Caterpillar Lift Truck DP15ND NDS NT NTS Service Operation & Maintenance Manual – PDF DOWNLOAD

Description

Caterpillar Lift Truck DP15ND NDS NT NTS Service Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Caterpillar Lift Truck DP15ND NDS NT NTS Service Operation & Maintenance Manual – PDF DOWNLOAD

FOREWORD :

The Occupational Safety and Health Administration (OSHA) prohibits employees under the age of 18 years old from operating
lift trucks, and is now mandating operator training for all lift truck operators.
SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness of the operator. To develop
the skill, the operator should read this manual to understand the following points:
(1) Working capabilities and limitations of the lift truck
(2) Make-up of the lift truck
(3) Safe driving and load handling procedures
It is the employer’s responsibility to make sure the operator can see, hear, and has the physical and mental ability to operate
the lift truck safely.
It is also important that a qualified person experienced in lift truck operation should guide new operators through several
driving and load handling operations before they attempt to operate the lift truck on their own.

TABLE OF CONTENTS:

Caterpillar Lift Truck DP15ND NDS NT NTS Service Operation & Maintenance Manual – PDF DOWNLOAD

1 SAFETY RULES FOR LIFT TRUCK OPERATORS 1-1
General 1-1
Warning Decals, Location 1-2
Decals for Dual Fuel Only 1-4
Warning Decals, Description 1-5
 No One under / on Forks 1-5
 Crush and Pinch Points 1-5
 Tipover Warnings 1-5
 With Headguard Decal / Load Backrest Extension 1-6
 Operator Restraint System Decal 1-6
 Deflate Air Before Loosening Nut Decal 1-6
 Precautions for Handling E C U decal 1-7
 Capacity Plate 1-7
 Back-up Alarm Decal 1-7
 No Riders Warning Decal 1-8
 Survive in a Tipover Decal 1-8
 Operation Warning Decal 1-9
 Engine Coolant Decal 1-10
 Parking Brake Adjustment Decal 1-10
 Radiator Cap 1-10
 Cooling Fan 1-11
 No Contamination Permissible Decal 1-11
 Duel Fuel Inst Decal 1-11
Safety Rules 1-12
Operating Precautions 1-22
Working Precautions 1-27
LP-Gas 1-34
2 KNOW YOUR LIFT TRUCK 2-1
Serial Number and Capacity Plate 2-1
Electrical Components 2-2
Model View 2-3
 MC Model 2-4
 FC Model 2-4
Driving Switches and Controls 2-5
 Direction Lever (Powershift) 2-6
 Turn Signal / Light Switch 2-6
 Key Switch 2-7
 Steering Column Tilt Lever 2-7
 Inching Pedal 2-8
Meter Panel 2-9
 Warning Lights and Indicator Lights 2-10
 LCD Screen 2-10
 Warning Lamps and Indicators 2-11
 Basic Screen Display 2-13
 Basic Operation 2-16
 When diagnostic code is shown on display 2-20
 Optional Functions 2-21
Presence Detection System 2-26
 Mast Interlock System 2-26
 Driving Interlock System 2-27
 Driving Interlock System Functions (Powershift models only) 2-28
 Neutral System 2-28
 Neutral System Functions 2-28
 Seat Belt Warning Lamp 2-29
 Seat Belt Warning Functions 2-29
 Parking Brake Warning Buzzer and Alarm Lamp 2-29
 Parking Brake Warning Functions 2-30
Operating Switches and Controls (MC Model) 2-31
 Lift Lever 2-31
 Tilt Lever 2-31
 Mast Vertical Switch (Optional) 2-32
 Attachment Lever (Optional) 2-32
Operating Switches and Controls (FC Model) 2-33
 Lift Lever 2-33
 Tilt Lever 2-34
 Attachment Lever A/B (Optional) 2-34
 Selector Switch Between Forth and Fifth Attachment 2-34
 Lowering Speed Selector Switch (Optional) 2-34
 Other Controls 2-35
 Emergency Mast Stop Button 2-35
 Forward and Back Adjustment Stopper Knob 2-36
 Up and Down Adjustment Stopper Knob 2-36
 Direction Switch (Optional) 2-36
Operator Seat 2-37
 Seat Adjustment 2-37
 Forward and Back Adjustment 2-37
 Adjustment of Suspension 2-38
 Reclining Angle Adjustment 2-38
 Pocket for the Manual 2-38
 Magazine Box 2-38
 Operator Presence Switch and Buzzer 2-39
Seat Belt 2-40
Engine Hood 2-42
 Hood Latch 2-42
Hydraulic Tank Oil Level / Filler Hole 2-43
Fuel Filler 2-44
Fork Locking Pins 2-45
Changing Forks 2-45
Drawbar Pin 2-46
Assist Grip 2-46
3 HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE 3-1
Know What Lift Truck Stability Is 3-1
Center of Gravity (CG) 3-1
Stability and Center of Gravity 3-1
Lift Truck Stability Base 3-2
Capacity (Weight and Load Center) 3-2
Capacity Plate 3-3
 For Example 3-3
Do’s and Don’ts to Avoid Tipover 3-3
How to Survive in a Tipover 3-8
4 REFUELING 4-1
Gasoline and Diesel Engine Equipped 4-1
LP-Gas Equipped 4-2
 For Standard LP-Gas Tank 4-3
 For Optional LP-Gas Tank 4-4
TABLE OF CONTENTS
TOC-2
5 OPERATION 5-1
New Lift Truck Break-in 5-1
Before Starting Engine 5-1
 Starting Engine 5-2
 Gasoline / LP-Gas Dual Fuel Type 5-3
 Instruction for Changeover of Fuel Between LP-Gas and Gasoline 5-3
 FC Model 5-3
Starting Engine 5-4
 Gasoline Engine Model 5-4
 LP-Gas Engine Model 5-5
 Diesel Engine Model 5-5
Engine Won’t Start 5-7
 When Engine Is “Flooded” 5-7
 When Engine Is Started after Long Idle Period 5-8
After Starting Engine 5-8
Before Moving Lift Truck 5-9
Lift Truck Operation 5-10
 Changing Speed 5-11
 Changing Direction 5-12
 Operating Techniques 5-13
 Steering (Turning) 5-13
 Inching 5-14
Stopping Lift Truck 5-15
 MANUAL 5-15
 POWERSHIFT 5-16
Parking Lift Truck (After Stopping) 5-17
6 OPERATING TECHNIQUES 6-1
Stacking Methods 6-1
 Stacking Different Loads in Size 6-1
 Stacking Small Identical Loads 6-1
 Stacking Large Identical Loads 6-1
Handling Loads Safely 6-2
 Fork Spread Adjustment 6-2
Before Operating the LIFT Truck 6-4
Flickering of the Mast Interlock Indicator Light 6-5
Inching Into and Lifting the Load 6-7
Traveling with the Load 6-9
Unloading 6-11
Working on Grades 6-14
 Normal Travel Position 6-14
 Traveling on a Grade 6-14
 Stopping on a Grade 6-14
 Starting on a Grade (Engine Stalls on a Grade) 6-15
7 STORING THE LIFT TRUCK 7-1
End of Each Shift Storage 7-1
Long Term Storage 7-1
 Storage within 3 Months 7-1
 Storage Exceeding 3 Months 7-2
8 TRANSPORTATION HINTS 8-1
Lift Truck Loading and Shipping 8-1
Lift Truck Lifting and Tiedown Information 8-1
9 SPECIAL SITUATIONS 9-1
Care in Cold Weather 9-1
 Fuel Oils and Lubrication Oils 9-1
 Battery 9-1
 Engine Coolant 9-2
Care in Hot Weather 9-2
 Fuel Oils and Lubrication Oils 9-2
 Battery 9-2
 Engine Coolant 9-2
Severe Dust or Lint Conditions 9-3
 Air Cleaner Element 9-3
 Engine Oil and Engine Oil Filter 9-3
 Hydraulic Oil 9-3
 Hydraulic Tank Return Filter 9-3
10 TROUBLESHOOTING 10-1
If a Tire Blows Out 10-1
 If a Tire Blows out During Traveling or Operation 10-1
Changing Tires 10-1
 Before Changing Tires 10-2
 To Remove Wheel 10-3
 To Raise Front Wheel 10-4
 To Raise Rear Wheel 10-5
 To Install Wheel 10-5
 To Add Air to Tires 10-6
 Dual Tire (Optional) 10-6
Stalled Engine 10-7
 Before Starting the Engine Again 10-7
If the Engine Coolant Temperature Gauge Shows Red Zone 10-8
If Torque Converter Oil Temperature Warning Lamp Glows
(Powershift) 10-9
Trouble with the LP-Gas Equipment 10-9
Starting with Jumper Cables 10-10
If Lamps Won’t Glow 10-11
 How to Check Fuses and Lamps 10-11
If the Lift Truck Won’t Change Directions 10-13
If the Mast Stops Moving 10-14
If the Mast and Attachments Malfunction (FC Model) 10-15
Diagnostic Codes and Explanations 10-16
11 MAINTENANCE 11-1
General 11-1
Inspection Precautions 11-2
Maintenance Schedule 11-3
 Every 10 Service Hours or Daily (Pre-Start),
Whichever Comes First 11-3
 Every 50 Service Hours or Weekly, Whichever Comes First 11-4
 One Month (30 days) or 200 Service Hours after Delivery of a
New Truck, Whichever Comes First 11-5
 Every 200 Service Hours or Monthly, Whichever Comes First 11-6
 Every 500 Service Hours or 3 Months, Whichever Comes First 11-7
 Every 1000 Service Hours or 6 Months, Whichever Comes First 11-8
 Every 2000 Service Hours or 1 year, Whichever Comes First 11-8
TABLE OF CONTENTS
TOC-3
Every 10 Service Hours or Daily (Pre-Start),
Whichever Comes First 11-10
 Faulty Operation Found the Day Before 11-10
 Oil, Fuel or Coolant Leaks 11-10
 Fuel Cap 11-10
 Tires and Rims 11-11
 Wheel Nuts 11-12
 Tire Pressure 11-13
 Lamps and Lens 11-13
 Assist Grip 11-13
 Overhead Guard 11-14
 Mast and Forks 11-14
 Load Backrest Extension 11-15
 Lift Chains 11-16
 Mast and Lift Bracket 11-17
 Lift Cylinder Mounting Bolts 11-18
 Tilt Cylinder Socket Bolts 11-18
 Lift and Tilt Cylinder 11-18
 Battery 11-19
 Engine Coolant 11-20
 Engine Oil 11-21
 Engine Cooling Fan 11-22
 Fan & Alternator Drive Belt 11-23
 Electrical Wires 11-24
 Brake Hoses, Pipes and Joints 11-24
 Hydraulic Oil 11-24
 Operator Seat 11-25
 Rear View Mirror 11-25
 Steering Column 11-25
 Steering Wheel 11-25
 Horn 11-26
 Service Brakes 11-26
 Parking Brake Lever 11-27
 Brake Pedal 11-27
 Inching Pedal (Powershift) 11-28
 Clutch Pedal 11-28
 Accelerator Pedal 11-28
 Seat Belt 11-29
 Fuel 11-29
 Head Lamp and Working Lamp 11-29
 Turn Signal Lamp 11-29
 Stop Lamps 11-30
 Back-up Lamps 11-30
 Lamps of Meter Panel 11-30
 Meter Panel 11-30
 Engine (Exhaust, Noise and Vibration) 11-31
 Mast Strip Sliding Surfaces 11-31
 Clutch 11-31
 Brake Pedal 11-32
 Steering Wheel 11-32
 Seat Belt Warning Lamp 11-33
 Parking Brake Warning Buzzer 11-33
 Mast Interlock System 11-34
 Driving Interlock System 11-35
 After the Daily (Pre-Start) Inspection 11-35
Every 50 Service Hours or Weekly, Whichever Comes First 11-36
 Hydraulic Hoses, Pipes and Joints 11-36
One Month (30 days) or 200 Service Hours after Delivery of a
New Truck, Whichever Comes First 11-36
 Radiator Filler Cap 11-36
 Radiator Rubber Hose 11-36
 Alternator 11-36
 Starter 11-37
 Cylinder Head Bolt & Manifold Nut 11-37
 Intake & Exhaust Valve 11-37
 Engine Oil 11-37
 Bolts and Nuts (Frame & Chassis) 11-37
 Injection Nozzle (LP-Gas Engine) 11-37
 Fuel Filter (Diesel) 11-38
 Fuel Filter (Gasoline) 11-38
 Hydraulic Tank Return Oil Filter 11-38
 Mast Support 11-38
 Tilt Socket Pins 11-38
 King Pins 11-38
 Tie Rod Pins 11-38
 Clutch Pedal Shifter Shaft (Manual) 11-38
 Gearshift Lever (Manual) 11-39
Every 200 Service Hours or Monthly,
Whichever Comes First 11-40
 Radiator Fin 11-40
 Battery 11-40
 Engine Idle Speed 11-40
 Tar in Vaporizer 11-40
 Fuel Hoses, Pipes and Joints 11-41
 Spark Plug 11-41
 Air Cleaner Element 11-41
 Mast Strip Sliding Surfaces 11-42
 Differential 11-43
Every 500 Service Hours or 3 Months,
Whichever Comes First 11-44
 Engine Oil 11-44
 Bolts, Nuts (Frame & Chassis) 11-45
 Fuel Filter (LP-Gas Engine) 11-45
 Lift Chains 11-46
 Mast Support 11-47
 Tilt Socket Pins 11-47
 Mounting Bush of Rear Axle 11-47
 King Pins 11-48
 Tie Rod Pins 11-48
 Clutch Pedal Shifter Shaft (Manual) 11-48
 Gearshift Lever (Manual) 11-48
Every 1000 Service Hours or 6 Months,
Whichever Comes First 11-49
 Alternator 11-49
 Starter 11-49
 Cylinder Head Bolt & Manifold Nut 11-49
 Fuel Filter (Diesel) 11-50
 Fuel Filter (Gasoline) 11-50
 Hydraulic System 11-51
 Air Cleaner Element 11-52
 Powershift Transmission 11-53
 Differential 11-53
TABLE OF CONTENTS
TOC-4
Every 2000 Service Hours or 1 Year,
Whichever Comes First 11-54
 Service Brake Fluid 11-54
 Engine Coolant 11-55
 Fuel Filter (LP-Gas Engine) 11-57
 Hydraulic Oil 11-58
 Parts to Be Changed Periodically 11-60
12 SERVICE DATA 12-1
Fuel Information 12-1
 Gasoline (Gas) Specification 12-1
 Diesel Fuel Specifications 12-1
 Liquefied Petroleum (LP-Gas) 12-1
Coolant Information 12-2
 Coolant Water 12-2
 Antifreeze Solution 12-3
Recommended Fuels and Oils 12-4
Specifications (Standard Models) 12-5
Refill Capacities 12-8
Capacities and Lift Truck Weight (Standard Models) 12-10
13 TO THE CAT LIFT TRUCK OWNER 13-1
The Importance of Genuine Parts 13-1
Instructions for Ordering Parts 13-2
Service Registration 13-3

CATERPILLAR LIFT TRUCK DP15ND NDS NT NTS SERVICE OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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