CATERPILLAR CAT DP115 FORKLIFT LIFT TRUCKS Service Repair Manual SN：4DP00011 and up

GENERAL INFORMATION

SENB8596

TRUCK MODELS COVERED This Service Manual furnishes servicing and maintenance information for the following trucks:

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SENB8596

GENERAL INFORMATION

NAMEPLATE AND SERIAL NUMBER LOCATIONS

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GENERAL INFORMATION

SENB8596

TECHNICAL DATA

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GENERAL INFORMATION

SENB8596

DIMENSIONS (APPROXIMATE)

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SENB8596

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GENERAL INFORMATION

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COOLING SYSTEM

SENB8596

SPECIFICATIONS

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COOLING SYSTEM

SENB8596

DESCRIPTION

The radiator with a tube-and-fin type core comes standard. The fins are corrugated. The cooling fan is of pusher type and has eight blades to provide high cooling efficiency. The lower tank has a built-in

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transmission oil cooler which, in operation, is constantly removing heat from the transmission oil returning from the torque converter.

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COOLING SYSTEM

SENB8596

REMOVAL AND INSTALLATION

Start by: a)

Remove the gas-filled cylinder and engine hood.

b)

Remove the radiator cover.

c)

Loosen the radiator drain cock to drain coolant from the radiator.

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COOLING SYSTEM

Suggestions for removal (1)

Fasten a hoist to the radiator and sling the radiator.

(2)

Remove the radiator mounts (at 4 places) and lift off the radiator.

Inspection (1)

Blow dirt and bugs, if any, from the radiator fins with compressed air. Be careful not to bend the fins because this will decrease cooling efficiency.

(2)

Replace the radiator if the fins are damaged beyond repair.

(3)

Check the rubber cushions of the radiator mounts for condition. Replace them if damaged or deteriorated.

(4)

Check the radiator hoses, upper and lower, for condition. Replace them if defective.

Installation To install, follow the reverse of removal sequence.

(1)

Slide the hoses on to the tubes of the radiator and tighten all the clamps. Make sure the hoses are properly clamped at flared portions of the tube.

(2)

Fill the cooling system with coolant to the correct level. Start the engine and, with the engine running at low idle, listen for any abnormal noise.

Check to be sure the coolant level in the reserve tank is correct.

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COOLING SYSTEM

SENB8596

TROUBLESHOOTING

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ELECTRICAL SYSTEM

SENB8596

SPECIFICATIONS

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ELECTRICAL SYSTEM

SENB8596

LOCATION OF COMPONENTS

For the components to which harnesses A, B and C are connected, see the pages which follows.

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SENB8596

ELECTRICAL SYSTEM

Harness A

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SENB8596

ELECTRICAL SYSTEM

Circuit numbers and color codes of harness A

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SENB8596

ELECTRICAL SYSTEM

Harness B (on the left side of engine room)

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SENB8596

COOLING SYSTEM

Harness C (on the right side of engine room)

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ELECTRICAL SYSTEM

SENB8596

DESCRIPTION Console Box 1 Engine coolant temperature gauge 2 Torque converter oil temperature gauge 3 Fuel gauge 4 Hour meter 5 Central vehicle monitoring system 6 Starter switch 7 Lighting switch 8 OK monitor check switch 9 Fuse box 10 Speed selector switch

Central vehicle monitoring system

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SENB8596

ELECTRICAL SYSTEM

Components in console box

Spare power source (terminal) The spare terminal is located on the lead from the fuse box in the control box. (Another spare terminal is located on the main harness side of the chassis.)

Cord color: LG (yellow/green) The step required to gain access to the spare terminal is to remove the rear panel of the control box. The terminal is taped to the harness protector.

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SENB8596

ELECTRICAL SYSTEM

Side Instrument Panel

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ELECTRICAL SYSTEM

Fuses

Optional fuses

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ELECTRICAL SYSTEM

SENB8596

Major Components Electronic control unit (ECU)

The electronic control unit (ECU) has a built-in 1-chip microcomputer. This computer processes signals from the travel speed sensor for actuating the speed selector system.

The ECU has “self-diagnostic� failure indicator lights which come on when any problem occurs in the electrical system, thereby allowing the operator to locate the problem. It has the following fail-safe systems so that failure of power, control circuit, or other components will not endanger the operator.

Fail-safe system

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SENB8596

ELECTRICAL SYSTEM

Starter switch (anti-restart type) This switch has a built-in mechanical lockout. This lockout restrains the key from turning to START position from ON position (as when the engine is

running) help to prevent damage to the starter pinionor flywheel ring gear. The ON position of the switch is for energizing the air heater.

Light Switch

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ELECTRICAL SYSTEM

SENB8596

LIGHT BULB SPECIFICATIONS

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SENB8596

ELECTRICAL SYSTEM

Combination Meter Disassembly

Assembly Follow the reverse of disassembly sequence.

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SENB8596

ELECTRICAL SYSTEM

Indicator bulb replacement 1.

2.

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Rear panel removal (on machine) (1)

Remove the screws (four) that hold the rear panel, and separate the rear panel from the meter panel and front panel.

(2)

Remove the bulbs from the printed circuit board by turning them counterclockwise.

Location of bulbs (on printed circuit board) 1

Brake fluid level indicator

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Fuel filter indicator (option)

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Air heater indicator

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Alternator indicator

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Engine oil pressure indicator

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Turn signal indicator

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Air cleaner indicator (option)

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Fuel level indicator (option)

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Engine coolant level indicator (option)

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Working light indicator (option)

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High-beam indicator (option)

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Instrument panel light

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SENB8596

ELECTRICAL SYSTEM

Side Instrument Panel Disassembly

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SENB8596

ELECTRICAL SYSTEM

Assembly Follow the reverse of disassembly sequence.

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ELECTRICAL SYSTEM

SENB8596

BATTERIES 1. Electrolyte specific gravity (S.G.) reading and battery condition

To check the battery for charging, take hydrometer readings on its electrolyte: the battery may be deemed to be fully charged if the readings are between 1.260 and 1.280 at normal temperature. The tendency of the charging system can be told from the way the electrolyte level goes down to expose cell plates. If refilling (with distilled water) is necessary every month or so, the system is tending to over-charge the battery.

If refilling is not required for over 3 months, it is likely that the system is inadequately charging.

(3) During charging, adjust the charging current to prevent the battery electrolyte temperature from rising beyond 45°C (113°F).

(4) When connecting the cables to the battery, begin with the cable for the positive (+) terminal. When disconnecting them from the battery, begin with the cable for the negative (–) terminal.

2. Precautions for battery charging (1) In slow-charging a dead battery, the charging current should be about 1/10 the capacity of the battery to be charged.

(2) In quick-charging the battery, the battery capacity in ampere should not be exceeded.

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SENB8596

ELECTRICAL SYSTEM

Installation of automatic engine stop solenoid 1. Install the solenoid switch and levers in position on the bracket.

2. Push plunger (1) in all the way. Move stop lever (2) (engine side) all the way to STOP position. Under this condition, adjust the length of solenoid rod (3) and connect it to the lever.

3. After installing the switch, move the engine stop lever to RUN position by hand to make sure the plunger end is not projecting from the solenoid switch.

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ELECTRICAL SYSTEM

SENB8596

TROUBLESHOOTING Starter System

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ELECTRICAL SYSTEM

Lighting System

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ELECTRICAL SYSTEM

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