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CAT GC15K LPG Forklift Instruction Manual

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Contents
1 CAT GC15K LPG Forklift
2 Product Information
3 Safety Related Signs
4 How to Read this Manual
5 Product Usage Instructions
6 FOREWORD
7 Safety Related Signs
8 SAFETY
9 Dimensions
10 Technical Data (Standard
Models)
11 Structure and Function
12 Removal and Installation
13 Installation
14 Inspection and Adjustment
15 Function
16 Disassembly and Reassembly
17 Combination Meter
18 Major Electrical Components
19 Battery Maintenance
20 Lamp Bulb Specifications
21 Troubleshooting
22 Documents / Resources
23 Related Posts

CAT GC15K LPG Forklift

Product Information

The Service Manual is a guide for servicing 1-ton to 3-ton internal combustion cushion models of CatTM Lift
Trucks. The manual contains instructions that are grouped by systems for easy reference. It is for use with LP Gas
units with an E in the chassis serial number and 4G63/4G64 Engine Service Manual and Liquefied Petroleum Gas
Supplements. The manual also includes disassembly diagrams, symbols, and abbreviations for easy
understanding.

Safety Related Signs

The service manual uses safety-related signs to emphasize important and critical instructions. The following signs
are used:

WARNING: Indicates 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.

How to Read this Manual

The disassembly diagrams in the manual are followed by disassembly sequence and suggestions for
disassembly. The symbols and abbreviations used in the manual include OP, R1/4, Rc1/8, G1/4A, and Rp1/8.

Product Usage Instructions

It is important to follow the instructions in the OPERATION & MAINTENANCE MANUAL for lubrication and
maintenance of the lift truck recommended by Cat. Improper performance of lubrication or maintenance
procedures is dangerous and could result in injury or death. Therefore, read and understand the OPERATION &
MAINTENANCE MANUAL before performing any lubrication or maintenance. Before removing or disassembling
any component, it is important to have knowledge of the system and/or components. The serviceman or
mechanic should use caution when performing service work. It is also important to check the weights noted in this
manual before removing any components due to the size of some of the truck components. Use proper lifting
procedures when removing any component. Basic precautions that should always be observed include reading
and understanding all warning plates and decals on the truck before operating, lubricating or repairing the product.
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, aprons 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.

FOREWORD

This service manual is a guide to servicing the 1-ton to 3-ton internal combustion cushion models of CatTM Lift
Trucks. The instructions are grouped by systems to serve the convenience of your ready reference. The long
productive life of your lift trucks depends to a great extent on correct servicing – the servicing is 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 number.
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:

WARNING: Indicates 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 the service life of, the machine.

Disassembly diagram (example)

Symbols or abbreviations

OP ……………….Option
R1/4……………..Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 ……………Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A…………..Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8……………Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

SAFETY

WARNING: The proper and safe lubrication and maintenance for this lift truck, recommended by Cat, are outlined
in the OPERATION & MAINTENANCE MANUAL for these trucks. Improper performance of lubrication or
maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION
& 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. 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. Do not operate this truck unless you have read and understand
the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could
result in injury or death.

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 sled. Use welders gloves,
hoods/goggles, aprons,s 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.
4. 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.
5. 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 the 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.
6. To avoid back injury, use a hoist when lifting components that weigh 23 kg (50 lb.) 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.
7. To avoid burns, be alert for hot parts on trucks that have just been stopped and hot fluids in lines, tubes, and
compartments.
8. 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 the cover loose to relieve any spring or other pressure, before removing the last
two bolts or nuts completely.
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. Always use tools that are in good condition and be sure you understand how to use them before performing
any service work.
11. 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.
12. 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.
13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang “Do not
Operate” tag in the Operator’s Compartment.
14. 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.
15. 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 rubbing against some object or hot surface. Do not
connect wiring to a line containing fluid.
16. 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.
17. 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. 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.
19. 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.
20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or
removed. Always make sure all raised components are blocked correctly and be alert for possible pressure
when disconnecting any device from a system that utilizes pressure.
21. 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.
Vehicle Exterior

Models
 Truck model Model code – Serial number Engine mounted

AT81C – 00011- up AT81D – 00011-

GC15K up AT81E – 00011- up

AT81C – 00011- up AT81D – 00011-

GC18K
up AT81E – 00011- up

AT82C – 00011- up AT82D – 00011-

GC20K
up AT82E – 00011- up
Mitsubishi 4G63 gasoline engine

AT82C – 00011- up AT82D – 00011-

GC25K
up AT82E – 00011- up

AT82C – 90011- up AT82D – 90011-

GC20K HO
up AT82E – 90011- up

AT82C – 90011- up AT82C – 90011-

GC25K HO
up AT82C – 90011- up

Mitsubishi 4G64 gasoline engine

AT83C – 00011- up AT83C – 00011-

GC30K
up AT83C – 00011- up

Serial Number Locations

Dimensions
 3-ton model
1-ton models 2-ton models
Truck Model s

Re
f. N
o. Item
GC20K GC25K
GC15K GC18K GC30K
GC20K HP GC25K HP

A Maximum fork height 3325 (131) 3340 (131) 3315 (130)

B Free fork height 115 (4.5) 130 (5.1) 135 (5.3)

Fork spacing (out-to-out) minim 200/960 (10

C 200/820 (8.0/32.3) 200/920 (8.0/36.2)
um/maximum /38)

D Fork length 1067 (42)

E Tilt angle (forward–backward) 5–10° 5–10° 5–6°

F Overall length 2055 (80.9) 2083 (82.0) 2227 (87.5) 2287 (90) 2455 (96.7)

G Overall width (outside of tires) 945 (37.5) 1055 (41.5) 1105 (43.5)

Overall height
H 2105 (83) 2110 (83.5) 2155 (85)
(to top of mast lowered)

Overall height
I 2022 (79.6) 2060 (81.1)
(to top of overhead guard)

Overall height
J 4550 (179) 4565 (180) 4535 (176)
(to top of mast extended)

K Trend (front) 793 (31.2) 877 (34.5) 902 (35.5)

L Trend (rear) 826 (32.5) 922 (36.3) 897 (35.5) 897 (35.5)

M Wheelbase 1190 (46.9) 1350 (53.1) 1500 (59.1)

N Load moment constant 376 (14.8) 399 (15.7) 412 (16.2)

O Rear overhang 479 (18.9) 507 (20.0) 475 (18.7) 532 (20.9) 529 (20.8)

P Ground clearance (at frame) 95 (3.7) 130 (5.1)

Technical Data (Standard Models)

Truck Model
GC15K GC18K GC20K GC25K GC30K
Item
 Rated capacity/load center
1500/500 ( 1800/500 ( 200/500 (4 2500/500 ( 3000/500 (
kg/mm (lb/in.) 3000/24) 3500/24) 000/24) 5000/24) 6000/24)

Maximum fork height

3300 (131) 3300 (131) 3300 (131)
mm (in.)

Lift speed (rated load) mm

590 (116) 510 (100) 470 (93)
/sec (fpm)

Work per Lowering speed (rated load)

formance
610 (120) 550 (108) 500 (98)
mm/sec (fpm)

Tilt angle (forward – backward) 5–10° 5–10° 5–6°

Free fork height

115 (4.5) 130 (5.1) 135 (5.3)
mm (in.)

Forward 15 (9.3) 16 (9.9) 16 (9.9)

Travel speed (loa
ded)

km/h (mph)
Reverse 15 (9.3) 16 (9.9) 16 (9.9)

Traveling Minimum turning radius 1760 (69.3 1790 (70.4 1945 (76.6 2002 (78.8 2169 (85.4
performa mm (in.) ) ) ) ) )
nce

Gradeability (rated load)

[at 1.6 km/h (1 mph)] 35 31 25.5 21 23

% tan

Overall length 2949 (116. 2980 (117. 4335 (170. 4392 (172. 4559 (179.
mm (in.) 1) 3) 7) 9) 5)

Overall width 1105 (43.5

945 (37.2) 1055 (41.5)
mm (in.) )

To top of m
ast lowered 2105 (83) 2110 (83.1) 2155 (85)
 To top of m
ast extende 4550 (179) 4565 (180) 4535 (176)
d
Overall height

mm (in.)
To top of
2060 (81.1
overhead g 2022 (79.6) 2060 (81.1)
)
uard

Wheel base 1500 (59.1

1190 (46.9) 1350 (53.1)
mm (in.) )

Front 793 (31.2) 877 (34.5) 902 (35.5)

Tread mm
(in.)
Dimensio Rear 826 (32.5) 922 (36.3) 897 (35.5) 897 (35.5)
ns

Load moment constant

376 (14.8) 399 (15.7) 412 (16.2)
mm (in.)

Rear overhang
479 (18.9) 507 (20.0) 475 (18.7) 532 (20.9) 529 (20.8)
mm (in.)

Ground clearance (at frame) 95 (3.7) 130 (5.1) 130 (5.1)

Front 18 ´ 6 ´ 12-1/8 21 ´ 7 ´ 15 21 ´ 8 ´ 15

Tire size m
m (in.)
16 ´ 6 ´ 10-
Rear 14 ´ 4-1/2 ´ 8 16 ´ 6 ´ 10-1/2
1/2

Service weight (empty) 4170

2630 (5800) 3650 (8050)
kg (lb) (9190)

Engine model 4G63 4G63 4G64

Mitsubishi
Make Mitsubishi Motors Mitsubishi Motors
Motors

Type Gasoline Gasoline Gasoline

Cooling System Water Water Water

 No. of cylinders – arrangement 4 -in-line 4 -in-line 4 -in-line

No. of strokes 4 4 4

Semi-
Types of combustion chambers Semi-spherical Semi-spherical
spherical

Overhead
Overhead valve and OH Overhead valve and OH
valve and
Valve arrangement C C
OHC

Engine

Integral wit
Integral with cylinder blo Integral with cylinder blo
h cylinder
Type of cylinder liners ck ck
block

86.5 ´ 100
Cylinder bore ´ stroke
85 ´ 88 (3.346 ´ 3.465) 85 ´ 88 (3.346 ´ 3.465) (3.406 ´ 3.
mm (in.)
937)

Displacement 2350 (143.

1997 (121.8) 1997 (121.8)
cc (cu in.) 4)

Truck Model
GC15K GC18K GC20K GC25K GC30K
Item

Compression ratio 8.5 : 1 8.5 : 1 8.6 : 1

Rated output
46/2400 46/2400 57/2400
Hp/rpm

Maximum torque
176 (18) [1
139 (14.2) [105]/1600 139 (14.2) [105]/1600
N·m (kgf·m) [lbf·ft]/rpm 30]/1600
 576 ´
Dimensions 604.6 ´
576 ´ 604.6 ´ 730.7 576 ´ 604.6 ´ 730.7
736.7
(length ´ width ´ height)
(22.7 ´ 23.8 ´ 28.8) (22.7 ´ 23.8 ´ 28.8)
mm (in.) (22.7 ´ 23.
8 ´ 29.0)

Weight (service)
150 (330) 150 (330) 150 (330)
kg (lb)

Location Rear Rear Rear

Open BTD
12° 12° 12°
C

Intake valves
Close ABD
40° 40° 40°
C

Engine Open BBD

54° 54° 54°
C

Exhaust valves
Close ATD
6° 6° 6°
C

Intake valv
0.00 (hot) 0.00 (hot) 0.00 (hot)
Valve clearance es

mm
Exhaust val
0.00 (hot) 0.00 (hot) 0.00 (hot)
ves

Ignition Spark Spark Spark

1–3–4–
Firing order 1–3–4–2 1–3–4–2
2

Ignition timing BTDC d

4 / 700 ± 50 (gasoline) 9/ 700 ± 50 (LPG)
egree/rpm

Fuel tank rated capacity liter 56 (15)

34 (9) 46 (12)
(U.S. gal.)

With exter
Type With external resistor With external resistor
nal resistor
 Ignition coil
Mitsubishi
Make Mitsubishi Electric Mitsubishi Electric
Electric

Non-conta
Non-contact point type ( Non-contact point type (
ct point typ
Type C.E.I.) C.E.I.)
e (C.E.I.)

Mitsubishi
Make Mitsubishi Electric Mitsubishi Electric
Electric
Distributor

Spark adva Centrifugal

Centrifugal pneumatic ty Centrifugal pneumatic ty
ncer pneumatic
pe pe
type

Ignition s
Type W14EX-U W14EX-U W14EX-U
ystem (g
asoline m
odels) Make Denso Denso Denso

14 ´ 1.25
Size 14 ´ 1.25 14 ´ 1.25
(0.55 ´ 0.0
mm (in.) (0.55 ´ 0.049) (0.55 ´ 0.049)
Spark plugs 49)

Gap 0.7 to 0.8 (

0.7 to 0.8 (0.028 to 0.03 0.7 to 0.8 (0.028 to 0.03
0.028 to 0.
mm (in.) 1) 1)
031)

Type Down-draft Down-draft Down-draft

Carburetor
Make Mikuni Kog
Mikuni Kogyo Mikuni Kogyo
yo

Type Pneumatic Pneumatic Pneumatic

Governor
Mikuni Kog
Make Mikuni Kogyo Mikuni Kogyo
yo

Type Diaphragm Diaphragm Diaphragm

Fuel syst Fuel pump Kyosan Ele

Make Kyosan Electric Kyosan Electric
em ctric
 Cyclone-p
Type ´ num Cyclone-paper element Cyclone-paper element ´
aper
ber ´1 1
element ´ 1
Air cleaner
Nippon Ro
Make Nippon Rokaki Nippon Rokaki
kaki

Pressure f
Type Pressure feed Pressure feed
eed

Oil pump Gear type Gear type Gear type

Paper-ele
Oil filter Paper-element type Paper-element type
ment type

Lubricatio
n system Oil pan 45 (1.2) 45 (1.2) 45 (1.2)

Refill capacities Oil filter 0.3 (0.1) 0.3 (0.1) 0.3 (0.1)

liter (U.S. gal.)

Total 4.8 (1.3) 4.8 (1.3) 4.8 (1.3)

Truck Model

GC15K GC18K GC20K GC25K GC30K

Item

Forced circ
Type Forced circulation Forced circulation
ulation

Corrugated
Corrugated fin (pressure Corrugated fin (pressure fin
Radiator
) type ) type (pressure)
type

Refill capacity liter (

9.85 (2.6) 9.85 (2.6) 9.85 (2.6)
U.S. gal.)
Cooling s
ystem
Centrifugal
Water pump Centrifugal type Centrifugal type
type
 Thermostat Wax type Wax type Wax type

Voltage
12 12 12
V
Battery
5-hr rating
32 40 40
Ah

Alternator type 3-phase 3-phase 3-phase

Capacity
Alternato 12 – 65 12 – 65 12 – 65
V–A
r and reg
ulator
Built-in IC t
Regulator Built-in IC type Built-in IC type
ype

Lever-shift
Type Lever-shift type Lever-shift type
type
Starter
Voltage – output
12 – 1.2 12 – 1.2 12 – 1.2
V – kW

3-element,
3-element, 1-stage, 2-ph 3-element, 1-stage, 2-ph
Type 1-stage, 2-
ase ase
phase

Torque con
verter Daikin DC
Model Daikin XT027 Daikin DC6649
6649

Stall torque ratio 2.8 3.0 3.0

Hydraulic c
Control and shift Hydraulic column shift Hydraulic column shift
olumn shift

Powershaft Forwar
transmissio 2.913 2.913 2.913
d
n
Ratios
Revers
2.913 2.913 2.913
e

Skew beve
Power tr Type of gears Skew bevel Skew bevel
Reduction l
ain
gear
Ratio 4.571 4.571 4.571

Axle housing Banjo Banjo Banjo

 straight be
Gears Straight bevel – 2 Straight bevel – 2
Differential Type of g vel – 2
ears- nu
mber Pinion Straight be
Straight bevel – 2 Straight bevel – 2
s vel – 2

Full hydros
Full hydrostatic power st Full hydrostatic power st
Type tatic power
earing earing
stearing

Inside 83° 83° 78°05´

Turning an
gle Outside 54° 56° 52°14´

Steering wheel diameter

330 (13) 330 (13) 330 (13)
mm (in.)

Steering cylinder

ID ´ rod OD m 63.5 ´ 40 (2.5 ´ 1.575) 76.2 ´ 50 (3.0 ´ 1.97)

m (in.)

Effective stroke
Steering 195 (7.68) 210 (8.27)
mm (in.)
system

Relief pressure
Steering
cylinder kPa (kgf/cm2) [psi 7845 (80) [1138]
]

Flow rate

liter (U.S. gal.)/mi 23 (6.07)

n

Full-floatin
Front axle Full-floating tubular type Full-floating tubular type g tubular ty
pe

Rear axle Elliott type Elliott type Elliott type

Front wheels Fixed type Fixed type Fixed type

Mounting Center-piv
Rear wheels Center-pivot type Center-pivot type
ot type
Traveling
system Toe-in m
0 0 0
m (in.)

Camber 1° 1° 1°
Wheel alig
nment
Caster 0° 0° 0°

Kingpin inclination 0° 0° 0°

Truck Model
GC15K GC18K GC20K GC25K GC30K
Item

Self-adjusti
Type Self-adjusting duo-servo Self-adjusting duo-servo ng duo-ser
vo

Drum diam
eter 310 (12.20
254 (10.00) 310 (12.20)
)
mm (in.)

Lining (leng
th ´ 344 ´ 60.0
´ 6.4 ´ 2
width ´ thic
kness 274.2 ´ 48.5 ´ 4.78 ´ 2 344 ´ 60.0 ´ 6.4 ´ 2 (13.54 ´ 2.
36 ´
´ number) (10.80 ´ 1.91 ´ 0.19 ´ 2) (13.54 ´ 2.36 ´ 0.24 ´ 2)
0.24 ´ 2)
mm (in.)

Service brake
Master cyli
22.22 (0.8
nder ID 22.22 (0.8748) 22.22 (0.8748)
748)
mm (in.)

Brake sy
stem
 Wheel cylin
der ID 28.58 (1.1
22.22 (0.8748) 28.58 (1.1252)
mm (in.) 252)

Mechanical
, mounted
Mechanical, mounted on Mechanical, mounted on
Parking brake Type front wheels front wheels on front wh
eels

Unitized ty
Body-frame Unitized type Unitized type
pe

Type Gear Gear Gear

Shimadzu
Model Shimadzu SGP1-27 Shimadzu SGP1-30
SGP1-34

Rated outp 79.9 (4876

64.8 (3954) 72.0 (4394)
ut )
Hydraulic pump
/2400 rpm /2400 rpm
liter (cu in.) /2400 rpm

Universal j
Drive line Universal joint Universal joint
oint

Model Shimadzu MSV 04-3-7645

 Control valve 18142 +49
0
18142 +490 (185 +5 ) 18142 +490 (185 +5 )
Relief pres 0
0 0
sure
0 0 (185 +5 )
kPa (kgf/c
[2361 +71 ] [2361 +71 ] 0
m2) [psi]
0 0 [2361 +71 ]

Type Variable Variable Variable

Hydraulic
system

Flow regulator val Regulated f

75 ± 3
ve low rate
(4577 ± 18
liter (cu in.) 50 ± 3 (3051 ± 183) 65 ± 3 (3967 ± 183)
3)
/min

ID 45 (1.77) 50 (1.97) 55 (2.17)

Lift cylinders

mm (in.)
1600 (62.9
Stroke 1650 (64.96) 1650 (64.96)
9)

ID 63 (2.48) 70 (2.76) 80 (3.15)

Tilt cylinders

mm (in.)

Stroke 96 (3.78) 111 (4.37) 111 (4.37)

Hydraulic tank capacity (approx.

)
21 (5.5) 30 (7.9) 36 (9.5)
liter (U.S. gal)
 Roller type
Mast Roller type CL Roller type CL
CL

100 ´ 17 ´ 19 ´ 11
Outer 115 ´ 22 ´ 27 ´ 12
(3.94 ´ 0.67 ´ 0.75 ´ 0.43
mm (in.) (4.53 ´ 0.87 ´ 1.06 ´ 0.47)
)
Mast dimensions (
Flange inside widt
h ´ Flange ´ thk (F.
R)´Flange thk (R.
E) ´ Web thk) 100 ´ 17 ´ 19 ´ 10
Inner 115 ´ 22 ´ 23 ´ 11
(3.94 ´ 0.67 ´ 0.75 ´ 0.39
mm (in.) (4.53 ´ 0.87 ´ 0.91 ´ 0.43)
)

#6309 ball
Type #6308 ball bearing #6309 ball bearing
bearing

Diam ´ widt
Main rollers
h
100 ´ 27 (3.94 ´ 1.06) 115 ´ 30 (4.53 ´ 1.18)
mm (in.)

Lubricating
Lubricating type needle Lubricating type needle r type needl
Type roller bearing oller bearing e roller bea
ring

Side rollers
Mast and Diam ´ widt
forks h 42´36 (1.6
42 ´ 36 (1.65 ´ 1.42) 42 ´ 36 (1.65 ´ 1.42)
5 ´ 1.42)
mm (in)

Lift chains BL534 BL634 BL834

 1067 ´ 125
Fork (length ´ width ´ thickness) 1067 ´ 100 ´ 35 1067 ´ 100 ´ 40 ´ 45

mm (in.) (42 ´ 4 ´ 1.4) (42 ´ 4 ´ 1.6) (42 ´ 5 ´ 1.

8)

Fork spacing (out-to-out) 200 to 820 200 to 920 200 to 960

mm (in.) (8 to 32.5) (8 to 36) (10 to 38)

Structure and Function

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.

Removal and Installation

Fan Belt Removal

Sequence:

1. Fan guard
2. Tensioner, Tensioner pulley
3. Support, Cooling fan
4. Universal joint
5. Fan belt

Start by:
Remove the engine hood and gas-filled cylinder.
Suggestions for Removal
Make sure the muffler, engine, and exhaust pipe are cool enough to touch with your hand.

Installation

To install, follow the reverse of the 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.
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 kg)[22
lbf] force exerted midway between the fan pulley and tensioner pulley.
4. Tighten the tensioner lock bolt and mounting bolt.
5. After the adjustment, install the fan guard. If cracks or other abnormalities are found in the fan guard, replace
the fan guard.

NOTE: Be careful not to damage the radiator core with the bar (screwdriver) during belt tension adjustment.

Console Box
1. Engine coolant temperature gauge
2. Chock control
3. Fuel gauge
4. Service hour meter
5. OK monitor
6. Starter switch
7. Lighting switch
8. Fuse box

OK Monitor

Function
 No. Indicator light OFF ON or flickering Remarks

1 Powershift transmission oil temp. indicator light Normal Overheating Option

2 Air cleaner element indicator light Normal Clogged Option

3 Brake fluid level indicator light Normal Low

4 Engine oil pressure indicator light Normal Low

5 The alternator not charging the indicator light Normal Abnormal

6 Check engine light Normal Service Engine 2004 Model

7 Engine coolant level indicator light Normal Low Option

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 the (ON)
position. (The indicator lights will go OFF when the engine starts.)

Disassembly and Reassembly

Console Box

Disassembly
1. Disconnect the electrical wires at connector 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 separate the front and rear panels.
4. Remove screws 4 (four) securing the instrument panel.1. Disconnect the electrical wires at the 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 separate the front and rear panels. 4. Remove screws 4 (four) securing
the instrument panel.

NOTE: To replace the instrument panel bulbs, remove screws 3 and 4.

Reassembly: To reassemble the console box, follow the reverse of the disassembly procedure.

Components in Console Box

1. Power relay
2. Power relay
3. Turn signal relay
4. Lighting switch
5. Starter switch
6. Fuses

Combination Meter

Disassembly
Sequence

1. Meter cover
2. Dial
3. Engine coolant temperature gauge
4. Service hour meter
5. Fuel gauge
6. Meter case
7. Printed circuit
8. Bulb
9. Socket

CAUTION: Be careful not to damage the printed circuit when disassembling the combination meter.

Reassembly: To reassemble the combination meter, follow the reverse of the disassembly procedure.
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 “OK Monitor”.

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 the (START) position while the engine is running.

Lighting Switch

Fuse Box
 Code Amp Circuit

A 10 A SOLENOID (F-R)

B 15 A Stop lamp, turn signals, backup lamps

C 15 A Spare terminal

Tail lamps, clearance lamps, working lamps (option), Instrument

D 15 A
panel lamps

E 15 A Head lamps

F 10 A Spare fuse

G 10 A Horn

H 15 A Fuel pump relay

J 10 A Engine, ECU

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.) Cord color Lg (yellowish green) Removing the console box rear panel will expose
this spare terminal which is fastened to the harness protector with vinyl tape.
Battery Maintenance

State of charge and electrolyte-specific gravity adjustment

The specific gravity rea

State of charge Adjustment
ding at 20°C (68°F)

If the difference in S.G. between any two cells is 0.020 or m

ore, effect a high current discharge to minimize the differen
1.280 to 1.265 Fully charged
ce and then recharge the battery. Adjust S.G. during rechar
ging.

Recharge the battery and adjust the electrolyte S.G. Make

1.260 to 1.225 One-half charged sure there is neither faulty components, loosely connected
cord nor corroded connection.

Recharge battery. If the difference in S.G. is large, adjust it

1.220 or lower Discharged
during recharging.

A cell with a low S.G. is

in shorted condition. Re During recharging, adjust the S.G. to 1.280 and 1.265.
If difference in S.G. is charge until voltage
If the difference in S.G. is more than 0.040 and a low S.G. i
more than 0.040 and S.G. stabilize and h
s found in certain cells only, replace battery.
ave remained constant
for more than 2 hours.

Specific gravity reading and state of charge To check the battery for state of charge, take hydrometer readings on
its electrolyte. The battery 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 the addition of distilled
water is necessary every month or so, the battery is overcharged. If addition is not required for more than 3
months, it is likely that the battery is inadequately charged.

Charging precautions

1. In slow charging, the charging current should be about 1/10 the capacity of the battery to be charged.
2. In quick charging, the battery capacity in the ampere should not be exceeded.
3. During charging, adjust the charging current to prevent the electrolyte temperature from rising beyond 45°C
(113°F).
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.

CAUTION: Be sure to turn OFF the starter switch and lighting switch before disconnecting or connecting the
battery cables to prevent the IC regulator from suffering damage.
Maintenance Free Battery
Maintenance Free Batteries do not require a specific gravity check but the following checks are required to extend
the life of your battery:

1. Visually inspect the battery for container, cover, or terminal damage that may have caused leakage of
electrolyte or internal damage. If serious damage is found, replace the battery.
2. Check the condition of the battery cables. Check for corrosion on the battery terminals and cable terminations.
Make certain the ground cable is making a good connection where it is grounded, and likewise, check the
connection of the cable to the starter relay and/or solenoid. Replace badly corroded cables or cables with
defective terminations.

Lamp Bulb Specifications

Troubleshooting

Starter System
Gauges

Lighting System
Battery

Documents / Resources
 CAT GC15K LPG Forklift [pdf] Instruction Manual
GC15K, GC18K, GC20K, GC20K HP, GC25K, GC25K HP, GC30K., GC15K LPG Forklift, LPG
Forklift, Forklift

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