caterpillar GP15N, GP18N, D20N, DP25N, DP30N, DP35N Lift Trucks Service Manuals PDF

These Service Manuals describe the specifications, maintenance, and service procedures for Mitsubishi diesel engines. Electronic material is a guide to servicing Cat® Lift Trucks. Factory instructions are grouped by systems to serve the convenience of your ready reference. The tutorial also covers general information about service data, service tools, overhaul, disassembly and inspection section, operation instruction, many screenshots, diagrams, and schemes.

Important Notice Wiring Diagrams/Schematics are NOT included

To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involve the disassembly, inspection, repair, and reassembly of the engine and engine parts. An online text comes in PDF format, includes 601 pages for reading. All pages are printable and readable. We recommend using Adobe PDF Reader, to be sure all images/graphics will display correctly.

Truck models covered in this manual:
• MC Truck (Mechanical Control System) Mechanically controlled hydraulic system (conventional lever system)
• FC Truck (Finger-tip Control System) Electronically controlled hydraulic system

This set includes:
- caterpillar Chassis & Mast MC/FC GP15N, GP18N, GP20CN, GP20N, GP25N, GP30N, GP35N Lift Trucks - 423 pages;
- caterpillar S4S Diesel Engine D20N DP25N DP30N DP35N Lift Trucks - 178 pages.

Serial numbers:
GP15N ET34L-00011-up
GP18N ET34L-40001-up
GP20CN ET34L-60001-up
GP20N ET17DL-00011-up
GP25N ET17DL-50001-up
GP30N ET13FL-00011-up
GP35N ET13FL-50001-up
DP15N ET16D-00011-up
DP18N ET16D-40001-up
DP20CN ET16D-60001-up
DP20N ET18C-00011-up
DP25N ET18C-50001-up
DP30N ET14E-00011-up
DP35N ET14E-50001-up

180396-up
DP20N P4000
DP25N P5000
DP30N P6000
DP35N P6500
            P7000

CONTENTS of S4S Diesel Engines Service Manual:

• GENERAL
  • External view
  • System flow diagrams
  • Engine serial number location
  • Main specifications
  • Tips on disassembling and reassembling
• SERVICE DATA
  • Maintenance service data
  • Tightening torque table
• SERVICE TOOLS
  • Special tool
• DETERMINATION OF OVERHAUL
  • Determining overhaul timing
  • Testing compression pressure
• DISASSEMBLY OF BASIC ENGINE
  • Disassembling and inspecting cylinder head and valve mechanism
  • Disassembling and inspecting flywheel
  • Disassembling and inspecting damper, gear case, timing gear and camshaft
  • Disassembling and inspecting piston, connecting rod, crankshaft and crankcase
• INSPECTION AND REPAIR OF BASIC ENGINE
  • Inspecting and repairing cylinder head and valve mechanism
  • Inspecting and repairing flywheel
  • Inspecting and repairing timing gear and camshaft
  • Inspecting and repairing piston, connecting rod, crankshaft and crankcase
• REASSEMBLY OF BASIC ENGINE
  • Reassembling piston, connecting rod, crankshaft and crankcase
  • Reassembling timing gear and camshaft
  • Reassembling flywheel
  • Reassembling cylinder head and valve mechanism
• FUEL SYSTEM
  • Removing fuel system
  • Disassembling, inspecting and reassembling fuel system
  • Installing fuel system
• LUBRICATION SYSTEM
  • Removing lubrication system
  • Disassembling, inspecting and reassembling lubrication system
  • Installing lubrication system
• COOLING SYSTEM
  • Removing cooling system
  • Disassembling, inspecting and reassembling cooling system
  • Installing cooling system
• INLET AND EXHAUST SYSTEMS
  • Removing turbocharger, inlet and exhaust system
  • Disassembling, inspecting and reassembling inlet and exhaust systems
  • Installing inlet and exhaust systems
• ELECTRICAL SYSTEM
  • Removing electrical system
  • Disassembling, inspecting and reassembling electrical system
  • Installing electrical system
• ADJUSTMENT AND OPERATION
  • Adjusting engine
  • Break-in operation
  • Performance test (JIS standard)

GROUP INDEX of Chassis & Mast MC/FC Service Manual:

• GENERAL INFORMATION
  • Model view
  • Truck models covered
  • Serial number locations
  • Dimensions
  • Technical data
• COOLING SYSTEM
  • Fan removal and installation
  • Fan belt inspection and adjustment
• ELECTRICAL SYSTEM
  • Console box
  • Chassis electrical devices
  • Battery maintenance
  • Electrical system schematic
• CONTROLLERS
  • Main functions
  • Service tool functions
  • Input/output monitor
  • Error codes and troubleshooting
• POWER TRAIN
  • Removal and installation
• POWERSHIFT TRANSMISSION
  • Torque converter
  • 1-speed transmission
  • Control valve
  • Automatic 2-speed transmission
• FRONT AXLE AND REDUCTION DIFFERENTIAL
  • Front tires
  • Front axle
  • Reduction and differential
  • REAR AXLE
  • Rear tires
  • Rear axle
  • Toe-in
  • Minimum turning radius
• BRAKE SYSTEM
  • Master cylinder
  • Wheel cylinders
  • Wheel brakes
  • Brake booster
• STEERING SYSTEM
  • Steering gear
  • Power cylinder
  • Flow divider
• HYDRAULIC SYSTEM
  • Hydraulic tank
  • Gear pump
  • Control valve
  • Lift and tilt cylinders
  • Flow regulator valve
  • Down safety valve
• MAST AND FORKS
  • Simplex mast
  • Duplex mast
  • Triplex mast
• SERVICE DATA
  • Maintenance standards
  • Periodic service chart
  • Periodic replacement parts
  • Lubrication instructions
  • Special tools