Caterpillar DP100N1, DP120N1, DP135N1, DP150N1, DP160N1 Operation and Maintenance Manual 99790-42010

Caterpillar DP100N1, DP120N1, DP135N1, DP150N1, DP160N1 Operation and Maintenance Manual 99790-42010 - Image 2

Caterpillar DP100N1, DP120N1, DP135N1, DP150N1, DP160N1 Operation and Maintenance Manual 99790-42010 - Image 3

Caterpillar DP100N1, DP120N1, DP135N1, DP150N1, DP160N1 Operation and Maintenance Manual 99790-42010 - Image 4

Caterpillar DP100N1, DP120N1, DP135N1, DP150N1, DP160N1 Operation and Maintenance Manual 99790-42010 - Image 5

caterpillar dp100n1 dp120n1 dp135n1 dp150n1 dp160n1 operation and maintenance manual 99790 42010 2

caterpillar dp100n1 dp120n1 dp135n1 dp150n1 dp160n1 operation and maintenance manual 99790 42010 3

Caterpillar DP100N1, DP120N1, DP135N1, DP150N1, DP160N1 Operation and Maintenance Manual 99790-42010

$30.00

Type Of Manual: Operation and Maintenance Manual
Manual ID: 99790-42010
Number of Pages: 222
Size: 24.3MB
Format: PDF

Category: Caterpillar Operation Manual PDF

Model List:
- DP100N1, DP120N1, DP135N1, DP150N1, DP160N1

1. FOREWORD
1.1. How to Use This Manual
1.2. LOCKOUT/TAGOUT
2. SAFETY RULES FOR LIFT TRUCK OPERATORS
2.1. General
2.2. Warning Decals, Location
2.3. Description of Danger, Warning, and Caution Decals
2.3.1. Fasten Seat Belt Decal
2.3.2. Survive in a Tipover Decal
2.3.3. Operation Warning Decal
2.3.4. Overhead Guard Decal
2.3.5. No Access With Engine Running Decal
2.3.6. Parking Brake Decal
2.3.7. No Riders Warning Decal
2.3.8. Pinch Points Decal
2.3.9. No One on the Fender
2.3.10. No One Under / On Forks and No One Between Mast and Chassis Decal
2.3.11. Brake Warning Buzzer Decal
2.3.12. Capacity Plate
2.3.13. Backup Alarm Decal
2.3.14. Operator Restraint System Decal
2.3.15. No Contamination Permissible Decal
2.3.16. Precautions for Handling ECU Decal
2.4. Safety Rules
2.5. Operating Precautions
2.6. Working Precautions
3. KNOW YOUR LIFT TRUCK
3.1. Serial Number and Capacity Plate
3.2. Electrical Components
3.3. Model View
3.3.1. FC Model (Type A)
3.3.2. FC Model (Type B)
3.3.3. LC Model
3.4. Driving Switches and Controls
3.4.1. Key Switch
3.4.2. Direction Lever (Powershift Model)
3.4.3. Inching Pedal
3.4.4. Turn Signal / Light Switch
3.4.5. Steering Column Tilt Lever
3.5. Meter Panel
3.5.1. Warning Icons Glow Check
3.5.2. LCD Screen
3.5.3. Warning Icons and Indicators
3.5.4. Basic Screen Display
3.5.5. Basic Operation
3.5.6. When Diagnostic Code Is Shown on Display
3.5.7. When Several Warnings Occur Simultaneously
3.5.8. Warning Symbols
3.5.9. Warning Icons
3.5.10. Optional Features
3.6. Side Panel
3.6.1. Speed Mode Selector Switch
3.6.2. Brake Warning Icon
3.7. Presence Detection System
3.7.1. Mast Interlock System
3.7.2. Mast Interlock System Functions
3.7.3. Driving Interlock System
3.7.4. Driving Interlock System With Operator Restraint Function (For Powershift Models With Australia Specification Only)
3.7.5. Driving Interlock System Functions (For Powershift Models Only)
3.7.6. Driving Interlock System Functions (For Powershift Models With Australia Specification Only)
3.7.7. Neutral System
3.7.8. Neutral System Functions
3.7.9. Seat Belt Warning Icon
3.7.10. Seat Belt Warning Functions
3.7.11. Parking Brake Warning Alarm and Warning Icon
3.7.12. Parking Brake Warning Functions
3.8. Operating Switches and Controls
3.8.1. FC Control Box (Type-A)
3.8.2. FC Control Box (Type-B)
3.8.3. Lift Switch
3.8.4. Tilt Switch
3.8.5. Lowering Speed Selector Switch (Optional)
3.8.6. Direction Switch (Optional)
3.8.7. Attachment Switch A/B (Optional)
3.8.8. Selector Switch Between Fourth and Fifth Attachment (Optional)
3.8.9. Other Controls (Standard)
3.8.10. Emergency Mast Stop Button
3.8.11. Forward and Backward Adjustment Stopper Knob (FC Control Box Type-A)
3.8.12. Up and Down Adjustment Stopper Knob (FC Control Box Type-A)
3.8.13. Forward and Backward Adjustment (FC Control Box Type-B)
3.8.14. Up and Down Adjustment (FC Control Box Type-B)
3.8.15. LC Control Box
3.8.16. Lift Lever
3.8.17. Tilt Lever
3.8.18. Attachment Lever A/B (Option)
3.9. Operator Seat
3.9.1. Seat Adjustment
3.9.2. Forward and Back Adjustment
3.9.3. Reclining Angle Adjustment
3.9.4. Adjustment of Suspension
3.9.5. Pocket for the Operation Maintenance Manual
3.9.6. Operator Presence Switch and Buzzer
3.10. Seat Belt
3.11. Fork Locking Pins
3.12. Drawbar Pin
3.13. Assist Grips and Foot Step
3.14. Engine Hood
3.14.1. Hood Latch
3.15. Hydraulic Tank Oil Filler Hole
3.16. Fuel Filler
3.17. Air Tank
4. HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE
4.1. Know What Lift Truck Stability Is
4.2. Center of Gravity (CG)
4.3. Stability and Center of Gravity (Top View)
4.4. Lift Truck Stability Base
4.5. Capacity (Weight and Load Center)
4.6. Capacity Plate
4.7. Dos and Donts to Avoid Tipover
4.8. How to Survive in a Tipover
5. REFUELING
5.1. Diesel Engine Equipped
6. OPERATION
6.1. New Lift Truck Break-in
6.2. Before Starting Engine
6.3. Starting Engine
6.4. Engine Wont Start
6.5. After Starting Engine
6.6. Before Moving Lift Truck
6.7. Lift Truck Operation
6.7.1. Changing Speed
6.7.2. Changing Direction
6.7.3. Operating Techniques
6.7.4. Steering (Turning)
6.7.5. Inching
6.8. Stopping Lift Truck
6.9. Parking Lift Truck (After Stopping)
7. OPERATING TECHNIQUES
7.1. Stacking Methods
7.1.1. Stacking Different Size Loads
7.1.2. Stacking Small Identical Loads
7.1.3. Stacking Large Identical Loads
7.2. Handling Loads Safely
7.2.1. Adjusting Fork Spread
7.3. Before Operating the Lift Truck
7.4. Blinking of the Mast Interlock Indicator Icon
7.5. Lifting the Load
7.6. Traveling With the Load
7.7. Unloading
7.8. Working on Grades
7.8.1. Normal Travel Position
7.8.2. Traveling on a Grade
7.8.3. Stopping on a Grade
7.9. Starting on a Grade (Engine Stalls on a Grade)
8. STORING THE LIFT TRUCK
8.1. End of Each Shift Storage
8.2. Long Term Storage
8.2.1. Storage Within Three Months
8.2.2. Storage Exceeding Three Months
9. TRANSPORTATION HINTS
9.1. Lift Truck Loading and Shipping
9.2. Lift Truck Lifting and Tie Down Information
10. SPECIAL SITUATIONS
10.1. Care in Cold Weather
10.1.1. Fuel Oils and Lubrication Oils
10.1.2. Battery
10.1.3. Engine Coolant
10.2. Care in Hot Weather
10.2.1. Fuel Oils and Lubrication Oils
10.2.2. Battery
10.2.3. Engine Coolant
10.3. Severe Dust or Lint Conditions
10.3.1. Air Cleaner Element
10.3.2. Engine Oil and Engine Oil Filter
10.3.3. Hydraulic Oil
10.3.4. Hydraulic Tank Return Filter
11. TROUBLESHOOTING
11.1. Stalled Engine
11.2. If a Tire Blows Out
11.2.1. If a Tire Blows out During Travel or Operation
11.3. Replacing Tires
11.4. Before Replacing Tires
11.4.1. To raise front wheel
11.4.2. To Remove Front Wheel
11.4.3. To Install Front Wheel
11.4.4. To Remove Rear Wheel
11.4.5. To Install Rear Wheel
11.4.6. To Add Air to Tires
11.5. Starting With Jumper Cables
11.6. If Lights Wont Glow
11.6.1. How to Check Fuses and Lights
11.7. If the Engine Coolant Temperature Gauge Shows RED Zone
11.8. If Torque Converter Oil Temperature Warning Icon Glows (Powershift Model)
11.9. If the Lift Truck Wont Change Direction
11.10. If the Lift Truck Wont Change Directions (For Powershift Models With Australia Specification Only)
11.11. If the Mast Stops Moving
11.12. If the Mast and Attachments Malfunction
11.13. Diagnostic Codes and Explanations
12. MAINTENANCE
12.1. General
12.2. Inspection Precautions
12.3. Maintenance Schedule
12.3.1. Every 10 Service Hours or Daily (Prestart), Whichever Comes First
12.3.2. Every 50 Service Hours or Weekly, Whichever Comes First
12.3.3. One Month (30 days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever Comes First
12.3.4. Every 500 Service Hours or 3 Months, Whichever Comes First
12.3.5. Every 1000 Service Hours or 6 Months, Whichever Comes First
12.3.6. Every 2000 Service Hours or 1 year, Whichever Comes First
12.3.7. Every 1 to 2 years
12.3.8. Every 2 years
12.3.9. to 4 years
12.3.10. Every 1500 Service Hours
12.3.11. Every 3000 Service Hours
12.4. Every 10 Service Hours or Daily (Prestart), Whichever Comes First
12.4.1. Faulty Operation Found the Day Before
12.4.2. Oil, Fuel, or Coolant Leaks
12.4.3. Brake Pedal
12.4.4. Parking Brake Lever
12.4.5. Service Brake
12.4.6. Air Tank
12.4.7. Engine Coolant
12.4.8. Icons of Meter Panel
12.4.9. Backup Buzzer
12.4.10. Backup Light
12.4.11. Stop Light
12.4.12. Battery
12.4.13. Mast Interlock System
12.4.14. Driving Interlock System
12.4.15. Parking Brake Warning Alarm and Warning Icon
12.4.16. Seat Belt Warning Icon and Alarm
12.4.17. Engine (Exhaust, Noise, and Vibration)
12.4.18. Engine Oil
12.4.19. Overhead Guard
12.4.20. Assist Grips
12.4.21. Seat Belt
12.4.22. Seat Adjustment
12.4.23. Hydraulic Oil
12.4.24. Tilt Cylinder Socket Nuts
12.4.25. Lift Chains
12.4.26. Mast and Forks
12.4.27. Wheel Nuts
12.4.28. Tires and Rims
12.4.29. Steering Wheel
12.4.30. Accelerator Pedal
12.4.31. Inching Pedal
12.4.32. Transmission Oil
12.5. Every 50 Service Hours or Weekly, Whichever Comes First
12.5.1. Alternator Belt
12.5.2. Air Cleaner
12.6. One Month (30 Days) or 200 Service Hours After Delivery of a New Lift Truck, Whichever Comes First
12.6.1. Cooling Oil (in Wet Disk Brake)
12.6.2. Cooling Fan
12.6.3. Battery Electrolyte Specific Gravity
12.6.4. Engine Oil and Oil Filter
12.6.5. Bolts and Nuts
12.6.6. Primary Fuel Filter
12.6.7. Secondary Fuel Filter
12.6.8. Hydraulic Tank Return Oil Filter and Strainer
12.7. Every 500 Service Hours or 3 Months, Whichever Comes First
12.7.1. Primary Fuel Filter
12.7.2. Secondary Fuel Filter
12.8. Lubrication Chart
12.8.1. Fan Belt Pulleys
12.8.2. Mast Support
12.8.3. Fork Guide Bar
12.8.4. Mast Strips Surfaces
12.8.5. Mast and Lift Bracket Side Rollers
12.8.6. Lift Chains
12.8.7. Tilt Socket Pins
12.8.8. Tilt Cylinder Pins
12.8.9. Tie Rod Pins
12.8.10. Rear Axle Supports
12.8.11. Universal Joints
12.9. Every 1000 Service Hours or 6 Months, Whichever Comes First
12.9.1. Air Dryer Desiccant
12.9.2. Air Cleaner
12.10. Every 2000 Service Hours or 1 Year, Whichever Comes First
12.10.1. Brake Fluid
12.10.2. Air Dryer Desiccant
12.11. Parts to be Replaced Periodically
13. SERVICE DATA
13.1. Fuel Information
13.1.1. Fuel Specifications
13.2. Coolant Information
13.2.1. Coolant Water
13.2.2. Antifreeze Solution
13.3. Recommended Fuels and Oils
13.4. Specifications (Standard Models)
13.5. Refill Capacities
13.6. Capacities and Lift Truck Weight (Standard Models)
14. TO THE CAT LIFT TRUCK OWNER
14.1. The Importance of Genuine Parts
14.2. Proper Disposal of Your Lift Truck
14.3. Instructions for Ordering Parts
14.4. Service Registration

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