Free Online Preview
Contents
1. Lift Trucks Service Manual Chassis amp Mast GC15K GC18K GC20K GC20K HP 81 00011 AT81D 00011 up AT81E 00011 up AT81C 00011 up AT81D 00011 up AT81E 00011 up AT82C 00011 up AT82D 00011 up AT82E 00011 up AT82C 90011 up AT82D 90011 up AT82E 90011 up GC25K GC25K HP GC30K For use with 4G63 4G64 Engine Service Manual and Liquefied Petroleum Gas Supplements AT82C 00011 up AT82D 00011 up AT82E 00011 up AT82C 90011 up AT82D 90011 up AT82E 90011 up AT83C 00011 up AT83D 00011 up AT83E 00011 up 99719 80150 FOREWORD This service manual 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 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 For the items pertaining to the engines refer to the following service manuals 4G63 4G64 Gasoline Engine Service Manual Pub No 99729 74120 For use with both gasoline and LP Gas engines 4G63 4G64 LP Gas Supplement Pub No 99729 85100 For use with LP Gas units with a D in the chassis serial numbe2. START oo 3 5 ELECTRICAL SYSTEM Lighting Switch OFF 1st 2nd Knob position 8 18 Stroke 0 3 0 3 Unit mm in HUNC P AARI dp 206481 Tail lamps licence plate lamp instrument lamp Battery fuses Working lamps option 3 6 Fuse Lim t b t 06509900 0096 LLL 101441D Spare Terminals The spare terminal cord extends from the fuse box in the console box Another spare terminal is located on the chassis side main harness Removing the console box rear panel will expose this spare terminal which is fastened to the harness protector with vinyl tape 3 7 ELECTRICAL SYSTEM Stop lamp turn signals backup lamps Spare terminal Tail lamps clearance lamps working lamps option Instrument panel lamps Head lamps Spare terminal 206424 ELECTRICAL SYSTEM Battery Maintenance 1 State of charge and electrolyte specific gravity adjustment specific gravity Specific gravity reading at 20 C 68 F State of charge Adjustment 1 280 to 1 265 Fully charged If difference in S G between any two cells is 0 020 or more effect a high current discharge to minimize the difference and then recharge battery Adjust S G during recharging 1 260 to 1 225 One half charged Recharge battery and adjust electrolyte S G Make sure there is neither faulty components loosely connected cord nor corroded con
3. BACK UP LAMP 10 W M p n RN Sio NAL LAMP mjg STO j AND TAIL LAMP OPTION 4 MALE SIDE OF CONNECTOR SHOWN 3 TERMINAL ARRANGEMENT OF CONNECTOR SHOWN BY MARK MUST BE TO CONSOLE BOX INSTRUMENT ARRANGEMENT 2 CIRCUIT SHOWN BY CHAIN DOUBLE DASH LINE MUST BE OPTIONAL CIRCUIT NOTES 1 UNLESS OTHERWISE SPECIFIED WIRE SIZE MUST BE 1 25mm2 REAR COMBINATION LAMP CONNECTOR FOR TURN SIGNAL SVV OP SHIFT LEVER CHART PE wer FOL GR c Lowe RAME HARNESS HEAD LAMP J REVERSER FLW 085 GC15K AT81C 00011 GC18K AT81C 00011 GC20K AT82C 00011 5019 80150 99719 80150 GC20K HP AT82C 90011 GC25K AT82C 00011 mE CA i emm inn m RB HEAD LAMP 12 V iub Es ALTERNATOR RELAY E m OIL PRESSURE SWITCH H GC25K HP AT82C 7 90011 m ENGINE GROUP BRAKE FLUID COOLANT SENSOR eed GC30K AT83C 00011 CONNECTOR FOR FRONT LAMP SWITCH OP SENSOR COMBINATION LAMP OP ENGINE THERMO UNIT T C THERMO SWITCH WITCH DUST INDICATOR OP FUEL TANK UNIT COEUNT Pub No 99719 80150 ALTERNATOR ENGINE GROUP 12 V 50A 3 13
4. C Fork spacing out to out 200 820 200 920 200 960 minimum maximum 8 0 32 3 8 0 36 2 10 38 ork length 1067 42 Tilt angle forward backward 5 10 5 10 5 6 Overall length 2055 80 9 2083 82 0 2227 87 5 2287 90 2455 96 7 Overall width outside of tires 945 37 5 1055 41 5 1105 43 5 Overall height to top of mast lowered 2105 83 2110 83 5 Overall height to top of overhead guard eee as 2060 81 1 Overall height to top of mast extended 4550 179 4565 180 Trend front 877 34 5 902 35 5 Trend rear 922 36 3 897 35 5 M Wheelbase 1350 53 1 1500 59 1 o ranen Go suem suco sane TP comic ean ac _ 3315 130 155555 H1 2155 85 4535 176 K No 1 5 GENERAL INFORMATION Technical Data Standard Models oom kg mm lb in 3000 24 3500 24 4000 24 5000 24 6000 24 3300 131 Work 470 93 performance Lowering speed rated load 610 120 550 108 500 98 mm sec fpm i Tilt angle forward backward 5 6 Free fork height mm in 115 4 5 130 5 1 135 5 3 Travel speed loaded 15 9 3 16 9 9 16 9 9 km h mph 15 9 3 16 9 9 16 9 9 s Minimumtumingradius mm n 1760 69 1790 704 1945 766 2002 78 8 performance Minimum turning radius mm in 1760 69 3 1790 70 4 1945 76 6 2002 78 8 2169 85 4 Gradeability rated load at 1 6 km h 1 mph 76 tan
5. Open BBDC mm Exhaust valves 00 Qoo Ignition timing BTDC degree rpm 4 700 50 gasoline 9 7700 x 50 LPG Fuel tank rated capacity liter U S gal 34 9 46 12 56 15 With external With external resistor With external resistor resistor UNTERE Make Mitsubishi Electric Mitsubishi Electrie uci Electric Exhaust valves Valve clearance Ignition coil Non contact Non contact point Non contact point type C E I type C E I point type C E I Mitsubishi Make Mitsubishi Electric Mitsubishi Electric Pon b Electric Ignition system Distributor gasoline models Centrifugal Centrifugal Centrifugal Spark advancer pneumatic type pneumatic type pneumatic type WIAEX U WIAEX U WIAEX U Make Denso Size 14 x 1 25 14 x 1 25 mm Gn 0 55 x 0 049 0 55 0 049 0 55 x 0 049 a 0 7 to 0 8 0 7 to 0 8 mm Gn 0 028 to 0 031 0 028 to 0 031 Spark plugs Carburetor Pneumatic Make Mikuni Kogyo Diaphragm Make Kyosan Electric m Make Nippon Rokaki Type Pressure feed Oil pump Gear type Paper el t Oil filter Paper element type Paper element type id 45 1 2 i 0 3 0 1 48 13 Governor Make Mikuni Kogyo Mikuni Kogyo Mikuni Kogyo Fuel system Puelaump Down draft Air cleaner 5 3 ge Lubrication system Refill capacities liter U S gal E me e EL E ME A
6. Overall length mm 2949 116 1 2980 117 3 4335 170 7 4392 172 9 4559 179 5 Overall width mm in 945 37 2 1055 41 5 1105 43 5 To top of 2105 83 2110 83 1 2155 85 mast lowered Overall height To top of 4550 179 4565 180 4535 176 mm in mast extended To top of 2022 79 6 2060 81 1 2060 81 1 overhead guard 1500 59 1 902 35 5 897 35 5 399 15 7 412 16 2 Rear overhang mm in 529 20 8 130 5 1 21x 8x 15 16 x 6x 10 12 4170 9190 4664 Motors Motors Motors Gasoline Water 4 in line 4 Semi Types of combustion chambers Semi spherical Semi spherical is Engine spherical Overhead valve and OHC Integral with cylinder block 86 5 x 100 Cylinder bore x stroke 85 x 88 3 346 x 3 465 85 x 88 3 346 x 3 465 3 406 x 3 937 Displacement cc cu in 1997 121 8 1997 121 8 2350 143 4 Tread mm in o B ec Tire size mm in Zu ec Overhead valve Overhead valve Valve arrangement and OHC and OHC Integral with Integral with T f cyli li ype of cylinder liners cylinder block cylinder block GENERAL INFORMATION Rated output Hp rpm 46 2400 46 2400 57 2400 N m kgf m Ibf ft rpm 105 1600 105 1600 130 1600 length x width x height mm in 22 7 x 23 8 x 28 8 22 7 x 23 8 x 28 8 227x238 x29 0 Location Open BTDC 12 Close ABDC 40 54 Engine valves
7. 1 In slow charging the charging current should be electrolyte or internal damage If serious damage 15 about 1 10 the capacity of the battery to be found replace the battery charged 2 Check the condition of the battery cables Check for 2 In quick charging the battery capacity in ampere corrosion on the battery terminals and cable should not be exceeded terminations Make certain the ground cable is making a good connection where it is grounded and likewise 3 During charging adjust the charging current to 5 5 M check the connection of the cable to the starter relay prevent the electrolyte temperature from rising beyond 45 113 and or solenoid Replace badly corroded cables or cables with defective terminations 4 When connecting the cables to the battery begin with the cable for the positive terminal When disconnecting them from the battery begin with the cable for the negative terminal 3 8 ELECTRICAL SYSTEM Watts Shape Remarks 12 V 21 Bulb Specifications Color of lends Head lamp Frosted Combination lamps front Lamp description Option Clearance lamps Frosted Option 7 Turn and stop lamps Red 8 23 Option Back up lamps Frosted Frosted Option inu ID ggg Combination lamps rear Option Workiing lamps Option front and rear Instrument panel lamps Monitor indicator lights Frosted 2059
8. 3967 183 liter cu in min Lift cylinders mm in Tilt cylinders mm in Hydraulic tank capacity approx liter U S gal 21 5 5 30 7 9 36 9 5 Flange inside width mm in 3 94 x 0 67 x 0 75 x 0 43 4 53 x 0 87 x 1 06 x 0 47 thk R E x Web thk mm in 3 94 x 0 67 x 0 75 x 0 39 4 53 x 0 87 x 0 91 x 0 43 Flow regulator 75 amp 3 4577 183 ll Type 6308 ball bearing 6309 ball bearing Main rollers Di th E 100 x 27 3 94 x 1 06 115 x 30 4 53 x 1 18 mm in Mast and Lubricating type needle roller bearing Diam 42 36 42 x 36 1 65 x 1 42 42 x 36 1 65 x 1 42 1 65 x 1 42 itch ns BS mm in 42 x 4 x 1 4 42 x 4 x 1 6 42 x 5x 1 8 mm in 8 to 32 5 8 to 36 10 to 38 1 9 forks Lubricating type Lubricating type Type needle roller bearing needle roller bearing Side rollers COOLING SYSTEM Structure and Function Cooling fan To engine To transmission from engine From torque converter 209479 The cooling fan is installed inside the engine compartment This helps minimize radiator core clogging and retain high cooling efficiency even in continuous operation for hours The radiator s lower tank has a built in transmission oil cooler 2 1 COOLING SYSTEM Removal and Installation Fan Belt Removal Sequence 1 Fan guard 4 Universal joint 2 Tensioner Tensioner pulley 5 Fan belt 3 Support Cooling fa
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 11 12 13 14 155 16 17 Always use tools that are in good condition and be sure you understand how to use them before performing any service work 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 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 Disconnect battery and discharge any capacitors electric trucks before starting to work on truck Hang Do not Operate tag in the Operator s Compartment 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 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 rubbin
10. Do not operate this truck unless you have read and understand the instructions in the OPERATION amp MAINTENANCE MANUAL Improper truck operation is dangerous and could result in injury or death 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 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 To avoid back injury use a hoist when lifting components which weigh 23 kg 50 Ib 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 To avoid burns be alert for hot parts on trucks which have just been stopped and hot fluids in lines tubes and compartments 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
11. 1 7 GENERAL INFORMATION Forced circulation Corrugated fin Corrugated fin Corrugated fin Coolin Radiator 8 pressure type pressure type pressure type Bm Refill capacity liter U S gal 9 85 2 6 9 85 2 6 9 85 2 6 Centrifugal type Centrifugal type Centrifugal type Thermostat Voltage v tt 0 5 hrrating 40 Alternator type on V A 12 65 12 65 12 65 and regulator Built in IC type Built in IC type Built in IC type ee Lever shift type Lever shift type Lever shift type Voltage V kW 12 12 12 12 12 12 3 element 1 stage 3 element 1 stage 3 element Torque 2 phase 2 phase 1 2 phase converter Daikin XT027 Daikin DC6649 Daikin DC6649 Stall torque ratio Type Forced circulation Forced circulation Control and shift Hydraulic column Hydraulic Powershaft shift shift column shift Powerman transmission 2 913 2 913 2 913 Ratios 2 913 2 913 2 913 Reduction gear 899 Skew beve Skew beve Skew beve 4 571 4 571 4 571 Axle housing Banjo Banjo Differential number power stearing power stearing power stearing Turning angle Stecring wheel diameter mm n Steering cylinder Steeri f IDxrodOD 63 5 x 40 2 5 x 1 575 76 2 x 50 3 0 x 1 97 system Effecti k 195 7 68 210 8 27 Steering mm in cylinder Relief pressure 4 11 kPa kgf cm psi dese end Flow rate 23 6 liter U S gal m
12. 43A 3 9 ELECTRICAL SYSTEM Troubleshooting Starter System Dead or weak battery Short or open in circuit Starter will not crank engine Poor continuity in starter switch Starter and starter relay defective Starter switch Turning off starter Open or short circuit switch will not stop Timing control solenoid defective engine Fuel cut solenoid defective Gauges Open or short in circuit Will not indicate at Gauge internally defective Gauge unit defective Gauge or gauge unit not of the type called for Engine coolant temperature Will not indicate accurately Loose terminal connection Will indicate higher Ground in circuit between gauge and gauge unit temperature than is actual Gauge internally defective Open or short in circuit Recharge or replace Repair or replace Replace Replace Repair or replace Replace Replace Repair or replace Replace Replace Replace Repair Repair Replace Repair or replace Will not indicate at Gauge internally defective Replace Gauge unit defective Replace Gauge or gauge unit not of the type Replace Will not indicate Me Fil E accurately Loose terminal connection Retighten Fuel gauge Will indicate Full Gauge unit poorly grounded Repair regardless of the un am cum ctas Ton Gauge internally defect
13. e tensioner lock bolt and mounting bolt 5 After the admustment install the fan guard If cracks or other abnormalities are found in the fan guard replace the fan guard Be careful not to damage the radiator core with the bar screwdriver during belt tension adjustment 2 4 Tensioner lock bolt Tensioner mounting bolt 16 mm 0 6 in 206461A ELECTRICAL SYSTEM Console Box Engine coolant temperature gauge 5 4 Chock control Fuel gauge Service hourmeter ervice ourmete eee exe OK monitor 7 H 34 Starter switch e p M5 Lighting switch Fuse box s N gt WN 209480 Monitor 209481 Function 2 Air cleaner clement indicator light Clogged Option 3 Brake Mid ievelndicatoright Normal tow 4 Engine oil pressure indicator light Normal Low 5 _ Altemator nt charging indicator ight Normal How to check indicator light bulbs The bulbs are normal if the indicator lights 1 2 and 3 come ON when the starter switch key is turned to ON position The indicator lights will go OFF when the engine starts 3 1 ELECTRICAL SYSTEM Disassembly and Reassembly Console Box Disassembly 1 Disconnect the electrical wires at connectors 1 In the gasoline models disconnect the choke cable on the engine side 2 Remove screws 2 four securing the cover 3 Remove screws 3 six and sepa
14. eplace Check and recharge Repair or replace Retighten Clean Dry and replace packings Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Correct if improperly installed replace if internally defective Replace Check and replace Repair or replace Replace Replace Replace Repair ELECTRICAL SYSTEM Battery Tends to run down rapldly Tends to get overcharged Drive belt slipping Stator coil grounded or open circuited in alternator Rotor coil open in alternator Brushes poorly seating on slip rings Diode ruptured Regulated voltage setting too low Not enough electrolyte or wrong proportion of acid to water Battery cell plates deteriorated forming possibly internal short circuit Terminal connections loose Open or loose connection between starter switch and regulator IG terminal Fuse blown or loosely set in holder Open or loose connection between F terminals of regulator and alternator Regulator IG and F terminals shorted or miswired Poor grounding of regulator F terminal Pressure coil open circuited in regulator Regulated voltage too high 3 12 Readjust Repair or replace Replace Replace brushes if worn Clean holder and polish slip rings Replace Readjust Refill and check specific
15. g against some object or hot surface Do not connect wiring to a line containing fluid 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 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 19 20 21 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 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 Relieve all pressure in air oil or water systems before any lines fittings or related items are disconnected or removed Always make
16. gravity Replace Clean and retighten Repair Replace and repair Repair Repair Repair Replace Readjust Electrical Schematic ENGINE OIL PRESSURE BRAKE FLUID LEVEL BATTERY CHARGE LIGHTING SW WIRING CHART oes ELEMENT LPG PRESSURE OP RADIATOR WATER FOR OPTIONAL CLOSED TYPE ALTERNATOR AND DISCONNECT SWITCH OP STARTING SW GASOLINE MODELS ENGINE GROUP T C OIL TEMPERATURE CONNECTION CHART ies sm ulna m mc ERE A DISTRIBUTER TO CHARGE LAMP TURN SIGNAL LAMP RELAY REAR COMBINATION LAMP OPTION SPARK PLUG ee STOP AND TAIL LAMP 23 8W TURN SIGNAL LAMP IGN ITION COIL 27 W FOR DUAL FUEL MODEL BACK UP LAMP 10W TYPE G LP OR GS LPS i FUEL CUT SOLENOID SOLENOID VALVE i FOR LPG i 5 i SOLENOID VALVE st POWER RELAY HEAD LAMP BACK UP BUZZER OPTION FOR GASOLINE i 0 lt A 031 E31 d Pie ened E SWITCH FOR a DUAL FUEL ic L Rr G ai 1 REAR WORKING LAMP OPTION i ee J O T S c STARTER MOTER E WR WARNING LAMP STROBE OPTION o BATTERY CABLE BATTERY CABLE 20B 7 EARTH TRAP CASE R H CONNECTOR FOR FRONT COMBINATION LAMP ds A d GMT SEEN Am AMP 42A C E HEAD LAMP 12 2 lt Er
17. in 3 6 07 Full floating tubular Full floating tubular Full floating Front axle type type tubular type Elliott type Elliott type Elliott type Fixed type Fixed type Fixed type Mount Center pivot Traveling ME Rear wheels Center pivot type Center pivot type system type men 9 Whee Kingpin o 1 8 GENERAL INFORMATION 15 8 GC20K GC25K GC30K Self adjusting Self adjusting self adjusting Type duo servo duo servo duo servo mm in Lining length x width xthicknes 274 2 48 5 x 4 78 x 2 344 x 60 0 x 64 x 2 dp ee x number 10 80 x 1 91 x 0 19 x 2 13 54 x 2 36 x 0 24 x 2 024 x 2 Brake system mm in cylinder 22 22 0 8748 22 22 0 8748 22 22 0 8748 mm in ze cylinder 22 22 0 8748 28 58 1 1252 28 58 1 1252 mm in Mech 1 Mechanical mounted Mechanical mounted Parking brake Type mounted on front wheels on front wheels on front wheels Body frame Unitized type Unitized Unitized EE E Pp Ger Shimadzu Shimadzu SGP1 27 Shimadzu SGP1 30 SGP1 34 Hydraulic pump Rated output 64 8 3954 72 0 4394 79 9 4876 liter in 2400 E 2400 2400 28 Driveline _ Univesaljont Shimadzu MSV 04 3 7645 Control valve Relief pressure 18142 185 18142 185 18142 0 kPa 71 71 185 0 71 kgf cm psi oh ook 2361 7 Regulated flow rate 50 3 3051 183 65 3
18. ive Replace tank Gauge unit defective Replace Moran diste Short or open circuit in wiring between Repair Empty regardless gauge and gauge unit of the amount of Gauge unit defective Replace fuel left in tank Gauge internally defective Replace 3 10 Lighting System Dead or weak battery Fuses blown out Will not light Open or short circuit Poor ground Filament burnt off in bulbs L D EN Dead or weak battery Burned contact points in switches Loose terminals Will light dimly Dirty lenses Waterdrops inside lenses Bulbs expired service life Lighting switch defective Will not light Bulbs burnt out Head lamps Turn signal switch defective Will not flash l Turn signal relay defective Turn signal relay defective Bulbs burnt out Turn signals Wrong wattage of bulbs Bulbs burnt out slow Will not go out Turn signal relay defective Will flash too Wrong wattage of bulbs fast Turn signal relay defective Backup lamp switch defective Back up lamps will not light Other lamps Bulbs burnt out Fuse blown out Will not give Open or short in circuit blast of sound Horn switch defective Horn defective Will give ugly Horn switch defective blast of sound Horn defective 3 11 ELECTRICAL SYSTEM Recharge or replace Check and replace Repair or replace Clean ground spot and re make connection R
19. n Start by Remove the engine hood and gas filled cylinder Suggestions for Removal Make sure the muffler engine and exhaust pipe is cool enough to touch with your hand 2 2 206419 COOLING SYSTEM Installation To install follow the reverse of removal procedure and take the following steps 1 After removing the belt turn the fan to examine the bearings for abnormal noise Replace the bearings if abnormally noisy 2 After installing the belt push it inward midway between the pulleys to make sure the tensioner pulley moves freely before tightening the tensioner lock bolt and mounting bolt 206420 2 3 COOLING SYSTEM Inspection and Adjustment Fan Belt Inspection 1 Make sure the belt is free from oil grease or other foreign matter Replace the belt if necessary A slightly dirty belt can be reused by cleaning with cloth or paper Do not clean the belt with gasoline or the like 2 At the time of overhauling the engine or adjusting the belt tension check the belt and replace it if defective Fan Belt Adjustment 1 Loosen the tensioner lock bolt and mounting bolt 2 Insert a small diameter bar or screwdriver into the tension adjustment hole for leverage and adjust the belt tension 3 Adjust the belt so that its deflection is 16 mm 0 6 in when the belt is pushed downward with 98 N 10 kgf 22 lbf force exerted midway between the fan pulley and tensioner pulley 4 Tighten th
20. nection 1 220 or lower Discharged Recharge battery If difference in S G is large adjust it during recharging If difference in S G A cell with a low S G During recharging adjust the S G to 1 280 and 1 265 is more than 0 040 is in shorted condition If difference in S G is more than 0 040 and a low S G is Recharge until voltage found in certain cells only replace battery and S G stabilize and have remained constant for more than 2 hours 2 Specific gravity reading and state of A CAUTION charge Be sure to turn OFF the starter switch and To check the battery for state of charge take lighting switch before disconnecting or hydrometer readings on its electrolyte The battery connecting the battery cables to prevent the may be fully charged if the S G reading is 1 280 to 1 265 at 20 C 68 F The state of charge can be told from the way the electrolyte level goes down to expose the cell plates If addition of distilled water is Maintenance Free Battery necessary every month or so the battery is IC regulator from suffering damage overcharged If addition is not required for more than 3 Maintenance Free Batteries do not require a specific months it is likely that the battery is inadequately gravity check but the following checks are required to charged extend the life of your battery 1 Visually inspect the battery for container cover or 3 Charging precautions terminal damage that may have caused leakage of
21. of lubrication or maintenance procedures is dangerous and could result in injury or death Read and understand the OPERATION amp 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 welders 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
22. r 4G63 4G64 LP Gas Supplement Pub No 99729 85110 For use with LP Gas units with an E in the chassis serial number Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions 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 99719 80150 HOW READ THIS MANUAL Disassembly diagram example Each disassembly diagram is followed by Disassembly sequence and Suggestions for disassembly Disassembly sequence Sequence 1 Cover Bolt Washer part name 2 Output shaft part name Suggestion for disassembly 1 Output shaft removal Clearance between cylinder and piston Taper pipe thread external 1 4 inch formerly 1 4 Taper pipe thread internal 1 8 inch formerly PT1 8 1 4 Straight pipe thread external 1 4 inch formerly 1 4 1 8 Straight pipe thread internal 1 8 inch formerly PS1 8 SAFETY The proper and safe lubrication maintenance for this lift truck recommended by Cat are outlined in the OPERATION amp MAINTENANCE MANUAL for these trucks Improper performance
23. rate the front and rear panels 4 Remove screws 4 four securing the instrument panel To replace the instrument panel bulbs remove screws 3 and 4 3 2 206422A Reassembly To reassemble the console box follow the reverse of disassembly procedure BUY NOW ELECTRICAL SYSTEM Components in Console Box 206423A 1 Power relay 4 Lighting switch 2 Power relay 5 Starter switch 3 Turn signal relay 6 Fuses 3 3 ELECTRICAL SYSTEM Combination Meter Disassembly Sequence 1 Meter cover Dial Engine coolant temperature gauge Service hourmeter Fuel gauge CAUTION O Cc NY Be careful not to damage the printed circuit when disassembling the combination meter Reassembly To reassemble the combination meter follow the reverse of disassembly procedure 3 4 206480 Meter case Printed circuit Bulb Socket CON O Bulb Replacement For bulb replacement remove the socket from the printed circuit by turning it to the left For configuration of the indicator lights refer to Monitor ELECTRICAL SYSTEM Major Electrical Components Starter Switch with Anti Restart Lock This switch has a built in anti restart lock so the key cannot be turned from ON to START position while the engine is running 203561A Connection Chart Starter neutral switch powershift transmission models Fuse box battery Fuse box fuel cut alternator solenoid o
24. sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure 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 GENERAL INFORMATION Vehicle Exterior 102696 Models Truck model Model code Serial number Engine mounted 8 00011 up 15 81 00011 up ATSIE 00011 up GC18K AT81C 00011 up AT81D 00011 up ATSIE 00011 up Mitsubishi 4G63 gasoline engine GC20K AT82C 00011 up AT82D 00011 up AT82E 00011 up GC25K AT82C 00011 up AT82D 00011 up AT82E 00011 up GC20K HO AT82C 90011 up AT82D 90011 up AT82E 90011 up GC25K HO AT82C 90011 up AT82C 90011 up Mitsubishi 4G64 gasoline engine AT82C 90011 up GC30K AT83C 00011 up AT83C 00011 up AT83C 00011 up 1 1 GENERAL INFORMATION Serial Number Locations YEO xps Fl a az o Z H mis 207070 GENERAL INFORMATION Dimensions k E 207071 GENERAL INFORMATION Unit mm in 1 ton models 2 ton models 3 ton models 15 18 GC20K GC25K GC20K HP GC25K HP 5 Maximum fork height 3325 131 3340 131 Free fork height 115 4 5 130 5 1
Download Pdf Manuals
Related Search