GC15K-18K-20K-20K-HP-25K-25K-HP-30K Service Repair Manual PDF Download

GC15K 18K 20K 20K HP 25K 25K HP 30K Forklift Trucks Caterpillar Cat workshop service repair manual download This product includes following Service Manuals: - Caterpillar 4G63, 4G64, 6G72 Liquefied Petroleum Gas Supplement; - Caterpillar 4G63, 4G64 Fuel System Supplement; - Caterpillar GC15K, GC18K, GC20K, GC20K HP, GC25K, GC25K HP, GC30K Chassis & Mast; - Caterpillar GC15K, GC18K, GC20K, GC20K-HP, GC25K, GC25K-HP, GC30K Options Supplement. This set comes in zip format, includes PDF files. For work with product you need to use these applications: 7-Zip (or any analog) and Adobe PDF Reader.. Serial Numbers: Liquefied Petroleum Gas Supplement 4G63 AA0001-ZZ9999 4G64 AA0001-ZZ9999 6G72 0A0001-0Z9999 Chassis & Mast GC15K AT81C-00011-up AT81D-00011-up AT81E-00011-up GC18K AT81C-00011-up AT81D-00011-up AT81E-00011-up GC20K AT82C-00011-up AT82D-00011-up AT82E-00011-up GC20K HP AT82C-90011-up AT82D-90011-up AT82E-90011-up GC25K AT82C-00011-up AT82D-00011-up AT82E-00011-up GC25K HP AT82C-90011-up AT82D-90011-up AT82E-90011-up GC30K AT83C-00011-up AT83D-00011-up AT83E-00011 Options Supplement GC15K AT81C-00001-99999 GC18K AT81C-00001-99999 GC20K AT82C-00001-89999 GC20K-HP AT82C-90001-99999 GC25K AT82C-00001-89999 GC25K-HP AT82C-90001-99999 GC30K AT83C-00001-99999 TABLE OF CONTENTS (Liquefied Petroleum Gas Supplement): Types of LP-gas Guideline for selecting LP-gas for lift-truck engines LP-gas knock rating and octane number Adverse effects of olefins on LP-gas fuel system Vapor pressure vs. temperature for mixture of propane and normal butane Structure and Function 1.Outline of LP-gas device 2.LP-gas device layout 3.Main component structures Actions to be taken in the event of a failure Troubleshooting Disassembly and reassembly 1.Main components of LP-gas device (4G63, 4G64) 2.Main components of LP-gas device (6G72) 3.Disassembly and reassembly of LP-gas carburetor /mixer 4.Disassembly and reassembly of converter/regulator (vaporizer) 5.Disassembly and reassembly of LP-gas filter, Fuel lock Inspection and adjustment 1.LP-gas tank inspection 2. Filter inspection 3.Converter (vaporizer) inspection and adjustment 4.Idle speed adjustment 5.Output power adjustment 6.Gas leak check procedure Introduction 1. Outline of CARB Tier 1 LP-gas system 2. CARB Tier 1 LP-gas layout 3. Main Component Illustrations Systems Operations 1. Explanation of Operation 2. Terminology Sub-system Operating Principles 1. Fuel Control 2. Fuel Control Operation 3. Throttle and Governor 4. Throttle and Governor Operation 5. Operating Specifications System Adjustments 1. Diagnostic Kit Installation 2. Adjustments 3. S15G Screen Layout S-15G Troubleshooting 1. Troubleshooting Problem Detail 2. Troubleshooting Tree Detail 3. Check Engine Light Blink Codes 4. System Fault Codes 5. Effects of Fault Conditions Vacuum System Diagram and Wiring Schematics 1. Vacuum System Diagram 2. S-15G Fuel System Wiring Schematic 3. ECU Pin Location and Function Inspection and Adjustment 1. Periodic Inspection Schedule TABLE OF CONTENTS (Fuel System Supplement): General General Information Notes, Cautions, and Warnings Fuel Systems Cautions English and Metric Fasteners Handling Electrostatic Discharge (ESD) Sensitive Parts Glossary of Terms Maintenance Maintenance Cooling System Engine Electrical System Maintenance Engine Crankcase Oil Checking/Filling Engine Oil Level Changing the Engine Oil Fuel System Inspection and Maintenance Manufacturer’s Recommended Maintenance Intervals LPG Fuel System Operation Typical LPG Fuel System Schematic Descriptions and Operation of the Fuel Systems Temperature Manifold Absolute Pressure Sensor (TMAP) LPG Fuel System Diagnostics LPG Fuel System Diagnosis Fuel System Description Diagnostic Aids LPG Fuel System Diagnosis Chart Symptom Diagnosis Symptom Diagnosis Wiring Schematics On-Vehicle Service Wire Harness Repair Communication Port C002 Oil Pressure Connector C003 Heated Oxygen Sensor (HEGO) Connector C004 Fuel Trim Valve (FTV) Connector C005 TMAP Connector C006 Coil Connector C007 Magnetic Pickup Connector C008 Throttle Connector C009 Pressure Trim Valve (PTV) Connector C010 Starter Solenoid Connector C011 Engine Coolant Temperature Sensor (ECT) Battery Positive Connector C014 Battery Positive Connector C015 Alternator Connector C016 Alternator Connector C017 Instrument Panel Connector C018 Instrument Panel Connector C019 Diagnostic Trouble Codes Description of ECM Based Diagnostics Using a Laptop Computer to Diagnose the System Connecting a Laptop Computer to the System Diagnostic Trouble Codes Data Stream Graphing and Data Logging Ignition System Testing Throttle Test Diagnostic Communication Error OBD System Check/Malfunction Indicator Lamp OBD System Check Troubleshooting Chart DTC 111-IAT High Voltage DTC 112-IAT Low Voltage DTC 113-IAT Higher Than Expected 1 DTC 114-IAT Higher Than Expected 2 DTC 115-Oil Pressure Low DTC 121-ECT High Voltage DTC 122-ECT Low Voltage DTC 123-ECT Higher Than Expected 1 DTC 124-ECT Higher Than Expected 2 DTC 131-MAP High Pressure DTC 132-MAP Low Voltage DTC 134-BP High Pressure DTC 135-BP Low Pressure DTC 142-Crank Sync Noise DTC 143-Never Crank Synched at Start DTC 211-Closed Loop Multiplier High (LPG) DTC 212-HO2S Open/Inactive DTC 224-Closed Loop Multiplier Low (LPG) DTC 243-Adaptive Lean High (LPG) DTC 244-Adaptive Lean Low (LPG) DTC 261-System Voltage Low DTC 262-System Voltage High DTC 511-COP Failure DTC 512-Invalid Interrupt DTC 513-A/D Loss DTC 514-RTI 1 Loss DTC 515-Flash Checksum Invalid DTC 516-Ram Failure DTC 531-External 5 Volt Reference Lower Than Expected DTC 532-External 5 Volt Reference Higher Than Expected DTC 554-Gaseous Fuel Lo Rev Overrun DTC 555-RTI 2 Loss DTC 556-RTI 3 Loss DTC 611-FPP High Voltage DTC 612-FPP Low Voltage DTC 613-FPP Higher Than IVS Limit DTC 614-FPP Lower Than IVS Limit DTC 631-TPS 1 Signal Voltage High DTC 632-TPS 1 Signal Voltage Low DTC 633-TPS 2 Signal Voltage High DTC 634-TPS 2 Signal Voltage Low DTC 635-TPS 1 Higher Than TPS 2 DTC 636-TPS 1 Lower Than TPS 2 DTC 637-Throttle Unable to Open DTC 638-Throttle Unable to Close DTC 651-Maximum Governor Speed Override DTC 652-Fuel Rev Limit DTC 653-Spark Rev Limit DTC 721-Transmission Over Temperature Fuel System Repair Instructions Throttle Body Assembly Replacement Engine Coolant Temperature Sensor Replacement Coolant Hose Replacement Vapor Hose Replacement Balance Line Hose Replacement PTV Hose Replacement FTV Hose Replacement Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor Replacement Three Way Catalytic Converter Muffler Replacement Magnetic Sensor Replacement Timing Wheel Replacement Timing Wheel Replacement Without Special Tool Magnetic Pickup Sensor Air Gap Adjustment GROUP INDEX (Chassis & Mast): GENERAL INFORMATION Vehicle Exterior, Models, Serial Number Locations, Dimensions, Technical Data (Standard Models) COOLING SYSTEM Structure and Function, Removal and Installation, Inspection and Adjustment ELECTRICAL SYSTEM Console Box – Disassembly and Reassembly, Major Electrical Components, Battery Maintenance, Lamp Bulb Specifications, Troubleshooting, Electrical Schematic POWER TRAIN Removal and Installation POWERSHIFT TRANSMISSION Structure and Function, Removal and Installation, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data FRONT AXLE AND REDUCTION DIFFERENTIAL Structure and Function, Removal and Installation, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data REAR AXLE Structure and Function, Removal and Installation, Rear Axle Assembly, Steering Cylinder, Adjustment, Troubleshooting, Service Data BRAKE SYSTEM Structure and Functions, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data STEERING SYSTEM Structure and Functions, Removal and Installation, Streering Gear, Troubleshooting, Service Data FUEL SYSTEM Outline of Dual Fuel Type HYDRAULIC SYSTEM Hydraulic Tank, Hydraulic Pump, Control Valve, Lift Cylinder, Tilt Cylinder, Structure and Functions, Removal and Installation, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data MAST AND FORKS Mast Systems, Structure, Removal and Installation, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data SERVICE DATA Maintenance Chart, Tightening Torques for Standard Bolts and Nuts, Planned Replacement Parts, Lubrication Chart, Weight of Major Components, Special Service Tools, Inspection Guide TABLE OF CONTENTS (Options Supplement): REAR COMBINATION LAMP KIT WORKING LAMP KIT WARNING LAMP KIT BACK BUZZER PIEZO KIT BACK MIRROR KIT OIL FILTER KIT (1-ton model) OIL FILTER KIT (2-, 3-ton models) ENCLOSED ALTERNATOR KIT SPARK PLUG KIT FASTENER KIT FRONT AXLE BREATHER KIT WIDE AXLE KIT (2-, 3-ton models) SEMI WIDE AXLE KIT (1-ton model) SEMI WIDE AXLE KIT (2-, 3-ton models) DUAL ELEMENT KIT DUST INDICATOR KIT File Size: 16 Mb File Format: PDF Language: English 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