Caterpillar Forklift DP15N

Apply a tester to terminal 1 and terminal 2 and measure the resistance value of the relay coil. Replace the coil with a new one if there is no continuity or the resistance value measured is outside the standard resistance value.

1. Measure the insulation resistance value between terminal 3 and terminal 4. Replace the contact with a new one if the measured insulation resistance value is not more than the value listed in the table below.

2. Apply the tester to terminal 3 and terminal 4.

3. When applying a voltage of 12 V ON and OFF across terminal 1 and terminal 2 under the above condition, check to see if the relay activates to cause continuity or not between terminal 3 and terminal 4. Replace the relay with a new one if it does not activate properly.

CAUTION: This part operates on DC 12 V (Gasoline/Dieselengine truck) power supply.

CAUTION: As the relay has an integrated diode between terminals, be careful about the polarity when inspecting. Replace the relay with a new one if an impact is given to it or if it is dropped.;

(1) With the clearance A between the lining and drum set approximately to specification, pull the cable with spring with a finger as shown. The lever should turn the adjusting screw wheel by one notch and, when the cable is released, return to the original position.

(2) If the lever fails, or is slow, to turn the adjusting screw wheel, check the position of the lever relative to the toothed wheel. The lever’s actuating tip should touch the toothed wheel at approximately 7 to 9 mm (0.28 to 0.35 in.) below the centerline of the screw. If the lever contact is out of the range, the lever will not correctly engage with the toothed wheel, therefore failing or slow to turn the wheel.

(3) If the automatic adjuster fails to operate correctly, take the following actions.

(a) Ensure that the adjusting spring is correctly hooked to the primary shoe.

(d) Replace the adjusting screw.

The following parts should be periodically changed as noted below.

These parts are made of materials which will deteriorate overtime. Further, it is difficult to determine visually whether or not they are still in good condition. Changing at proper intervals will reduce the risk of injury to the operator and damage to the truck.

4000 service hours or 2 years, whichever comes first:

• Rubber parts of power cylinder

• Hydraulic hoses of steering system

4000 to 8000 service hours or 2 to 4 years, whichever comes first:

(1) Check the belt for contamination with oil, grease and dust. Replace the belt if required. When the contamination is slight, remove it and clean with rag or wiping paper. Do not use gasoline, oil or any other solvent to clean the belt.

(2) During engine overhaul or belt tension adjustment, closely check the belt’s condition. Replace the belt with a new one if it has any sort of damage.

Apply a force of 98 N (10 kgf) [22 lbf] perpendicularly to the belt at a point midway between the fan pulley and tension pulley. Adjust the tension so that belt deflection becomes between 11 to 13 mm (0.43 to 0.51 in.).

When connecting the hoses to the radiator, fit their ends fully on the fittings and secure them with clamps. Make sure that each hose is correctly connected and prevented from disconnection by the flare of the fitting.

Fill the radiator with coolant containing antifreeze. Start and operate the engine to let it warm up while checking for abnormal noise. Make sure that the quantity of coolant is as specified by checking the level in the reserve tank.;

Simplex Mast Inspection after disassembly (all models)

(1) Check each roller for wear, binding or other defects.

(2) Check each roller on rolling surface for pitting or other defects.

(3) Check the mast member and the welded joints of crossmembers, shafts and supports for cracks.

(4) Check the mast support bushings for wear or other defects.

(1) Check the main rollers and side rollers for smooth rotation. Inspect each roller for wear and cracks.

(2) Check the welded portions of the bracket for cracks.