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
Requirements: Adobe PDF Reader