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Caterpillar Cat DP20N Lift Truck Service Manual – Complete Set – PDF DOWNLOAD
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Caterpillar Cat DP20N Lift Truck Service Manual – Complete Set – PDF DOWNLOAD
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Description
Caterpillar Cat DP20N Lift Truck Service Manual – Complete Set – PDF DOWNLOAD
DESCRIPTION:
Caterpillar Cat DP20N Lift Truck Service Manual – Complete Set – PDF DOWNLOAD
FOREWORD:
This service manual is a guide for servicing Cat® Lift Trucks. 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.
- Cat® Lift Trucks 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.
K15, K21, or K25 Gasoline engine
S4Q2 or S4S Diesel engine
1. 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 DP20N Lift Truck Service Manual – Complete Set – PDF DOWNLOAD
99719-3F110-00_FOREWORD..................................... 1 99719-3F110-00_FOREWORD................................. 5 99719-3F110-01_GENERAL_INFORMATION.......................... 25 99719-3F110-01_GENERAL INFORMATION...................... 25 99719-3F110-02_COOLING_SYSTEM............................... 33 99719-3F110-02_COOLING SYSTEM........................... 33 99719-3F110-03_ELECTRICAL_SYSTEM............................ 39 99719-3F110-03_ELECTRICAL SYSTEM........................ 39 99719-3F110-04_CONTROLLER................................... 107 99719-3F110-04_CONTROLLER............................... 107 99719-3F110-04_CONTROLLERS.................................. 179 99719-3F110-05_POWER_TRAIN.................................. 251 99719-3F110-05_POWER TRAIN.............................. 251 99719-3F110-06_CLUTCHES..................................... 265 99719-3F110-06_CLUTCHES................................. 265 99719-3F110-07_MANUAL_TRANSMISION........................... 303 99719-3F110-07_MANUAL TRANSMISION....................... 303 99719-3F110-07_MANUAL_TRANSMISSION.......................... 331 99719-3F110-08_POWERSHIFT_TRANSMISSION...................... 359 99719-3F110-08_POWERSHIFT TRANSMISSION.................. 359 99719-3F110-09_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........ 451 99719-3F110-09_FRONT AXLE AND REDUCTION DIFFERENTIAL.... 451 99719-3F110-10_REAR_AXLE.................................... 479 99719-3F110-10_REAR AXLE................................ 479 99719-3F110-11_BRAKE_SYSTEM................................. 495 99719-3F110-11_BRAKE SYSTEM............................. 495 99719-3F110-12_STEERING_SYSTEM.............................. 519 99719-3F110-12_STEERING SYSTEM.......................... 519 99719-3F110-13_HYDRAULIC_SYSTEM............................. 541 99719-3F110-13_HYDRAULIC SYSTEM......................... 541 99719-3F110-14_MAST_AND_FORKS............................... 609 99719-3F110-14_MAST AND FORKS........................... 609 99719-3F110-15_SERVICE_DATA................................. 705 99719-3F110-15_SERVICE DATA............................. 705 99719-3F120-01.............................................. 731 99719-3F120-03.............................................. 739 99719-3F120-03.......................................... 739 99719-3F120s............................................ 807 99719-3F120s_01..................................... 807 99719-3F120s_02..................................... 808 99719-3F120s_03..................................... 809 99719-3F120s_04..................................... 810 99719-3F120-15.............................................. 811 99719-3F120T-00............................................. 839 99719-6M110-06_POWERSHIFT_TRANSMISSION...................... 862 99719-6M110-07_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........ 954 99719-6M110-08_REAR_AXLE.................................... 982 99719-6M110-09_BRAKE_SYSTEM................................. 998 99719-6M110-10_STEERING_SYSTEM..............................1022 99719-6M110-11_HYDRAULIC_SYSTEM.............................1042 99719-6M110-12_MAST_AND_FORKS...............................1130 99719-6M110-13_SERVICE_DATA.................................1218 99719-6W110-00_FOREWORD.....................................1287 99719-6W110-01_GENERAL......................................1293 99719-6W110-02_ELECTRICAL_SYSTEM............................1297 99719-6W110-02A_WIRING_DIAGRAM..............................1307 99719-6W110s_Gasoline...................................1307 99719-6W110s_Diesel.....................................1308 99719-6W110-03_CONTROLLER...................................1309 99719-6W110-04_POWER_TRAIN..................................1325 99719-6W110-05_TORQUE_CONVERTER_DRIVE_TRANSMISSION..........1345 99719-6W110-06_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........1349 99719-6W110-07_BRAKE_SYSTEM.................................1375 99719-6W110-08_SERVICE_DATA.................................1403 99719-35120-00_FOREWORD.....................................1411 99719-35120-00_FOREWORD.................................1412 99719-35120-01_GENERAL_INFORMATION..........................1419 99719-35120-01_GENERAL INFORMATION......................1419 99719-35120-02_COOLING_SYSTEM...............................1429 99719-35120-02_COOLING SYSTEM...........................1429 99719-35120-03_ELECTRICAL_SYSTEM............................1436 99719-35120-03_ELECTRICAL SYSTEM........................1436 99719-35120-04_CONTROLLERS..................................1507 99719-35120-04_CONTROLLERS..............................1507 99719-35120-05_POWER_TRAIN..................................1565 99719-35120-05_POWER TRAIN..............................1565 99719-35120-06_CLUTCHES.....................................1582 99719-35120-06_CLUTCHES.................................1582 99719-35120-07_MANUAL_TRANSMISION...........................1619 99719-35120-07_MANUAL TRANSMISION.......................1619 99719-35120-08_POWERSHIFT_TRANSMISSION......................1643 99719-35120-08_POWERSHIFT TRANSMISSION..................1643 99719-35120-09_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........1688 99719-35120-09_FRONT AXLE AND REDUCTION DIFFERENTIAL....1688 99719-35120-10_REAR_AXLE....................................1716 99719-35120-10_REAR AXLE................................1716 99719-35120-11_BRAKE_SYSTEM.................................1727 99719-35120-11_BRAKE SYSTEM.............................1727 99719-35120-12_STEERING_SYSTEM..............................1750 99719-35120-12_STEERING SYSTEM..........................1750 99719-35120-13_HYDRAULIC_SYSTEM.............................1767 99719-35120-13_HYDRAULIC SYSTEM.........................1767 99719-35120-14_MAST_AND_FORKS...............................1854 99719-35120-14_MAST AND FORKS...........................1854 99719-35120-15_SERVICE_DATA.................................1945 99719-35120-15_SERVICE DATA.............................1945 99719-38210-00_FOREWORD.....................................1965 99719-38210-00_FOREWORD.................................1966 99719-38210-01_GENERAL_INFORMATION..........................1986 99719-38210-01_GENERAL INFORMATION......................1986 99719-38210-02_COOLING_SYSTEM...............................1994 99719-38210-02_COOLING SYSTEM...........................1994 99719-38210-03_ELECTRICAL_SYSTEM............................1999 99719-38210-03_ELECTRICAL SYSTEM........................1999 99719-38210-04_CONTROLLER...................................2071 99719-38210-04_CONTROLLER...............................2071 99719-38210-05_POWER_TRAIN..................................2142 99719-38210-05_POWER TRAIN..............................2142 99719-38210-06_CLUTCHES.....................................2156 99719-38210-06_CLUTCHES.................................2156 99719-38210-07_MANUAL_TRANSMISION...........................2194 99719-38210-07_MANUAL TRANSMISION.......................2194 99719-38210-08_POWERSHIFT_TRANSMISSION......................2221 99719-38210-08_POWERSHIFT TRANSMISSION..................2221 99719-38210-09_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........2313 99719-38210-09_FRONT AXLE AND REDUCTION DIFFERENTIAL....2313 99719-38210-10_REAR_AXLE....................................2341 99719-38210-10_REAR AXLE................................2341 99719-38210-11_BRAKE_SYSTEM.................................2357 99719-38210-11_BRAKE SYSTEM.............................2357 99719-38210-12_STEERING_SYSTEM..............................2380 99719-38210-12_STEERING SYSTEM..........................2380 99719-38210-13_HYDRAULIC_SYSTEM.............................2401 99719-38210-13_HYDRAULIC SYSTEM.........................2401 99719-38210-14_MAST_AND_FORKS...............................2468 99719-38210-14_MAST AND FORKS...........................2468 99719-38210-15_SERVICE_DATA.................................2564 99719-38210-15_SERVICE DATA.............................2564 99719-69120-00..............................................2589 99719-69120-01..............................................2612 99719-69120-02..............................................2617 99719-69120-03..............................................2622 99719-69120-03A.............................................2661 99719-69120-04..............................................2665 99719-69120-05..............................................2781 99719-69120-06..............................................2794 99719-69120-07..............................................2888 99719-69120-08..............................................2915 99719-69120-09..............................................2933 99729-87120-01..............................................2958 99729-87120-02..............................................2966 99729-87120-03..............................................2977 99729-87120-04..............................................2981 99729-87120-05..............................................2984 99729-87120-06..............................................3000 99729-87120-07..............................................3026 99729-87120-08..............................................3045 99729-87120-09..............................................3059 99729-87120-10..............................................3069 99729-87120-11..............................................3079 99729-87120-12..............................................3085 99729-87120-13..............................................3114 99729-88100-00..............................................3124 99729-88100-01..............................................3139 99729-88100-02..............................................3147 99729-88100-03..............................................3159 99729-88100-04..............................................3163 99729-88100-05..............................................3166 99729-88100-06..............................................3182 99729-88100-07..............................................3209 99729-88100-08..............................................3228 99729-88100-09..............................................3242 99729-88100-10..............................................3252 99729-88100-11..............................................3262 99729-88100-12..............................................3268 99729-88100-13..............................................3307
CATERPILLAR CAT DP20N LIFT TRUCK SERVICE MANUAL – COMPLETE SET – PDF DOWNLOAD:
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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