PDF Service and Maintenance Manual Caterpillar DP25N Lift Truck - 9 MB
This comprehensive manual provides all the necessary information for the Caterpillar DP25N Lift Truck.
It covers service procedures, daily operating instructions, and scheduled maintenance tasks.
With this guide, technicians can perform everything from minor adjustments to major overhauls.
Keep your Cat lift truck in optimal working condition for maximum productivity and safety.
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--- Page 1 ---
SAFETY RULES FOR LIFT TRUCK OPERATORS
SAFETY RULES FOR LIFT TRUCK OPERATORS
General
The safety rules and regulations in this section are Continuing improvement and advancement of product
representative of some, but not all rules and regulations design may have caused changes to your lift truck, which
that apply to lift trucks. Rules are paraphrased without are not included in this publication. Whenever a question
representation that they have been reproduced verbatim. arises regarding your lift truck, or this publication, please
contact your authorized Cat lift truck dealer for the latest
All lift truck users should be familiar with their Local,
available information.
Regional, and National regulations. Operate this lift truck in
accordance with local regulations. All lift truck users should be familiar with their Local,
Regional, and National regulations.
The most effective way of reducing the risk of serious
injuries, or even death, to you and others, is for you to know
how to operate the lift truck properly. Drive alertly and
avoid maneuvers or conditions that could cause accidents.
Be professional.
Do not operate your lift truck if it is in need of maintenance,
repair or appears to be unsafe in any way. Report all unsafe
conditions immediately to your supervisor, then contact
your authorized Cat lift truck dealer.
Do not attempt any adjustments or repairs unless you are
trained and authorized to do so.
1-1
--- Page 3 ---
KNOW YOUR LIFT TRUCK
Mast Vertical Switch (Optional)
When the mast is placed at a tilt-back position without load,
push the tilt lever forward while pressing the switch. The
mast stops at a vertical position.
E00105
Attachment Lever (Optional)
The mast interlock will not work for the attachment levers. 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.
2-34
--- Page 4 ---
TROUBLESHOOTING
To Remove Wheel
(1) Loosen the wheel nuts about two rotations.
Note: Only loosen the wheel nuts. Do not remove them.
(2) Position the jack under the lift truck at the specified
1
jacking point.
Note: For jacking point, see 10-4 "To Raise Front Wheel" and
10-5 "To Raise Rear Wheel".
(3) Raise the lift truck by operating the jack until the tire
just clears the ground.
P00070
1. Wheel nut
(4) Remove the wheel nuts (loosened in Step 1).
(5) Firmly hold the wheel with both hands and remove it 1
from the lift truck.
1)
P00109
1. Wheel nut 1) Countersink
R WARNING
DO NOT loosen rim bolts.
R CAUTION
Be careful NOT to strip the bolt threads when removing the
wheel.
P00074
10-3
--- Page 5 ---
MAINTENANCE
(1) Remove the filler cap.
Q00084
(2) Remove the hydraulic tank drain plug. Allow the oil to
drain. Clean and install the drain plug.
(3) Fill the hydraulic tank. See 12-11 "Refill Capacities". Put
the filler cap back on.
(4) Start the engine and operate the hydraulic controls and
the steering system through a few cycles to fill the
filters and lines.
(5) Retract all hydraulic cylinders and stop the engine.
Q00085
(6) Remove the filler cap and the dip stick. Keep the oil
level at the HIGH mark on the dip stick.
E00078
(7) Put the drain plug back in place.
1)
Q00035
1) Correct level range
11-54
--- Page 6 ---
SAFETY RULES FOR LIFT TRUCK OPERATORS
R WARNING
Travel safely on grades with a loaded lift truck!
When ascending or descending grades loaded lift trucks
must be driven with the load upgrade.
D00321
R WARNING
Travel safely on grades with an empty lift truck!
Unloaded lift trucks must be operated on all grades with the
forks downgrade.
When descending grades, use service brake and engine
brake.
D00319
R WARNING
Be particularly careful when driving up or down a
steep slope!
Use extreme care to reduce the risk of fork tips or the
bottom of the pallet from touching the ground.
D00317
R WARNING
Starting the lift truck on an upgrade carefully!
When starting the lift truck on an upgrade, BE SURE to use
the parking brake.
D00320
1-24
--- Page 7 ---
REFUELING
For Standard LPG Tank
(1) Park the lift truck on level ground.
(2) Lower the forks until the fork tips touch the ground.
(3) Apply the parking brake.
(4) Place the direction lever in the NEUTRAL position.
(5) Run the engine at low idle.
(6) Discharge the static electricity.
(7) Close the fuel valve on the LPG tank. Run the engine
until it stops, then turn the key switch to the OFF
position.
(8) Disconnect the fuel supply line.
(9) Loosen the retaining clamps, and remove the tank. D00388
(10) Make sure the replacement tank is the correct type.
(11) Inspect the replacement tank for damage such as dents, scrapes, or gouges and for leakage at valves or threaded
connections.
(12) Check for debris in the relief valve and for damage to various valves and the liquid level gauge.
(13) Inspect the couplings for deterioration, damage, or missing flexible seals.
(14) When lifting the tank for mounting, hold with both hands to prevent injury, and check the tank clamp lock.
(15) Clamp the tank securely.
(16) Connect the fuel supply line.
(17) Open the fuel valve by turning it slowly counterclockwise. If the fuel valve is opened too quickly, a back pressure check
valve will shut off the fuel supply. If this happens, close the fuel valve completely, wait five seconds, and then open the fuel
valve very slowly.
(18) Check the LPG fuel lines and fittings with a soap solution after filling the tank or when looking for leaks.
4-3
--- Page 8 ---
MAINTENANCE
Tires and Rims
Check
R WARNING
- Make sure the replacement tire is of the same size, type, and load range. See manufacturer name plate located on the front
of the lift truck for correct tire size.
- When replacing tires, replace them in sets, even if only one of the tires is damaged. If new and used tires are used on the
same axle, tilting of the mast and rapid tire wear will result.
- Use only tires recommended by the manufacturer.
R CAUTION
The lift truck tires are highly inflated. Even slight damage to the tire or rim may cause a blowout of the tire.
How to check
- Are all the tires free of cuts, gouges, or foreign objects?
- Are all the rims free of distortion or cracks? 1)
- Is the tread groove depth more than 5 mm (0.2 in.)
when checked with a tire depth gauge?
If not, replace the tire.
Q00447
1) Limit: 5 mm (0.2 in.)
Note:
- For replacing tires, see 10-1 "Replacing Tires".
- Contact your authorized Cat lift truck dealer when requesting to replace tires.
11-10
--- Page 9 ---
Operation & Maintenance Manual
MC/FC
GP15N CT34A-02001-up DP15N CT16E-01001-up
GP18N CT34A-41001-up DP18N CT16E-41001-up
GP20CN CT34A-61001-up DP20CN CT16E-61001-up
GP20N CT17E-01001-up DP20N CT18D-01001-up
GP25N CT17E-53001-up DP25N CT18D-55001-up
GP30N CT13G-02001-up DP30N CT14F-04001-up
GP35N CT13G-51001-up DP35N CT14F-53001-up
Original Instructions
Keep this manual in your lift truck as a ready reference 99710-6E120
--- Page 10 ---
KNOW YOUR LIFT TRUCK
When a serious warning of the lift truck and an
engine moderate warning occur simultaneously
1
On main display, the diagnostic code 1) will glow. Also, all of 2
the five warning icons 1 shown in the illustration on the
right will blink and the engine check indicator icon 2 will
glow. When recovered from the serious warning of the lift
truck, the diagnostic code 2) will glow.
Also, the engine check indicator icon 2 and multi-purpose
warning icon 3 stay ON.
1)
2
2) E01141
1. All warning icons blink 1) The diagnostic code with white
2. Engine check indicator icon characters on a black
glows background glows
2) The diagnostic code with black
characters on a white
background glows
2-26
--- Page 11 ---
OPERATING TECHNIQUES
R WARNING
Be careful not to drag the forks.
K00140
R WARNING
- DO NOT travel with the mast tilted FORWARD or with
the load in the elevated position. This will increase the
possibility of the lift truck tipping over.
- DO NOT tilt the mast with the load in the elevated
position.
- DO NOT leave the lift truck with the load in the elevated
position.
K00162
Working on Grades
Normal Travel position
- Keep the forks or the load at a safe travel height, which
is 15 to 20 cm (6 to 8 in.) from the ground.
2
- Tilt the mast back more than 6° when the lift truck is
empty. Tilt the mast fully BACKWARD when the lift truck
is loaded.
1
K00163
1. 15 to 20 cm (6 to 8 in.) 2. 6° Tilt back
Traveling on a Grade
R WARNING
- DO NOT continuously use the brake pedal alone. This
could result in brake failure and an accident.
- DO NOT use the inching pedal when traveling down a
grade. This prevents the engine from acting as a brake.
- DO NOT place the direction lever in the NEUTRAL
position when traveling down a grade.
Travel up a grade in the FORWARD direction and down a
grade in the REVERSE direction when the lift truck is loaded.
When travelling down a long grade, switch the speed
selector switch to 1 speed, and use engine brake and service
brake. K00146
6-13
--- Page 12 ---
SERVICE DATA
SERVICE DATA
Fuel Information
Use only fuel recommended in this section.
Diesel Fuel Specifications
- Types of Fuel
The recommended fuels provide maximum engine service life and performance. They are distillate fuels. They are
commonly called diesel fuel, furnace oil, gas oil or kerosene (for cold weather operation). Mitsubishi Caterpillar Forklift Inc.
strongly recommends the use of fuels that meet the recommended fuels specification.
- Fuel Sulfur Content
The percentage of sulfur in the fuel will affect the engine oil recommendations. Fuel sulfur is chemically changed during
combustion to form both sulfurous and sulfuric acid. These chemically attack metal surfaces and cause corrosive wear.
- Any API classification performance of oil should have sufficient TBN for fuels with less than 0.5% sulfur. For fuels with 0.5%
to 1. 5% sulfur by weight, engine oil must have a TBN of 20 times the percentage of fuel sulfur as measured by the ASTM
(American Society of Testing Materials) D-2896 method. (ASTM D-2896 can normally be found at your local technological
society, library or college. )
Liquefied Petroleum (LPG)
Specifications
Use grade HD5 LPB. LP-Gas is a highly volatile fuel with an octane rating of 100 to 140. Follow local ordinances regarding
storage and/or filling of LP-Gas tanks.
12-1
--- Page 13 ---
SAFETY RULES FOR LIFT TRUCK OPERATORS
R WARNING
Inspect a trailer before entering!
- The brakes on the highway trucks or trailers must be
applied, and wheel chocks or other positive mechanical
means must be used to prevent unintentional
movement of highway trucks and trailers.
- DO NOT travel along the edge of the dock. The lift truck
may fall off the dock.
- Before starting work, check the allowable load of dock
plate, and if it does not have enough strength to
withstand the weight of the lift truck carrying a load, do
D00343
not use it.
- When entering a trailer, use outriggers so that trailer
will not sink.
- Travel slowly on dock plate when getting in or out of
trailers or railroad.
- Ask the driver of the trailer not to move the trailer until
the work is completed.
- Use any anchoring equipment available in the dock to
secure the trailer or railroad, and also secure the dock
plate to prevent it from falling off.
- Obey the instructions of the supervisor when working
as a team.
R WARNING
Fork positioner operation!
- DO NOT operate the fork positioner while carrying loads.
- DO NOT handle off-center loads.
R WARNING
Side shifter operation!
When sideshifting to pick up loads, BE SURE that forks are
centered under the load. DO NOT side shift while traveling
with loads.
D00402
R WARNING
DO NOT raise or lower a load while side shifted, as it is
dangerous.
DO NOT side shift the forks with the load raised higher than
150 cm (59 in.) unless safety is assured by the load stack or
carrier deck just below the forks.
D00403
1-29
--- Page 14 ---
HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE
R WARNING
DO NOT turn sharply, even with an empty raised
mast, to avoid a tipover!
A lift truck with a raised mast will tipover more easily than a
lift truck with a lowered mast because the stability of the lift
truck worsens.
F00072A
R WARNING
Wear a hard hat if recommended or required by your
employer or applicable regulations.
F00074
R WARNING
Be aware of the stability of an empty lift truck!
An empty lift truck will tipover more easily than a loaded
one in a lowered position.
D00313
How to Survive in a Tipover
R DANGER
DO FASTEN YOUR SEAT BELT!
Remember, your chances for survival with the seat belt
fastened in a tipover are better if you stay in the lift truck.
F00087A
3-8
--- Page 15 ---
MAINTENANCE
Item Service Page
Mast Support Lubricate 11-37
King Pins Lubricate 11-38
Universal Joint Lubricate 11-38
Every 200 Service Hours or Monthly, Whichever Comes First
Item Service Page
Mast Strip Sliding Surfaces Lubricate -
Lift Chains Lubricate -
Every 500 Service Hours or 3 Months, Whichever Comes First
Item Service Page
Bolts and Nuts (Frame & Chassis) Check -
Differential Oil Check oil level -
Tilt Socket Pins Lubricate -
Tie Rod Pins Lubricate -
Mast Support Lubricate -
King Pins Lubricate -
Mounting Bush of Rear Axle Lubricate -
Fuel Filter (LPG Models) Clean -
Battery Check specific gravity of electrolyte -
Engine Oil/Oil Filter Replace -
Brake Drum Nuts & Bolts Check -
Brake Drum & Shoes Check -
Radiator Fin Check / Clean -
Electrical Wires Check -
Engine Idle Speed Check -
Intake & Exhaust Valve Check Clearance -
Positive Crankcase Ventilation Valves & Hoses Check clearance -
Tar in Vaporizer Check / Drain -
Injection Nozzle (LPG Models) Check -
Spark Plug Check gap -
Universal Joint Lubricate -
Every 1000 Service Hours or 6 Months, Whichever Comes First
Item Service Page
Transmission Oil / Wash Strainer Replace / Clean -
Hydraulic Tank Return Oil Filter / Wash Strainer Replace / Clean -
11-5
--- Page 16 ---
SAFETY RULES FOR LIFT TRUCK OPERATORS 13
D00019 D00021 D00027
No smoking while refueling! Unauthorized addition or modification is Avoid being splashed by scalding hot cool-
DO NOT fill the fuel tank while the engine is prohibited! ant!
running or the operator is on the lift truck. Keep DO NOT add to or modify the lift truck unless Wait until the engine cools before opening or
away from flames or spark sources. Turn off all authorized in writing by the manufacturer to do loosening the radiator cap. If you cannot wait,
electrical switches on the lift truck. Pump fuel in so. Any changes approved by the manufacturer use a heavy cloth and gloves to protect yourself.
a well-ventilated area. require a new capacity plate and decals after Stand to the side, protect your face, and slowly
modification. loosen cap.
D00023 D00025 D00029
Know all signals and traffic rules! Know the lift truck and attachments! Turn OFF the key switch before servicing!
Know who is responsible for signaling. Learn to Read and understand the operating, inspection DO NOT service this lift truck while engine is
tell at a glance what the signal means, and what and maintenance instructions in the OPERA- running unless absolutely necessary.
action you should take. TION & MAINTENANCE MANUAL and the
decal on the lift truck.
13 13
--- Page 17 ---
HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 80
◆ How to Survive in a Tipover
Remember, your chances for survival with the
seat belt fastened in a tipover are better if you
stay in the lift truck. If the lift truck starts to tip
over:
– DO NOT jump off!
– Firmly hold on to the steering wheel.
– Brace your feet.
– Lean away from impact.
– Lean forward. D00073
Be aware of the stability of an empty lift
truck!
An empty lift truck will tip over more easily than
a loaded one in a lowered position.
F00031
80 80
--- Page 18 ---
MAINTENANCE 144
• Engine Coolant
.Check Coolant Level Adding Coolant
Park the lift truck on level ground with forks
CAUTION
lowered until fork tips touch the floor, parking
brake applied, direction lever in neutral position Keep fire away from undiluted antifreeze as – Recommended concentration range of ASC
and engine stopped. Block the wheels securely. it is FLAMMABLE. is 30% to 60% by volume.
– ASC of less than 30% concentration does
not provide sufficient corrosion protection.
CAUTION – Concentrations over 60% adversely affect
freeze protection and heat transfer rates.
DO NOT add water only. This dilutes the anti- – Avoid mixing different brands of coolant.
freeze/summer coolant protection and – Select an ASC suitable for use in engines
adversely affects the engine. BE SURE to using aluminum alloy parts.
FULL F
premix antifreeze/summer coolant (ASC) with – Select an ASC which contains silicate of less
LOW L
tap water (soft water). than 0.2% by weight.
If coolant has to be added frequently, have
Q00030 your authorized Cat lift truck dealer check the
1. Raise the engine hood. cooling system.
2. Maintain the coolant level between the FULL
and LOW marks on the reserve tank.
3. Close and secure the hood.
144 144
--- Page 19 ---
SAFETY RULES FOR LIFT TRUCK OPERATORS
Decals for Dual Fuel Only
1
D00706
1. Dual Fuel Inst. decal
1-4
--- Page 20 ---
KNOW YOUR LIFT TRUCK
Operator Seat
Seat Adjustment
R WARNING
Adjust the operator seat slide forward and back position
before starting the engine. After adjusting, check the 1) 2
operator seat to make sure it is properly locked. DO NOT
adjust the operator seat while the lift truck is in motion.
3 1
4
E00119
1) MC model 3. Adjusting knob
1. Reclining lever 4. Side lever
2. Seat belt
1)
2
1
3 E00125
1) FC model 2. Adjusting knob
1. Seat belt 3. Side lever
Forward and Back Adjustment
Move the lever, slide the seat to one of the eleven positions,
and release the lever.
E00120
R WARNING
Your lift truck comes equipped with a genuine Cat Lift Truck operator restraint system and an operator presence switch. Should
it become necessary to replace the seat for any reason, it must only be replaced with a genuine Cat Lift Truck operator restraint
system equipped with an operator presence switch.
2-37
--- Page 21 ---
TROUBLESHOOTING
Stalled Engine
If the engine stalls, hydraulic pressure is lost in the power
steering. This increases your steering effort.
In this case, stop your Lift truck in a safe area and restart the
engine.
P00116
Before Starting the Engine Again
Check the following items, and remove the cause of the stall.
- Lack of fuel
- Engine overloading
10-7
--- Page 22 ---
MAINTENANCE
(23) Put the reserve tank filler cap back on.
1)
2)
Q00097
1) FULL 2) LOW
Fuel Filter (LP-Gas Engine)
Change
Note: Park the lift truck in an authorized refueling area with the forks lowered until the fork tips touch the floor or ground,
parking brake applied, direction lever in the neutral position, engine stopped and the wheels blocked.
The engine must be cooled down.
(1) Close the fuel valve on the LP-Gas tank. The fuel shutoff
valve turns clockwise to close. Run the engine until fuel
in the fuel line runs out and the engine stops. Turn the
key switch to OFF.
(2) Raise the engine hood.
1)
Q00069
1) Close
(3) Disconnect the fuel line.
(4) Remove the fuel lock filter.
1
Q00070
1. Fuel lock filter
11-57
--- Page 23 ---
KNOW YOUR LIFT TRUCK
Direction Lever (Powershift Model)
This lift truck is equipped with a neutral switch. Be sure to
put the direction lever in NEUTRAL position before starting
the engine.
1
2
3
E00436
1. Forward (F) 3. Reverse (R)
2. Neutral (N)
Turn Signal / Light Switch