Caterpillar Forklift DP20N

(1) Transmission oil level check

(a) Check the transmission fluid level with the level gauge.

(b) Start and run the engine at an idling speed for about 3 minutes, and then stop the engine.

(c) Wait for about 30 seconds after stopping the engine, and check the level.

(d) The checking procedure must be completed within 5 minutes after the engine has stopped.

(a) Warm up the engine to raise the temperature of the transmission oil.

Control Valve Assembly Inspection after Disassembly

Check valves for burrs, scratches, dents and other surface defects.

(1) Check that all moving and sliding contact parts move smoothly.

(2) Check for clogged orifices.

(3) Replace springs if they are broken or bent. Measure the free length of springs.;

(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.;

Inspection of output time when starter switch is turned to ON

When a tester is applied to terminal 2 and terminal 1 and a voltage of 12 V is applied between terminal 3 and terminal 1, there is continuity between terminal 2 and terminal 1 for 15 seconds at room temperature. Replace the glow timer with a new one if it does not operate properly.

Inspection of output time when starter switch is turned to START

When a tester is applied to terminal 2 and terminal 1 and a voltage of 12 V is applied between terminal 4 and terminal 1, there is continuity between terminal 2 and terminal 1 for 5 seconds. Replace the glow timer with a new one if it does not operate properly.;

Difference in S.G. between any two cells is 0.020 or more?

Faulty components, loosely connected cord or corroded connection present?

Voltage and S.G. stabilize and have remained constant for more than 2 hours?

S.G. is more than 0.040 and a low S.G. is found in certain cells only?

Specific gravity reading and state of charge

Addition of distilled water is necessary every month or so?