.4 Hydraulic Tank 11.5 Hydraulic Pump (Gear Pump) 11.6
Control Valve 11.7 Flow Regulator Valve (for Models with FC Control Valve Only)
11.8 Down Safety Valve 11.9 Lift Cylinder 11.10 Tilt Cylinder 11.11 Disassembly
and Reassembly 11.11.1 Hydraulic Pump 11.11.2 Lift Cylinder 11.11.3 Tilt Cylinder
11.11.4 Flow Regulator Valve 11.11.5 Piping 11.11.6 Suction Strainer and Return
Filter 11.12 Inspection and Adjustment 11.12.1 Hydraulic Tank 11.12.2 Control
Valve 11.12.3 Descent Test 11.12.4 Forward Tilt Test 11.13 Troubleshooting
11.13.2 Hydraulic System Cleaning After a Component Failure 11.14 Service Data
11.15 MC Control Valve 11.15.1 Structure and Operation 11.15.2 Control Valve,
Removal and Installation 11.15.3 Disassembly and Assembly 11.16 FC Control
Valve 11.16.1 Structure and Operation 11.16.2 Disassembly and Assembly
CHAPTER 12 MAST AND FORKS 12.1 Simplex Mast 12.1.1 Mast System 12.2
Structure and Functions 12.2.1 Simplex Mast (5A15C to 5A33C) 12.2.2 Mast
Operation 12.3 Removal and Installation 12.3.1 Mast and Lift Bracket Assembly
12.4 Disassembly and Reassembly 12.4.1 Simplex Mast Disassembly 12.4.2
Simplex Mast Reassembly 12.5 Removal and Installation of Mast Rollers and
Strips without Removing 12.5.1 Simplex Mast 12.6 Inspection and Adjustment
(Simplex Mast) 12.6.2 Forks 12.6.3 Chain Tension Inspection and Adjustment
12.6.4 Checking Chain Elongation 12.6.5 Adjusting Clearance Between Lift
Bracket Roller and Inner Mast 12.6.6 Mast Roller Clearance Adjustment 12.6.7
Mast Strip Clearance Inspection and Adjustment 12.6.8 Tilt Angle Adjustment
12.6.9 Right and Left Lift Cylinder Stroke Inspection and Adjustment 12.7
Troubleshooting (Simplex Mast) 12.8 Service Data (Simplex Mast) 12.9 Duplex
Mast 12.9.1 Mast System 12.10 Structure and Functions 12.10.1 Duplex (Dual
Full-Free Panoramic) Mast (5B15C to 5B33C) 12.10.2 Mast Operation 12.11
Removal and Installation 12.11.1 Mast and Lift Bracket Assembly 12.12
Disassembly and Reassembly 12.12.1 Duplex Mast Disassembly 12.12.2 Duplex
Mast Reassembly 12.13 Removal and Installation of Mast Rollers and Strips
without Removing 12.13.1 Duplex Mast 12.14 Inspection and Adjustment (Duplex
Mast) 12.14.1 Inspection and Adjustment (Duplex Mast) 12.14.2 Forks 12.14.3
Chain Tension Inspection and Adjustment 12.14.4 Checking Chain Elongation
12.14.5 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 12.14.6
Mast Roller Clearance Adjustment 12.14.7 Mast Strip Clearance Inspection and
Adjustment 12.14.8 Tilt Angle Adjustment 12.14.9 Right and Left Lift Cylinder
Stroke Inspection and Adjustment 12.15 Troubleshooting (Duplex Mast) 12.16
Service Data (Duplex Mast) 12.17 Triplex Mast 12.17.1 Mast System 12.18
Structure and Functions 12.18.1 Triplex (Triple Full-Free Panoramic) Mast (5C15C
to 5C33C) 12.18.2 Mast Operation 12.19 Removal and Installation 12.19.1 Mast
and Lift Bracket Assembly 12.20 Disassembly and Reassembly 12.20.1 Triplex
Mast Disassembly 12.20.2 Triplex Mast Reassembly 12.21 Removal and
Installation of Mast Rollers and Strips without Removing 12.21.1 Triplex Mast
12.22 Inspection and Adjustment (Triplex Mast) 12.22.2 Forks 12.22.3 Chain
Tension Inspection and Adjustment 12.22.4 Checking Chain Elongation 12.22.5
Adjusting Clearance between Lift Bracket Roller and Inner Mast 12.22.6 Mast
Roller Clearance Adjustment 12.22.7 Mast Strip Clearance Inspection and
Adjustment 12.22.8 Tilt Angle Adjustment 12.22.9 Right and Left Lift Cylinder
Stroke Inspection and Adjustment 12.23 Troubleshooting (Triplex Mast) 12.23.1
Troubleshooting (Triplex Mast) 12.24 Service Data (Triplex Mast) 12.24.1 Triplex
Mast CHAPTER 13 SERVICE DATA 13.1 Maintenance Schedule 13.2
Maintenance Note 13.2.1 Brake System 13.2.2 Cooling System 13.2.3 Electric
System 13.2.4 Engine System 13.2.5 Frame and Chassis 13.2.6 Fuel System
13.2.7 Hydraulic System 13.2.8 Ignition System 13.2.9 Intake System 13.2.10
Front End Section 13.2.11 Steering and Axle System 13.2.12 T/M and Drive
System 13.2.13 Wheels and Tires 13.2.14 General 13.3 Tightening Torque for
Standard Bolts and Nuts 13.4 Periodic Replacement Parts 13.4.2 Location of
Periodic Replacement Parts 13.5 Lubrication Instructions 13.5.1 Lubrication Chart
13.5.2 Fuel and Lubricant Specifications 13.5.3 Adjustment Value and Oil
Quantities 13.6 Special Service Tools 13.6.1 Special Service Tools (Standard
Tools for Both MC and FC LiftTrucks) 13.6.2 Special Service Tools (for FC Lift
Truck Only) 13.6.3 Special Service Tools (for Powershift Transmission)
OPERRATION MANUAL CHAPTER 1 SAFETY RULES AND PRACTICES 1.1
SAFETY SIGNS AND SAFETY MESSAGES 1.2 WARNING SYMBOLS AND
LEVELS 1.3 OPERATOR QUALIFICATIONS 1.4 SAFETY GUARDS 1.5
PERSONAL PROTECTIVE EQUIPMENT FOR OPERATING LIFT TRUCK 1.6
DAILY INSPECTION 1.7 OPERATOR RESPONSIBILITY 1.8 GENERAL 1.9 NO
RIDERS 1.10 TRAVELING 1.11 LOADING 1.12 DOCKBOARDS (BRIDGE
PLATES), TRUCKS AND RAILROAD CARS 1.13 SURFACE AND CAPACITY
1.14 FUEL HANDLING 1.15 INSTALLATION OF ATTACHMENTS 1.16 IN CASE
OF TIP-OVER 1.17 TRANSPORTING LIFT TRUCK 1.17.2 APPROACH ANGLE,
DEPARTURE ANGLE AND GANGWAY 1.17.3 HOISTING (LIFTING) UP THE
TRUCK 1.18 FUNCTION TESTS 1.19 TRACTION BAR 1.20 POSITION OF DATA
AND CAPACITY PLATES AND DECALS 1.21 DATA AND CAPACITY PLATES
AND DECALS 1.21.2 DATA PLATE 1.21.3 IDENTIFICATION NUMBERS 1.21.4
CAUTION DRIVE DECAL (IN CASE OF TIP-OVER DECAL) 1.21.5 WARNING
DRIVE DECAL (TRAINED AND AUTHORIZED) 1.21.6 PINCH POINT DECAL
1.21.7 CAUTION FORK DECAL 1.21.8 MAST WARNING DECAL 1.21.9
CAUTION DRIVE DECAL (OPERATION) 1.21.10 RADIATOR WARNING DECAL
1.21.11 COOLING FAN WARNING DECAL 1.21.12 ADJ LPG WARNING DECAL
1.21.13 LPG LATCH WARNING DECAL 1.21.14 LPG FUEL WARNING DECAL
CHAPTER 2 OPERATING CONTROLS AND FUNCTIONS 2.1 APPLICATIONS
2.2 APPLICATION FOR CAT LIFT TRUCKS 2.3 PROHIBITED APPLICATIONS
FOR CAT LIFT TRUCKS 2.4 MAIN COMPONENTS 2.5 METERS, INDICATORS
AND WARNING LIGHTS 2.5.2 LCD 2.5.3 OPERATION BUTTONS 2.5.4 !
MULTIPURPOSE WARNING LIGHT 2.5.5 MALFUNCTION INDICATOR
LIGHT-ENGINE CHECK WARNING 2.5.6 OIL PRESSURE WARNING LIGHT
2.5.7 CHARGE WARNING LIGHT 2.5.8 PARKING BRAKE WARNING LIGHT
2.5.9 SEAT BELT WARNING LIGHT 2.5.10 METER DISPLAY 2.5.11 WATER
TEMPERATURE GAUGE 2.5.12 FUEL GAUGE 2.5.13 TRANSMISSION
POSITION 2.6 MALFUNCTION AND WARNING INDICATIONS 2.6.2 MAST
INTERLOCK WARNING 2.6.3 LPG LEVEL WARNING/LPG RACK LOCK
WARNING 2.6.4 TORQUE CONVERTER FLUID TEMP WARNING 2.6.5
RADIATOR LEVEL WARNING 2.6.6 AIR CLEANER WARNING 2.6.7 SERVICE
REMINDER DISPLAY 2.6.8 DISPLAYS WHEN MALFUNCTION OCCURS 2.7
DRIVER RECOGNITION MODE 2.8 LPG REMAINING TIME MANAGEMENT 2.9
SWITCHES 2.9.2 HORN BUTTON 2.9.3 REAR RIGHT GRIP WITH HORN
BUTTON 2.9.4 IGNITION SWITCH 2.9.5 LIGHTING AND TURN SIGNAL
SWITCHES 2.9.6 MAXIMUM SPEED CHANGE SWITCH (OPTION) 2.9.7
THROTTLE SENSITIVITY ADJUST SWITCH (OPTION) 2.9.8 BACK-UP
OPERATION LIGHT SWITCH (OPTION) 2.10 OPERATING CONTROLS 2.10.2
SELECTOR LEVER 2.10.3 PARKING BRAKE LEVER 2.10.4 INCHING BRAKE
PEDAL 2.10.5 BRAKE PEDAL 2.10.6 ACCELERATOR PEDAL 2.10.7
CARGO-HANDLING CONTROL LEVERS 2.10.8 ANSI/ITSDF STANDARDS FOR
LIFT TRUCK CLAMP ATTACHMENTS 2.10.9 STEERING CHARACTERISTICS
CHAPTER 3 OPERATING THE LIFT TRUCK 3.1 OPERATION 3.2 INSPECTION
BEFORE OPERATING 3.3 LIFT TRUCK OPERATING PRECAUTIONS 3.4
PRECAUTIONS FOR COLD AND HOT WEATHER 3.5 OPERATIONAL
PROCEDURES 3.6 LPG LIFT TRUCK STARTING 3.7 PROCEDURE FOR JUMP
STARTING EFI ENGINES 3.8 AUTOMATIC TRANSMISSION 3.9 LOADING 3.10
TRANSPORTING LOADS 3.11 UNLOADING 3.12 CLIMBING 3.13 STOPPING
CAT Forklift GP40 Service, Operation & Maintenance Manual

AND PARKING THE LIFT TRUCK 3.14 FORKS 3.15 SEAT ADJUSTMENT 3.15.1
SUSPENSION SEAT OPERATOR'S WEIGHT ADJUSTMENT 3.15.2 FORWARD
AND BACKWARD CONTROL LEVER 3.15.3 BACKREST INCLINATION
ADJUSTMENT 3.15.4 LUMBAR ADJUSTMENT 3.15.5 SWIVEL SEAT 3.16 SEAT
BELT 3.17 TOP PANEL 3.18 TILT STEERING WHEEL 3.19 SERVICE RELEASE
LATCH 3.20 RADIATOR COVER 3.21 REARVIEW MIRROR (OPTION) 3.22 LPG
CYLINDER (TANK) HOLDER CHAPTER 4 GENERAL CARE AND
MAINTENANCE 4.1 WET CELL BATTERY CARE AND MAINTENANCE 4.2
BATTERY SPECIFIC GRAVITY 4.3 DAILY INSPECTION 4.4 OPERATOR'S
DAILY CHECKLIST (SAMPLE) 4.5 MAINTENANCE AND INSPECTION 4.5.1
ENGINE OIL LEVEL 4.5.2 REFILLING ENGINE OIL 4.5.3 ENGINE COOLANT
LEVEL 4.5.4 REFILLING ENGINE COOLANT 4.5.5 COOLING SYSTEM
BLEEDING INSTRUCTIONS 4.5.6 BRAKE FLUID LEVEL 4.5.7 REFILLING
BRAKE FLUID 4.5.8 AUTOMATIC TRANSMISSION FLUID LEVEL 4.5.9
REFILLING AUTOMATIC TRANSMISSION FLUID 4.5.10 HYDRAULIC OIL
LEVEL 4.5.11 REFILLING HYDRAULIC OIL 4.5.12 STEERING WHEEL PLAY
4.5.13 WHEEL AND TIRE 4.5.14 TIRE REPLACEMENT 4.5.15 CHECKING MAST
4.5.16 CHECKING LIFT CHAIN 4.5.17 FORK INSPECTION 4.5.18 FORK REPAIR
4.5.19 CHECKING HORN 4.5.20 CHECKING LIGHTS 4.5.21 CHECKING
CARGO-HANDLING CONTROL LEVER(S) 4.5.22 CHECKING BRAKE PEDAL
4.5.23 PEDAL FREE PLAY 4.5.24 CHECKING PARKING BRAKE LEVER 4.5.25
CHECKING TOP PANEL LOCK 4.5.26 FUSES 4.5.27 CHECKING AIR CLEANER
4.5.28 CHECKING FAN BELT 4.5.29 DRAINING OF TAR FROM THE
VAPORIZER 4.5.30 PRECAUTIONS FOR USING LPG 4.5.31 RECOMMENDED
LPG FUEL TYPE 4.5.32 CYLINDER (TANK) SIZE 4.5.33 LPG CYLINDER (TANK)
REPLACEMENT 4.5.34 REFILLING LPG CYLINDERS (TANKS) 4.5.35
PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE 4.5.36 PERIODIC
MAINTENANCE AND LUBRICATION SCHEDULE FOR EMISSION CONTROL
SYSTEM 4.5.37 LUBRICATION CHART 4.5.38 RECOMMENDED LUBRICANTS
4.5.39 RECOMMENDED SAE VISCOSITY CHART 4.5.40 PUTTING LIFT TRUCK
IN STORAGE 4.6 SIDE SHIFT 4.6.1 OVERVIEW OF SIDE SHIFT 4.6.2 MAIN
TERMS USED IN THIS SECTION 4.6.3 SAFETY RULES AND PRACTICES 4.6.4
SIDE SHIFT CONTROL LEVER OPERATION 4.6.5 SIDE SHIFT OPERATION
4.6.6 DAILY CHECKS AND SIMPLE MAINTENANCE CHAPTER 5
SPECIFICATIONS 5.1 MODEL IDENTIFICATION 5.1.1 MODEL VARIATION
(LONG MODEL CODE) BREAKDOWN 5.2 MAIN TRUCK 5.2.1 MAIN TRUCK -
2C7000 AND 2C8000/2C8000-SWB 5.3 MAST 5.3.1 2C7000 AND
2C8000/2C8000-SWB 5.4 FUEL AND OIL CAPACITY 5.5 ENGINE 5.6 ENGINE
OIL CAPACITY 5.7 NOISE LEVEL
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The $2 mutuels paid: Exterminator, straight $61.20, place $23.10, show $12.40; Escoba, place $4.90,
show $4.60; Viva America, show $13.20.
Start good. Won handily; place driving. Winner, ch g, 3, by McGee—Fair Empress. Trainer H. McDaniel.
 FORTY-FIFTH DERBY 1919
A record Derby in more ways than one was this year’s Louisville’s big racing attraction. Never was there
such a crowd, the dimensions of which reminded me of Epsom and of Flemington. A vast surging mass
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of one and the failure of others. A record Derby also because of the fact that two horses in the same
ownership finished first and second, and also for the first time in its history the spoils fell to a
sportsman who hails from the land of “God save the king and heaven bless the maple leaf forever.”
Fortunately the morning’s promise of still more rain was not fulfilled, nary an umbrella did I see raised
during the course of the afternoon. Many there were who availed themselves of the privilege of
watching the race from the infield, though the grandstand was not filled to that overflowing that has
marked the decision of former Derbies. This was true because of the fact that the whole grandstand
was reserved, an extra charge being demanded for admission. Surely this is a mistake, ugh! What next?
What would have happened it is hard to say had Jupiter Pluvious again gone to work. The going itself
was more than fair. The Churchill Downs course never becomes holdings as does Lexington; proof of
this is the winner’s more than good time, made when competing for the Derby.
Now then for the Derby. The gelding Be Frank is first on view, presenting a well trained appearance.
Vindex, though out on the course for a warming up canter, did not pass the stands. His manners are
even yet not by any means perfect, whinnying and nickering when returning to the paddock, a
magnificent specimen of a thorough bred, perhaps a trifle long of back, carrying abundant condition,
too, but in every way a gentleman to look at. Along came the Canadian pair Billy and Barton, by odds
the best ordered horses in the race, Kelly especially looked fit to run for the proverbial king’s ransom,
his whippet like contour convincing evidence that Trainer Bedwell has lost nothing of his skill, and
Barton, too, though built on somewhat more generous lines, had the look of one trained to the minute.
Indeed, it is comforting to know that there are yet to be found those who can prepare a horse for a ten
furlongs race. Eternal and Sailor also are shown, the favorite more bulky than ever, Sailor put up on
more rangy lines. Little Regalo was the last to come out, evidently on the best of terms with herself,
evincing an interest in the spectators and playing with her pony companion on her return. St. Bernard,
Frogtown and Under Fire I did not see, the paddock was altogether impossible. The absolutely fit
condition of the Ross pair was the subject of much favorable comment, the magnificence of Vindex, the
lack of scope of Eternal, the well being of Regalo, all of us had something to say, but there goes the
bugle. Starter Dade did not keep us waiting long, and from the outset the Ross chestnut, Sir Barton,
was at the head of affairs, followed, as they pass the stand, by Eternal, Vindex and Billy Kelly. On they
sweep round the upper turn, Barton galloping easily in front of Eternal, Billy Kelly third, just in front of
Vindex, then came St. Bernard and Sennings Park, well clear of the rest. Only one-half mile has been
run when Vindex rapidly compounds and quickly falls to the rear. On spins the chestnut well in advance
of Eternal and Kelly; won’t he ever come back? Oh no, as long as weight and condition serve, both of
which are in his favor. Eternal momentarily makes a stab at the three-eighths, but is done, absolutely
done thereafter. Billy Kelly now looms up, and as they straighten for home makes his gallant effort, but
it is of no avail, even to the application of the rawhide he is unable to respond, and Sir Barton sails
home an easy winner after making every yard of the pace. Under Fire comes out of the ruck at the end
to take third place, the son of Swynford again shows lack of pace in the early running, but came along
stoutly at the finish, the rest scattering. Yes, scattering; there was no rattling horse against horse at any
part of the race. It was thus Sir Barton broke his maiden, assisted of course in this by his pull in weight
and also by his superior racing condition. Billy Kelly’s condition, too, saved him the place, and this is a
feat which Trainer Bedwell is deserving of all praise and of which he may well be proud. Under Fire’s
gameness and race horse qualities enabled him to obtain third place, and some day, later along, he is
certain to develop into a cup horse of the best sort, sound, long winded and hardy as they come.
Regalo disappointed me. Fillies, however, are ever uncertain in this spring season. The form displayed
by Vindex was altogether too bad to be true. Maybe he has his peculiarities as had his grandsire St.
Maclou. Eternal did not have the appearance of a thoroughly trained horse. Maybe he was more fit than
was thought and does not fancy a distance. As for the rest, they simply are not of Derby calibre. The
time, 2:09⅗, was remarkably good, everything, track and atmospheric conditions, considered and goes
a long way to show that the Kentucky Derby this year, at all events, was a true run, honest race.
“EXILE.”

SUMMARY

May 10, 1919. Track heavy. $20,000 added. Value to Winner $20,825, second $2,500, third, $1,000,
fourth $275. Time—24⅕, 48⅖, 1.14, 1.41⅘, 2.09⅘.

Sir Barton, 112½, J. Loftus 1

Billy Kelly, 119, E. Sande 2
Under Fire, 122, M. Garner 3

Vulcanite, 110, C. Howard; Sennings Park, 122, H. Lunsford; Be Frank, 119, J. Butwell; Sailor, 119, J.
McIntyre; St. Bernard, 119, E. Pool; Regalo, 117, F. Murphy; Eternal, 122, A. Schuttinger; Frogtown,
119, J. Morys; Vindex, 122, W. Knapp.
Winner Chestnut Colt, by Star Shoot—Lady Sterling. Owned by J. K. L. Ross. Trained by H. G. Bedwell.
 FORTY-SIXTH DERBY 1920
A droning buzz as if from 45,000 human bees, a sudden silence as felt before a storm, and then an
outburst of sound over topped in volume by the rebel yell let out by Uncle Billy Garth, of Virginia,
thousands of fluttering spasms of dying thrills, and then the finish of the forty-sixth Kentucky Derby
passed into history.
Running a great and game race, that did credit to his illustrious namesake, Paul Jones, a son of Sea
King and May Florence, led from start to finish of the mile and a quarter, and won under a drive by a
good neck. Fighting it out to the last ounce of endeavor, Harry Payne Whitney’s Upset, that owner’s
home bred son of Whisk Broom II. and Pankhurst, finished in second place, with four lengths to spare
over George W. Loft’s On Watch, who was early favorite in the winter books for this big event.
On Watch was four lengths in front of Damask another of the Whitney entry, while Donnacona, the
other of the Loft pair to start, was fifth, with Blazes, stable mate of Paul Jones, sixth. The race was
worth $30,375 to the winner, and there was $4,000 for Upset, who ran second, and $2,000 for On
Watch, as the short end of the rich purse, while Damask saved his entry fee when he finished in fourth
place, $275.
For once, the monster throng, many of whom had witnessed many other Derbies, awakened to a
perfect day, just as perfect as a day in June, but the track was slow, as was evidenced by the time of
2:09. The record for this race was made by Old Rosebud, who did the distance in 2:03⅖.
The start of the race could not have been better, the seventeen thoroughbreds getting away in almost
perfect alignment, after having been at the post less than four minutes.
Paul Jones was the first to show in front, following the rise of the barrier, but pounding along at his
throat-latch was Prince Pal, with the others following closely. By the time the leader had reached a point
opposite the padlock gate, a few hundred yards from the starting line, the others had begun to string
out.
On they came with Paul Jones showing the way. As the field passed the grandstand, the first time,
Jockey Ted Rice nestled low in the saddle. He was rating his mount nicely and the son of Sea King was
eager to run. On they sped around the first turn and into the back stretch. Here By Golly made his
move for the honor and glory that goes to the winner of the Derby. He hung close to the heels of Paul
Jones as they swung into the straight-away, and then fell back beaten.
Wildair took up the chase. He closed to the saddle girth of the Parr winner and they swept along at a
tearing pace. One or the other must falter, the crowd knew, but Paul Jones proved his mettle. Wildair
dropped back.
On Watch then drew the gaze of the spectators. As the field passed the half-mile post he shot forward
and sped past his tiring opposition. On he continued as they rounded the last turn, and an old
horseman shouted.
“On Watch wins.”
But On Watch had spent himself and all the courage and stamina at his command could not overhaul
the driving duo out front. At the furlong pole Paul Jones met his sternest test. He seemed to be
weakening from the long, hard struggle. Upset appeared to be the stronger. But Jockey Rice again
called on his game little mount and Paul Jones did as Hanover or Hindoo would have done. He would
not be denied.
Paul Jones met challenge with challenge and at the close displayed a heart of iron as he drove madly
under the wire with Upset at his throat-latch.
Throughout the stretch the twain waged a heartrending duel. As they took the final turn Upset made his
bid. Inch by inch he forged past rump and flank and withers. He stretched fiery nostrils alongside the
gelding’s throat. Only the blazed face remained between him and victory. On they came past the furlong
pole, and still the blazed face would not be dislodged. It remained there to the end.
This triumph of the East was more than a victory for Kentucky. The ugly little brown boasts blood that
long has been the pride of the Blue Grass. His dam is by Hamburg, which got Jersey Lightning, the dam
of Regret, and Hamburg’s sire was the immortal Hanover, by Hindoo, winner of the Kentucky Derby of
1881. Hindoo was from the loins of Virgil out of Florence, by Lexington, and he by Boston, the great
Boston.

SUMMARY

May 8, 1920. Track slow. $30,000 added. Value to winner $30,375, second, $4,000, third $2,000, fourth
$275. Time—23⅘, 48⅕, 1.14⅘, 1.42, 2.09.

Paul Jones, 126, T. Rice 1

Upset, 126, J. Rodriguez 2
On Watch, 126, N. Barrett 3

Damask, 126, E. Ambrose; Donnacona, 126, W. J. O’Brien; Blazes, 126, C. Kummer; By Golly, 126, L.
Lyke; Wildair, 126, L. Fator; Bersagliere, 126, T. Murray; Patches, 126, J. Hanover; Herron, 126, J.
Butwell; Sandy Beal, 126, I. Williams; Prince Pal, 126, A. Schuttinger; David Harum, 126, C. Fairbrother;
Cleopatra, 121, L. McAtee; Peace Pennant, 126, M. Garner; Sterling, 126, J. Callahan.
Winner, Brown Gelding, by Sea King-May Florence, by Hamburg. Owned by R. Parr. Trained by Wm.
Garth.

I love the Hoss from Hoof to Head,

From Head to Hoof and Tail to Mane.
I love the Hoss, as I have said
From Head to Hoof and back again.
I love my God the first of all,
Then Him that perished on the Cross
And next my Wife and then I fall
Down on my knees and Love the Hoss.

James Whitcomb Riley.

Transcriber’s Note:
The original text does not contain a Table of Contents. The Table of Contents included near the
beginnning of this file was created by the transcriber as an aid for the reader.
The mismatched parenthesis on page 10 is presented as in the original. Otherwise, punctuation errors
have been corrected without note.
Other than the corrections noted by hover information, inconsistencies in spelling and hyphenation have
been retained.
 *** END OF THE PROJECT GUTENBERG EBOOK HISTORY OF THE
KENTUCKY DERBY, 1875-1921 ***

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