Caterpillar DP80 DP90 Low Noise Options Supplement Service Manual – PDF DOWNLOAD

99709-89101

Service Manual Low Noise Options Supplement DP80 DP90

T32B-00011-up T32B-50001-up

For use with DP80, DP90 Lift Trucks

FOREWORD

This manual is a supplement to the Service Manual for the standard version Caterpillar® Lift Truck DP80/90, Pub. No. 99709-89100. It contains service instructions unique to the low-noise version Caterpillar Lift Truck DP80/90. For information on items not covered in this supplement, please refer to the manual for the standard version DP80/90 lift truck.

Long productive life of your lift trucks depends to a great extent on correct servicing – the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing. Caterpillar reserves the right to change specifications or design without notice and without incurring obligation.

Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions: WARNING

Indicates a specific potential hazard resulting in serious bodily injury or death.

CAUTION

Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of, the machine.

NOTE

Indicates a condition that can cause damage to, or shorten service life of, the machine.

Pub. No. 99709-89101

WARNING

SAFETY WARNING The proper and safe lubrication and maintenance for this lift truck, recommended

by Caterpillar, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks.

Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance.

The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components.

Following is a list of basic precautions that should always be observed.

1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product.

2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welder’s gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery.

3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.

WARNING Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.

4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.

5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more.

Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

7. To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments.

8. Be careful when removing cover plates.

Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot.

10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

11. Reinstall all fasteners with same part number.

Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts.

12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck.

13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck.

Hang “Do not Operate” tag in the Operator’s Compartment.

14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

15. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.

18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly.

20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

TABLE OF CONTENTS General ...................................................................................................... 1 1. Measures to reduce radiator fan noise ..................................... 2 2. Measures to prevent engine noise from leaking through gap around radiator ....................................................................... 3 3. Addition of under cover ................................................................ 4 4. Insulator-lined engine-transmission compartment sides .... 5 5. Insulating the front area of the engine-transmission compartment .................................................................................... 6 6. Engine cover with increased sound-absorbing performance ..................................................................................... 7 7. Seat frame ........................................................................................ 8 8. Insulators on dashboard and cab floor .................................... 9 9. Measures to absorb differential gear noise ............................. 9 10. Cab ..................................................................................................... 10 11. Heater ................................................................................................ 11 12. Cab electrical equipment ............................................................. 12 Removal and installation of engine and transmission unit .......... 15

General The low-noise version of the DP80/90 lift truck features, in addition to all the characteristics its standard version incorporates, noise reducing and deadening measures that ensure quieter environment during operation both around the truck and in the operator’s compartment. These measures include the following: 1. A radiator cooling fan of improved air-blowing efficiency is used to reduce “voom” noise.

2. Noise damping material provided around the radiator at the rear of the engine-transmission compartment to effectively confine noise in the compartment.

3. Insulator-lined under cover is provided at the bottom of the engine-transmission compartment to impede propagation of noise.

4. The inside of the engine-transmission compartment is lined with noise damping material.

5. Noise damping material added to the area in front of the engine-transmission compartment helps confine noise in the compartment.

6. The engine cover having increased sound-absorbing performance effectively prevents engine-transmission compartment noise from reaching the cab through the top of the compartment.

7. The seat frame is designed to prevent the engine-transmission compartment noise and engine vibration from reaching the cab through the top of the compartment. The seat frame also serves as a cab mount.

8. The dashboard and cab floor use insulator to help prevent the engine-transmission compartment noise from reaching the cab through the top of the compartment.

9. The front surface of the front axle housing is covered with insulator to absorb the noise from the differential gear.

10. A cab is adopted to improve the operator’s acoustic environment.

11. The cab is equipped with a heater.

For further information on each of the noise reducing measures outlined above, refer to the corresponding pages in this supplement.

–1–

The following description pertains to those areas of the low-noise version trucks which are different from the standard version trucks.

1. Measures to reduce radiator fan noise (1) The radiator fan has an improved air-blowing efficiency and generates less noise.

(2) To achieve the above, the fan uses a large-diameter driven pulley a longer V-belt.

(3) To ensure adequate air flow, the fan assembly and its fitting parts have been changed. Also, a diffuser has been added.

(4) The new fan belt can be adjusted in the same procedure as with the standard version.

(5) The fan and V-belt can be removed and installed in the same procedures as with the standard version.

Airflow Airflow

208988

–2–

2. Measures to prevent engine noise from leaking through gap around radiator (1) The radiator is cowled around to confine the engine noise inside.

(2) The radiator access cover is of a special structure for a higher sound-proof capability.

(3) The radiator, its hoses and other related parts are basically the same as those of the standard version trucks except the heater return pipe which is connected to the radiator lower hose.

(4) The radiator must be removed complete with the cowling.

208989

Cowling around the radiator

208990

Radiator access cover

–3–

3. Addition of under cover (1) An insulator-lined under cover, consisting of four parts (1 to 4), is provided at the bottom of the enginetransmission compartment to confine noise from the engine and transmission in the compartment.

(2) The under cover must be removed and installed from under the truck.

208991

–4–

4. Insulator-lined engine-transmission compartment sides (1) The inside surfaces of the engine-transmission compartment side walls are lined with insulator to absorb and effectively confine engine and transmission noise in the compartment.

208992

–5–

5. Insulating the front area of the engine-transmission compartment (1) To effectively confine engine and transmission noise, the front area of the engine-transmission compartment (the rear area of the front axle housing) and the area above the front axle housing are closed with insulator.

208993

–6–

6. Engine cover with increased sound-absorbing performance (1) The low-noise version uses an engine cover lined with insulator which has a sound absorbing capability higher than that of the standard version trucks.

208994

–7–

7. Seat frame (1) A seat frame with insulator is used to impede transmission of engine and transmission noise and dampen engine vibration before being transmitted to the cab. The seat frame also serves as a cab mount.

(2) The standard version does not use the seat frame or any other similar structure.

(3) The seat frame is installed via four mounts (b) onto the truck frame using four bolts (a). To the seat frame, the steering column, parking brake lever, heater and other components are attached. The seat frame can be removed by removing the bolts (a) while supporting it with a hoist.

208995

–8–

8. Insulators on dashboard and cab floor (1) The operator’s foot area in the dashboard and cab floor is covered with noise insulating material to dampen noise being transmitted through the area.

(2) A vinyl mat is fitted over the top surface of the dashboard.

(3) A thick mat is laid over the cab floor.

9. Measures to absorb differential gear noise (1) The front portion of the front axle housing is covered all around with pieces of insulator material.

208996

–9–

10. Cab (1) A cab has been designed to achieve a quieter operator’s compartment.

(2) The cab is equipped with a heater.

(3) The cab’s three windows (front, rear and roof windows) are equipped with wipers.

(4) The cab can be equipped with optional rear working lamp and strobe lamp.

(5) The cab can be removed in the following procedure.

• Disconnect the lighting system wiring wherever appropriate.

• Attach slings to the four hanger brackets on the cab roof, then attach the slings onto the hoist. (Do not lift the cab at this stage.)

• Remove the four cab mounting bolts B. • Lift the cab.

When installing the cab, follow the removal procedure in reverse.

(6) The cab weighs approximately 300 kg (660 lbs).

208997

– 10 –

11. Heater (1) The heater uses the heat of the engine jacket water (hot water) that is made to circulate through the heater core.

Air is blown by the fan through the heater core and heated air is distributed throughout the cab interior.

(2) • The air flow is switchable between “fresh air introduction” and “inside air circulation”.

• The air flow direction can be switched between “heating” and “defrosting”. While there are two air outlets, only one of these is used.

• A desired air flow rate can be selected from the “HIGH”, “MIDDLE” and “LOW” positions.

Diesel engine

Valve Defroster outlet

Heater

Radiator

Inside air circulation Heating air outlet

To engine water pump

Fresh air

Air inlet duct

Heater bracket

208998

– 11 –

12.Cab electrical equipment 1. The cab comes standard with the following electrical equipment.

(1) Front wiper motor (2) Rear wiper motor

For items (1) to (5), refer to the cab harness wiring diagram on page 13.

(3) Roof wiper motor (4) Washer motor (5) Room lamp (one) (6) Front head lamp (one on each side, two in total) (7) Front combination lamp (one on each side, two in total) (8) Rear combination lamp (one on each side, two in total) (9) Heater

For items (6) to (8), refer to the lighting circuit diagram in the Service Manual for the standard version DP80/90.

For item (9), refer to the cab harness wiring diagram on page 13.

2. The following items can be installed on the cab as optional equipment.

Refer to the lighting circuit diagram in the Service Manual for the standard version DP80/90.

(1) Rear working lamp (one) (2) Strobe lamp (one)

3. Before disconnecting connectors/terminals, put marks on them and relevant wires in order to facilitate reconnection.

4. Wiring harness terminals located in the cab are as shown below.

Left front of cab

Right front of cab

Front combination lamp GR GL

6

R

9

7 1 8 5 4

3

2

208999

209000

Connectors terminals for wipers, room lamp, rear working lamp, and strobe lamp No.

Color

9

WR

Washer motor

8

LB

Front wiper motor

7

LR

Front wiper motor

6

LW

Front wiper motor

5

R

Room lamp

4

RB

Strobe lamp

3

RY

Rear working lamp

2

W

Wiper motor power

1

B

Ground wipper motor

Connectors/terminals for head lamps and combination lamps

Connection

– 12 –

– 13 –

Truck side

Front wiper SW

Cab power

Rear working lamp SW (OP)

Strobe lamp SW (OP)

18 19 20

20

W WB

R 1

2

5

4

LW 8 LY 7 L 6

LW 14 LY 13 LB 11

9

20

18

16

19

Heater switch

Cab side

B

WR

LB LR LW

19 18

RB RY

Roof wiper SW

Rear wiper SW

Front wiper motor

20 19 18 15

20 15

18

15

LW LR LB L

19 18

19 20

16

RL 17 WR 16

8 5

LW LY LB

3

9 5 7 8

9 7

LW LY LB

1

8

5

Lo Med Hi

7

9

W LW LY B

Heater

B W LY LW

Washer motor

Room lamp

Roof wiper motor

17

16 17

Color code R: Red B: Black W: White L: Blue LB: Black on blue background LR: Red on blue background

2 RB

M

209001

Rear wiper motor

Fan motor

14 10 12 13

12 12 14 13 13 10 10 14

4

Strobe lamp (OP)

Working lamp (OP)

White on blue background Yellow on blue background Black on red background Blue on red background Yellow on red background Red on white background

RY

LW: LY: RB: RL: RY: WR:

5. Cab harness wiring diagram

Cab harness cables connection table Circuit

Color

Connection

20

LW

Front wiper motor – Front wiper switch

19

LR

Front wiper motor – Front wiper switch

18

LB

Front wiper motor – Front wiper switch

17

RL

15 – Washer motor

16

WR

Front wiper switch – Washer motor

15

L

14

LW

Rear wiper motor – Rear wiper switch

13

LY

Rear wiper motor – Rear wiper switch

12

W

5 – Rear wiper motor

11

LB

5 – Rear wiper switch

10

B

Rear wiper motor – 9

9

B

Roof wiper motor – Body ground

8

LW

Roof wiper motor – Roof wiper switch

7

LY

Roof wiper motor – Roof wiper switch

6

L

5

W

Fuse box – Roof wiper motor

4

RY

Body working lamp switch – Working lamp

3

B

2

RB

1

R

5 – Front wiper motor

5 – Roof wiper switch

Cab ground – 9 Body strobe lamp switch – Strobe lamp Fuse box – Room lamp

– 14 –

Removal and installation of engine and transmission unit As far as removal and installation operations of the engine and transmission unit are concerned, the low-noise version has the following two major differences from the standard version in the structure.

(1) A cab is used in the low-noise version, while a head guard is used on the standard version. Using the cab involves addition of the seat frame in the low-noise version.

(2) An under cover is provided at the bottom of the engine-transmission compartment in the low-noise version.

When removing the engine and transmission unit, first remove the cab and under cover and then remove the seat frame.

1. Cab removal Remove the cab by following the removal procedure on page 10.

2. Seat frame removal Make the following preparations prior to removing the seat frame.

(1) Steering column • Disconnect the connectors of the harnesses around the steering column (buzzer and turn signal lamp harnesses).

• Leave the steering column installed on the seat frame.

(2) Parking brake • Disconnect the parking brake cable from the parking brake lever.

(3) Engine coolant line for heater • Disconnect the coolant hose from the heater core unit.

(4) Harnesses and wires • Disconnect the connectors of those harnesses and wires which would otherwise be pulled when the seat frame is lifted.

The subsequent steps to be followed to remove the engine and transmission unit is basically the same as that with the standard version (refer to the Service Manual for the standard version DP80/90, Pub. No. 99709-89100).

When reinstalling the unit, follow the removal sequence in reverse.

– 15 –

Memo

TECHNICAL PUBLICATIONS FEEDBACK (Please print)

Dealer name: __________________________

Submitted by: _________________________

Address: _____________________________

P. O. Box: ____________________________

City: ________________________________

State: ________________________________

Zip code: _____________________________

Country: _____________________________

The following discrepancy or omission has been discovered in: Operation & Maintenance Manual

Option Bulletin

Part List/Manual

Special Instruction

Service Manual

Service Data Manual

Electronic Manual

Other: ___________________________

Publication # ________________________

Engine model # ________________________

Truck model # _______________________

Issue date # ___________________________

Truck serial # _______________________

Page # _______________________________

(Please print)

Explanation of discrepancy or omission: _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________

Please fax or mail completed form to: Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2011 W. Sam Houston Parkway N. Houston, Texas 77043-2421 Fax: 713-365-1616

Mitsubishi Caterpillar Forklift Europe B.V. Attn: Service Engineering P. O. Box 30171 1303 AC, Almere, The Netherlands Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. Attn: Service Engineering No. 2 Tuas Avenue 20 Singapore 638818 Republic of Singapore Fax: 65-861-9277

Service Manual

DP80, DP90 Low Noise Options Supplement

Pub. No. 99709-89101

Mitsubishi Caterpillar Forklift Europe B.V. Hefbrugweg 77 1332 AM Almere, The Netherlands

99709-89101

Copyright © 2001 by MCFA. All Rights Reserved.

CATERPILLAR and CAT are registered trademarks of Caterpillar Inc.

Printed in the U.S.A.