Caterpillar forklift 2.5 ton specification free download

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The most common forklift battery is one that contains lead-acid and includes a lead plate negative electrodean electrolyte solution of sulfuric acid and another lead peroxide plate positive electrode.

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Workers must know what equipment is installed on the forklift and whatnot, and act accordingly to maintain a safe cateripllar. If the floor is slippery or if there are pedestrians or other nearby vehicles, you must drive below the speed limit.

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– Caterpillar forklift 2.5 ton specification free download


Clamp bolt tightening torque Unit Layout 3. After starting the engine and letting it warm up during operation, check for abnormal noises. Check the coolant level in the reserve tank to ensure it meets the specification. Chassis Electrical Devices Wiring Outline Positionandcontent ofprintedsymbols The gasoline-engine truck is also provided with an engine automatic stop mechanism of the fuel cut system.

This prevents starter breakage or flywheel damage caused by an operator restarting the truck when the engine is running The gasoline- and diesel-engine models use the same starter switch.

In the diesel-engine models, ON position of the switch is for energizing the glow plugs. Replace the horn if it does not sound or its sound is abnormal. Operating voltage: DC 12 V Notice: The installed position in an actual truck is as per the illustration. Stop lamp switch Connect a tester across the terminals and check that the lamps turn ON and OFF when the push rod extended projection is to the specified value.

Measure the insulation resistance value across the terminals when the push rod is pushed in. Replace the switch if the measured insulation resistance value is not more than the value listed below. Apply an ohmmeter between the terminal and body of the sender unit and check for continuity resistance value.

Replace the sender unit if there is no continuity or the measured resistance value is outside the standard resistance value. Notice: The illustration is for a gasoline-engine truck. Replace the thermoswitch if the measured insulation resistance value is not more than the value listed in the table below. Internal resistance: 0. NOTE When installing the thermoswitch, tighten it to the specified torque. If there is no continuity or the resistance value measured is outside the standard resistance value, replace the coil.

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

Apply an ohmmeter across terminal 3 and terminal 4. 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 between terminal 3 and terminal 4. Replace the relay if it does not activate properly. Replace the relay if it was dropped or abused. Glow plugs 5. Reassembly Follow the disassembly sequence in reverse. Bulb replacement For bulb replacement, remove the socket from the rigid board by turning it counterclockwise.

For configuration of the indicator lights, refer to page Be careful not to damage the rigid board when disassembling the instrument panel. State of charge and electrolyte specific gravity S. Specific gravity reading and state of charge To check the battery for state of charge, take hydrometer readings on its electrolyte.

The battery may be fully charged if the S. The state of charge can be told from the way the electrolyte level goes down to expose the cell plates. If addition of distilled water is necessary every month or so, the battery is overcharged. If addition is not required for more than 3 months, it is likely that the battery is inadequately charged.

Adjust S. Make sure there is neither faulty components, loosely connected cord nor corroded connection. If difference in S. Recharge until voltage and S. Electrolyte leakage, During recharging, adjust S. After leaving battery for 12 to 96 hours, conduct a high current discharge test. For wiring composed of two colors, the first color shows a base color and the second color a marking color.

Adjustable Armres t – combines anatomical support with free movement and perfect hand positioning. Features fingertip hydraulic controls for smooth mast movements and comfortable operation. Intermediate Step and Ergonomic Grab Handles – allow easy and smooth on-off access to a wide, unobstructed and comfortable operator compartment with low seat position.

Never re-install any part that has been once removed. Readjustment 5. At this time, make sure that the chalk draws a line circle on the ground.

The radius of this circle is assumed to be the minimum turning radius R. Standard value. Adjustment and Testing DPN Hydraulic wet multiplate disc type mm – 16 Brake booster Center brake drum internal expanding type Air compressed by the compressor is dehumidified by an air drier, and filled in the air tank.

Since the air master compresses the brake fluid with this compressed air, the wheel brake activates to brake the truck. A: From brake control valve B: To air master C: From air tank D: To atmosphere Relay valve controls the braking pressure corresponding to pressure change in pipeline at the brake control valve side, which can extremely shorten the time required to increase braking pressure.

Compressed air in the air tank is directly sent to the air master to prevent delay of brake application. When releasing the brake, the compressed air from air master is discharged directly from the relay valve. The compressed air in air tank is led to air master from this inlet port. When this force comes to be larger than the force acting on top face from brake control valve, the diaphragm and valve rod will be pushed up. Also, the inlet valve is closed by the spring, and the pressure of air master maintains a pressure which is equal to that at the brake control valve side.

Releasing the brake pedal will drop the air pressure from brake control valve. Since the valve rod lifts further to open the exhaust port, air in the air master is discharged through the center of inlet valve. A: Air tank side port B: Air master side port By depressing the pedal, a volume of compressed air in proportion to the displacement of the pedal depressed, is supplied to the cylinder shell section in the air master.

When releasing the foot from the pedal, the compressed air in the cylinder shell is discharged into the atmosphere. Brake fluid pressurized by the compressed air supplied from the brake control valve is used to activate the wheel cylinder. The piston plate is pushed by the return spring to the left as shown in the illustration. This compressed air pushes the return spring to the right as shown in the illustration via the piston plate, and also pushes the hydraulic piston through the push rod connected to the piston plate.

When the hydraulic piston begins to work, the check valve yoke which has touched to the stopper is returned by the spring. Therefore, the ball comes into close contact with the seat surface by the brake fluid in the cylinder, and closes the circuit to reservoir tank. In this way, the brake fluid in the hydraulic cylinder is adjusted to the pressure corresponding to compressed air pressure by moving the piston, and applied to the wheel cylinder. Thus, the piston plate is pushed by the return spring and returns to the initial position.

The hydraulic piston returns to the left in the illustration by the oil pressure from the wheel cylinder. At this time, when the check valve yoke touches the stopper, the ball will separate from seat surface, and circuit to the reservoir tank will be opened.

In this way, the brake fluid in the hydraulic cylinder is depressurized and the brake is released. Since the cause by which the stroke of piston plate becomes longer is wear of brake lining, adjustment of brake lining is needed. The brake shoe has a T-shaped cross section, and the lining of non asbestos material is stuck on its outside as a friction surface.

The support point at lower end of shoe is supported by the boss of anchor bracket, and the recess at the top is connected to the push rod of wheel cylinder. The intermediate rib section is also supported by the return spring and adjusting cam. The adjusting cam is a eccentric cam, and rotation of the cam is required when clearance adjustment of the brake shoe is performed. The wheel cylinder is the opposed piston type, and its body section is bolted to the anchor bracket.

When the brake pedal is not depressed, the brake shoe is retracted with the return spring, since the pressure of brake fluid is not applied to the wheel cylinder.

When the brake pedal is depressed, the push rod of wheel cylinder is extended to right and left, and which result in the linings of brake shoe pressed onto the brake drum, resisting the return spring force. In this way, the wheel brake is activated, and truck is slowed down and stopped. Air compressed by the compressor is dehumidified by an air drier, and fills the air tank. Since the brake booster compresses the brake oil with this compressed air, the wheel brake activates to brake the truck.

The brake booster converts energy of compressed air, which is supplied from brake control valve, into oil pressure force, and activates the wet disc brake installed to the front axle. Because the compressed air is used as source to increase the force, the force to depress the pedal is reduced with the braking effect improved. When the switch built into the chamber is activated a warning buzzer sounds. This means the disk and plates in the wheel hub have reached the service limit.

The push rod also pushes the piston of master cylinder. This parking brake is an internal expanding type, and brakes the brake drum mounted to the input flange part in the front axle with the parking brake lever and flexible wire.

Even though the main purpose of parking brake system is preventing a motor movement at the time of parking, it is also used as an auxiliary brake if the wheel brake system is defective. Lever operating effort. The parking brake is of an internally expanding type that a cam operation expands the brake shoe inside the drum. It has an adjuster assembly installed at the bottom to adjust a clearance made between the lining and drum.

In addition, since it is also difficult to loosen bolts on nut side, remove using the special tool. Bolt in awkward position. Spring setter. Special tool Anchor pin puller: If necessary, repair the inside surface by grinding it. Special tool Spring setter: Spring setter. Replace, if the clearance exceeds the service limit. Clearance between piston and cylinder body. Replace, if there is any defect. Fit of piston cups in cylinder body. However, use the complete bag if purchased for use in repair kits.

Adjustment and Testing 5. The shoe assembly should also be replaced in the following cases: 1 When installation of lining and brake shoe is poor. Replace the drum if uneven wear exceeds 0. Insert the other end of the vinyl tube into the container filled with brake fluid. Insert the other end of the vinyl tube into the container filled with the brake fluid. The bleeder screw should be tightened after brake fluid flows as a solid stream without any bubbles.

NOTE a Exercise care so that the brake fluid level in the reserve tank does not become too low during this operation. At this time, also replace the O-ring of brake piston, sleeve, and floating seal together. Air may be mixed in circuit.

Tighten the bleeder screw, before the. NOTE During operations, refill oil as required so that the oil in the brake oil tank does not run short. Release the brake pedal. Apply soap and water solution to the exhaust side port on the brake control valve, and check for bubbles.

If it bubbles, air has leaked from the exhaust valve. Perform the same test with the brake pedal fully depressed, and inspect the air leakage of the exhaust valve. Remove the plug of exhaust side port and check the valve for damage. Release the parking brake lever. Remove the grommet from the adjusting hole. Turn the adjuster assembly up all the way until the lining-todrum clearance is removed.

From this position, turn the adjuster assembly back down about eight notches to obtain the correct liningto-drum clearance. To measure the lining-to-drum clearance, remove the grommet from the dust cover and insert a thickness gauge.

Change fluid with recommended type resulting in fluid leaks. Procedure and Suggestions for Removal and Installation This truck has employed a full-hydraulic steering system that consists of steering valve, priority valve, power cylinder, and so on. Also with the load sensing mechanism the operator is provided with steering operations which are comfortable and hardly affected by the load conditions. The turning of the steering wheel is changed to a hydraulic pressure in the steering valve, then transformed to the steering force in the power cylinder on the rear axle.

Hydraulic oil. Flow rate required for the steering operation is determined at the priority valve. If the steering system does not require a large quantity of hydraulic oil, the rest of the hydraulic oil will be supplied to other operation device lines. Except on the steering operation, most of the hydraulic oil can be used for other operation devices.

The steering valve was designed with a load sensing circuit. This load sensing circuit functions as to balance between the downstream oil pressure of variable orifice in the steering valve and the counter-side oil pressure of the spool in the priority valve. This offers a smooth steering operation that is not affected by the variation in load conditions.

Column position when steering column is tilted fully forward Column position when lock is released. When the tilt lever 3 is turned counterclockwise,the plates A and B are fixed between the bolt and nut.

This adjustment can be achieved by turning the tilt lock lever clockwise to loosen it after locking the column lock lever. Then, tilt the steering column to an optimal angle and turn the tilt lock lever counterclockwise i. This column lock lever is useful for such cases where the entire column unit must be tilted forward i.

As shown in the figure, if you push the lock lever to the left, the lock lever can be disengaged from the lock pin, and the steering column can tilt to the front. Procedure and Suggestions for Removal and Installation 3. Suggestions for disassembly and reassembly 1 The important point in servicing the hydraulic system is to proceed your operation in a clean environment and never allow any abrasive matters to enter inside the system.

These must be replaced with new ones disregarding with or without damage after they have been used for a specified period of time. Installation Follow the procedure shown below: 1 Turn the protrusion a of handling sensor on the combination switch by hand to the shown direction in the figure.

The protrusion on the combination switch must fit with the concave provided on the steering wheel. Turn this for several times clockwise and counterclockwise until it fits in completely. Inspection after installation Inspection of the operation effort of steering wheel 1 Apply the parking brake. The steering effort must be lower than the following value.

Steering effort at the outer circumference of steering wheel. Installation Replacement must follow the reverse order of removal. This bleeds air from the relief valve. Disassembly 1 Put an alignment mark on the tilt lock lever and nut B to ensure proper reassembly. Reassembly When the alignment marks have faded out or the lever is to be replaced with new one, install it according to the following procedure.

The illustration on the right shows the relative positions of the consisting parts between tilt and neutral under the condition of the column lock lever being locked. This corresponds to the condition when the lever is locked.

Priority valve Flow regulator valve Lift cylinder Tilt cylinder Inspection and Adjustment The gear pump draws oil from the hydraulic tank and sends it to the priority valve. The oil pressure is metered and divided by this priority valve into two systems, one for the hydraulic system and the other for the steering system.

The oil that goes to the hydraulic system is sent through the control valve to the hydraulic cylinders. The hydraulic tank is an integral structure with the frame and is provided with a strainer at the oil supply port, suction strainer, and return filter to keep the oil clean. Of the service oil discharged from the gear pump, only the amount required for steering operation will be supplied by the priority valve to the steering control valve, the remaining oil will be forwarded to circuits of other service equipment.

When the steering is in neutral position, almost all of the service oil will be used for operating all the other service equipment. Priority relief pressure. The control valve is an assembly of more than one valve block which are mounted together by three tie bolts. Each block has a pump port and tank port, and is mounted with a cartridge-type pilot-operate relief valve. The lift cylinder is a single working type of which the pressurized oil reacts only in one direction for pressing the piston.

The bottom-side port has a flow regulator valve built in, and oil return pipe at the rod side port. The tilt cylinder is a dual working type and has the rod end threaded for adjusting the balance between the right and left when the mast is mounted.

The tilt angle setting can be modified through an optional adjustment of collar and socket. The flow regulator valve will pass the entire amount of service oil fed from the pump as-is while the lift cylinder is raising the mast, but controls the flow rate passing through it by automatically closing down the orifice when the lift cylinder is lowering the mast. As the result, the descending speed of mast can be maintained constant irrespectively of whether the load is light or heavy.

In addition, since the right and left flow regulator valves are linked together, the lowering speed of mast by both cylinders can be even. NOTE Before disconnecting each pipe, prepare oil receivers to catch oils remaining in the pipes and hoses. Further, take appropriate measures for the connections of pipes and control valves to prevent dust and dirt from entering in the openings. Disconnect the return hose on the right and left lift cylinders at their connectors.

NOTE During this operation never touch the lift lever of the control valve. Push the lift lever of the control valve forward slowly to lower the mast. Prepare containers to catch oil, which should remain in the high-pressure hose. Before lifting up the inner mast, wrap the inner mast channel with a protective cloth and attach a wire rope around the inner mast in such a way that includes an extra turn.

NOTE The rod end section of the lift cylinder has some shims inserted, record the number of shims inserted in each cylinder, right or left, before removal. Attach a wire rope on the lift cylinder before removing the cylinder clamp. Follow the removal procedure in reverse while noting the following instructions.

When the fork tips reach the ground, stop the engine. Use two pieces of wire rope. Start the engine and retract the cylinder rod to minimum while lowering the crane. Then, stop the engine. NOTE This cap serves as to confine the oil to within the cylinder and prevent the cylinder rod from extending. Before lifting the tilt cylinders, be sure to attach both the right and left caps. Removing tilt cylinder Lift the tilt cylinder to be removed by a crane.

Remove the tilt cylinder pin mounting bolt. Remove the cylinder head and rod cover with Hook Wrench A. Special tool Truck model Hook wrench A. Piston rod. Support both ends of the piston rod with V-shaped blocks, and measure its runout using a dial gauge at the center while turning the piston rod.

Replace the piston rod, if it is seriously damaged in the threaded part. Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust. Apply a coat of oil to each inside surface of rings, bushings, and cylinder tube before reassembly.

Before tightening the rod cover, apply Loctite to the threaded part of the cylinder tube. Remove the guide bushing using Hook wrench A. Special tool Hook wrench A. Ring and packing First fit the one side of the piston seal into the mounting groove provided on the piston, then press-in the other side. Inspection and Adjustment 8. When the oil is checked immediately after operating the control lever, be careful not to mistake the bubbles of oil as a mixture with water.

Suction strainer, Return filter Check for damage or clogging, and clean or replace. This test operation is desirable to be performed on the test stand, however, since the actual service is impossible, use the following method with the gear pump installed on the truck.

Installing oil pressure indicator: Remove the plug from the connector of delivery hose and attach the following tool instead. At the neutral position the oil pressure meter must read 1 MPa Continue to run the engine in this condition for 10 minutes and listen to see if the pump generates abnormal sound. Then, adjust the adjusting screw to set the pressure to 3 MPa Continuously raise the pressure further by 2 MPa If the oil temperature or pump temperature abnormally rises, cancel the load and lower the temperature to continue the test operation, or disassemble the pump again to inspect the inside.

The gauge, connector, hose, etc. NOTE The reference amount of tightening-in of adjusting screw for relief valve is such that one turn varies the pressure for approx. Main relief valve pressure setting. NOTE The reference amount of tightening-in of adjusting plug is such that one turn produces a change of approx.

DPN: 40 mm 1. DPN: 41 mm 1. Retighten or replace. Replace pump. Mast height 3 to 5 m [9. Mast height 3 to 4. Mast assembly Bind the end of the lift chain with a rope, etc. Leave an approximately 3 m 9. Start the engine and raise the inner mast up to a position where the main rollers of the lift bracket come out. During this step, maintain the lift chain pulled downward. Lift the inner mast until it comes to a position where the main rollers of lift bracket can be removed, then reverse the truck to separate the lift bracket from the truck.

Lower the inner mast and stop the engine. Then, stop the engine and disconnect the hose. Remove the hose at the return connector side. Return connector. NOTE For this operation be sure to use a hoist having a capacity enough to support the mast assembly.

Lay it down flat with the lift bracket side facing upward on level ground. NOTE In order to avoid any obstruction in the subsequent disassembly, laying the removed mast assembly on a sufficient space in both directions of mast sliding toward the top and bottom.

When cylinder rod installation bolts are removed, make record of how many shims are used and which side of cylinder the shims are installed to. Show related SlideShares at end.

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Here is our extensive Caterpillar forklift manual collection PDF formats that includes the Caterpillar forklift repair and parts documentation that you need for your warehouse or forklift-supported operation.

These manuals contain all the parts, repair and maintenance information for your lift truck as provided by CAT. We can often find manuals. And even a few rare ones too. From electric lift trucks to internal combustion IC , Caterpillar has a wide range of forklifts to serve your materials handling needs.

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Just click through to the model you are looking for and download the PDF document to your device or computer. It just takes a few seconds of your time and you will then have the manual you need on. Do you need manuals for a different make or model of lift truck? Then please browse our other forklift manual content on this site:. Do you need help locating the correct manual for one of the Caterpillar forklifts at your facility?

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