This set includes following service manuals:
- caterpillar 4G63, 4G64, 6G72 Liquefied Petroleum Gas Supplement - 78 pages;
- caterpillar 4G63, 4G64 Fuel System Supplement - 247 pages;
- caterpillar GC15K, GC18K, GC20K, GC20K HP, GC25K, GC25K HP, GC30K Chassis & Mast - 310 pages;
- caterpillar GC15K, GC18K, GC20K, GC20K-HP, GC25K, GC25K-HP, GC30K Options Supplement - 24 pages.
This set comes in zip format, includes PDF files. We recommend to use Adobe PDF Reader, to be sure all images / graphics will display correctly.
Service manual (Liquefied Petroleum Gas Supplement) contains operating instructions and maintenance procedures for the LP-gas device of caterpillar LP-gas fuel lift trucks.
Service manual (Fuel System Supplement) has instructions and procedures for the 4G63, 4G64 Engine EPA Fuel Systems and is to be used in conjunction with the engine service manual. The information, specifications and illustrations used in this manual are based on information that was current at the time this issue was written.
Service manual (Chassis & Mast) is a guide to servicing the 1-ton to 3-ton internal combustion cushion models of Cat Lift Trucks. The instructions are grouped by systems to serve the convenience of your ready reference.
Service manual (Options Supplement) is a guide to servicing of the options for caterpillar Lift Truck models from 1.5-ton to 3.0-ton.
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
- 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
- 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
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