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Caterpillar Cat DP20 HS Lift Trucks Service Manual – Complete Set – PDF DOWNLOAD
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Caterpillar Cat DP20 HS Lift Trucks Service Manual – Complete Set – PDF DOWNLOAD
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Description
Caterpillar Cat DP20 HS Lift Trucks Service Manual – Complete Set – PDF DOWNLOAD
DESCRIPTION:
Caterpillar Cat DP20 HS Lift Trucks Service Manual – Complete Set – PDF DOWNLOAD
FOREWORD :
- This service manual is a guide for servicing Towmotor forklift. The long productive life of your truck(s) depends on regular and proper servicing, servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair, or rebuild job.
- The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing. Towmotor Forklifts reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience the instructions are grouped by systems as an easy reference.
For engine servicing, please refer to the applicable engine service manual.
K25 Gasoline engine
S4S Diesel engine
SAFETY PRECAUTIONS :
- Be sure to read this service manual and understand the contents before proceeding with the work. Improper truck operation is dangerous and could result in injury or death. Be sure to familiarize yourself with the systems and components described herein before proceeding with removal or disassembly work.
- For heavyweight components, BE SURE to check the weight of each component beforehand by referring to this service manual. Also, for safety, use proper lifting equipment for removal/ installation work. Following is a list of basic precautions that should always be observed.
(1) Read and understand all warning plates and decals on the truck before proceeding with operation, lubrication, or repair work.
(2) Always wear safety glasses and protective shoes when working around trucks. Be sure to wear safety glasses to prevent any type of metal from getting into your eyes when using a hammer or sledge. Use welders gloves, hood/goggles, apron, and other protective clothing appropriate to the welding operation. Do not wear loose clothing or accessories that can be caught in moving parts. Do not wear rings when you work.
(3) Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before proceeding with the work.
(4) Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.
(5) Use steps and assist grips (if equipped) when you mount or dismount the truck. Clean the steps, hand rails, and floor of operator seat beforehand. Always face the truck when using steps, ladders, and walkways. If you cannot use the designed access system, use ladders, scaffolds, or work platforms to ensure the safety at the workplace.
(6) To avoid back injury, use a hoist when lifting components which weigh 23 kg (51 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Make sure the load is well balanced prior to lifting. (7) To prevent burns, DO NOT touch hot sections of the truck immediately after stopping the truck.
(8) Remove covers carefully. When removing the last two bolts or nuts, loosen gradually to release spring force or pressure.
(9) Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. Use extreme care immediately after stopping.
(10) Use well maintained tools in a proper way.
TABLE OF CONTENTS:
Caterpillar Cat DP20 HS Lift Trucks Service Manual – Complete Set – PDF DOWNLOAD
99720-91100-01_SAFETY_RULES_FOR_FORKLIFT_TRUCK_OPERATORS................... 1 99720-91100-02_KNOW_YOUR_FORKLIFT_TRUCK.................................... 33 99720-91100-03_HOW_TO_AVOID_A_TIPOVER_HOW_TO_SURVIVE_ONE................... 51 99720-91100-04_REFUELING................................................... 59 99720-91100-05_OPERATION................................................... 63 99720-91100-06_OPERATING_TECHNIQUES........................................ 81 99720-91100-07_STORING_THE_FORKLIFT_TRUCK.................................. 93 99720-91100-08_TRANSPORTATION_HINTS........................................ 95 99720-91100-09_SPECIAL_SITUATIONS.......................................... 97 99720-91100-10_TROUBLESHOOTING.............................................101 99720-91100-12_SERVICE_DATA................................................113 99720-91110_00_FOREWORD....................................................119 99720-91110_11_MAINTENANCE.................................................129 99720-91110_13_TO_THE_TOWMOTOR_FORKLIFT_OWNER..............................185 99720-91110_14_INDEX.......................................................189 99729-90100-00_FOREWORD....................................................193 99729-90100-00_FOREWORD................................................194 99729-90100-01_GENERAL_INFORMATION.........................................210 99729-90100-01_GENERAL INFORMATION.....................................210 99729-90100-02_COOLING_SYSTEM..............................................216 99729-90100-02_COOLING SYSTEM..........................................216 99729-90100-03_ELECTRICAL_SYSTEM...........................................221 99729-90100-03_ELECTRICAL SYSTEM.......................................221 99729-90100-04_POWER_TRAIN.................................................259 99729-90100-04_POWER TRAIN.............................................259 99729-90100-05A_POWERSHIFT_TRANSMISSION....................................269 99729-90100-05B_POWERSHIFT_TRANSMISSION....................................307 99729-90100-06_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL.......................357 99729-90100-06_FRONT AXLE AND REDUCTION DIFFERENTIAL...................357 99729-90100-07_REAR_AXLE...................................................383 99729-90100-07_REAR AXLE...............................................383 99729-90100-08_BRAKE_SYSTEM................................................401 99729-90100-08_BRAKE SYSTEM............................................401 99729-90100-09_STEERING_SYSTEM.............................................422 99729-90100-09_STEERING SYSTEM.........................................422 99729-90100-10_HYDRAULIC_SYSTEM............................................441 99729-90100-10_HYDRAULIC SYSTEM........................................441 99729-90100-11_MAST_AND_FORKS..............................................502 99729-90100-11_MAST AND FORKS..........................................502 99729-90100-12_SERVICE_DATA................................................593 99729-90100-12_SERVICE DATA............................................593 99729-90100-13_HOW_TO_READ_CIRCUIT_DIAGRAMS................................613 99729-90100-13_HOW TO READ CIRCUIT DIAGRAMS............................613 99729-90100-14_CIRCUIT_DIAGRAM_FOR_DUAL_GAS_LPG_ENGINE_MODELS..............626 99729-90100-14_CIRCUIT DIAGRAM FOR DUAL GAS/LPG ENGINE MODELS..........626 99729-90100-15_CIRCUIT_DIAGRAM_FOR_DIESEL_ENGINE_MODELS....................646 99729-90100-15_CIRCUIT DIAGRAM FOR DIESEL ENGINE MODELS................646 DIESEL_ENGINE_99729-91100_00_FOREWORD......................................664 DIESEL_ENGINE_99729-91100_01_GENERAL.......................................672 DIESEL_ENGINE_99729-91100_02_MAINTENANCE_STANDARDS.........................678 DIESEL_ENGINE_99729-91100_03_SPECIAL_TOOLS.................................690 DIESEL_ENGINE_99729-91100_04_GENERAL_INSTRUCTIONS..........................696 DIESEL_ENGINE_99729-91100_05_DISASSEMBLY,_ENGINE_MAIN_PARTS................704 DIESEL_ENGINE_99729-91100_06_INSPECTION_AND_REPAIR,_ENGINE_MAIN_PARTS......722 DIESEL_ENGINE_99729-91100_07_REASSEMBLY,_ENGINE_MAIN_PARTS.................748 DIESEL_ENGINE_99729-91100_08_FUEL_SYSTEM...................................764 DIESEL_ENGINE_99729-91100_09_LUBRICATION_SYSTEM............................772 DIESEL_ENGINE_99729-91100_10_COOLING_SYSTEM................................780 DIESEL_ENGINE_99729-91100_11_INLET_AND_EXHAUST_SYSTEM......................786 DIESEL_ENGINE_99729-91100_12_ELECTRICAL_SYSTEM.............................790 DIESEL_ENGINE_99729-91100_13_ADJUSTMENTS,_BENCH_TEST,_PERFORMANCE_TESTS....812 DIESEL_ENGINE_99729-91100_14_TROUBLESHOOTING...............................822
CATERPILLAR CAT DP20 HS LIFT TRUCKS SERVICE MANUAL – COMPLETE SET – PDF DOWNLOAD:
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