Caterpillar Cat GP15ZN Forklift Lift Trucks Service Repair Manual SN:T34-50011 and up

Service Manual

99719-35120For use with S4Q2, S4S and K15/K21/K25 Engine Service Manuals.

GP15N T25C-50001-upGP15ZN T34-50011-upGP18N T25C-70001-upGP18ZN T34-70001-upGP20CN T34-20001-upGP20N T17D-00011-upGP20ZN T35-00011-upGP25N T17D-50001-upGP25ZN T35-50001-upGP30N T13F-30011-upGP35AN T13F-50001-up

DP15N T16D-50001/60001-upDP18N T16D-70001/80001-upDP20CN T16D-85001/87001-upDP20N T18C-00011/10001-upDP25N T18C-50001/60001-upDP30N T14E-30011/40001-upDP35AN T14E-50001/60001-up

GPE15N T25C-58001/68001-upGPE15ZN T34-58011/68001-upGPE18N T25C-78001/88001-upGPE18ZN T34-78001/88001-upGPE20CN T34-28001/38001-upGPE20N T17D-08011/18001-upGPE20ZN T35-08011/18001-upGPE25N T17D-58001/68001-upGPE25ZN T35-58001/68001-upGPE30N T13F-38011/48001-upGPE35AN T13F-58001/68001-up

Chassis & Mast MC/FC

FOREWORD

This service manual is a guide for servicing Cat® Lift Trucks. For your convenience theinstructions are grouped by systems as a ready reference.

The long productive life of your lift truck(s) depends on regular and proper servicing.Servicing consistent with what you will learn by reading this service manual. Read therespective sections of this manual carefully and familiarize yourself with all of the componentsbefore attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual are for trucks withserial numbers in effect at the time of printing. Cat Lift Trucks reserve the right to changespecifications or design without notice and without incurring obligation.

The trucks listed in this manual are powered by K15/K21/K25 gasoline engines or S4Q2/S4Sdiesel engines. For engine servicing, please refer to the applicable engine service manual.

Pub. No. 99719-35120

Safety Related Signs

The following safety related signs are used in this servicemanual to emphasize important and critical instructions:

Indicates a potentially hazardoussituation which, if not avoided, couldresult in death or serious injury.

Indicates a potentially hazardoussituation which, if not avoided, mayresult in death or serious injury ordamage to the machine.

Indicates a condition that can causedamage to, or shorten service life of,the machine.

NOTE

WARNING!

CAUTION!

The serviceman or mechanic may be unfamiliar withmany of the systems on this truck. This makes itimportant to use caution when performing servicework. A knowledge of the system and/or componentsis important before the removal or disassembly of anycomponent.

Because of the size of some of the truck components,the serviceman or mechanic should check the weightsnoted in this Manual. Use proper lifting procedureswhen removing any components.

Following is a list of basic precautions that shouldalways be observed.

1. Read and understand all warning plates and decalson the truck before operating, lubricating orrepairing the product.

2. Always wear protective glasses and protectiveshoes when working around trucks. In particular,wear protective glasses when pounding on any partof the truck or its attachments with a hammer orsledge. Use welders gloves, hood/goggles, apronand other protective clothing appropriate to thewelding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings fromfingers when working on machinery.

3. Do not work on any truck that is supported only bylift jacks or a hoist. Always use blocks or jackstands to support the truck before performing anydisassembly.

4. Lower the forks or other implements to the groundbefore performing any work on the truck. If thiscannot be done, make sure the forks or otherimplements are blocked correctly to prevent themfrom dropping unexpectedly.

5. Use steps and grab handles (if applicable) whenmounting or dismounting a truck. Clean any mudor debris from steps, walkways or work platformsbefore using. Always face truck when using steps,ladders and walkways. When it is not possible touse the designed access system, provide ladders,scaffolds, or work platforms to perform safe repairoperations.

6. To avoid back injury, use a hoist when liftingcomponents which weigh 23 kg (50 lb.) or more.Make sure all chains, hooks, slings, etc., are ingood condition and are of the correct capacity. Besure hooks are positioned correctly. Lifting eyesare not to be side loaded during a lifting operation.

7. To avoid burns, be alert for hot parts on truckswhich have just been stopped and hot fluids inlines, tubes and compartments.

8. Be careful when removing cover plates. Graduallyback off the last two bolts or nuts located atopposite ends of the cover or device and pry coverloose to relieve any spring or other pressure, beforeremoving the last two bolts or nuts completely.

9. Be careful when removing filler caps, breathers andplugs on the truck. Hold a rag over the cap or plugto prevent being sprayed or splashed by liquidsunder pressure. The danger is even greater if thetruck has just been stopped because fluids can behot.

SAFETY

WARNING!

The proper and safe lubrication andmaintenance for these l i ft trucks,recommended by Cat Lift Trucks, are outlinedin the OPERATION & MAINTENANCE MANUAL.

Improper performance of lubrication ormaintenance procedures is dangerous andcould result in injury or death. Read andunderstand the OPERATION & MAINTENANCEMANUAL before performing any lubrication ormaintenance on these trucks.

WARNING!Do not operate these trucks unless you haveread and understood the instructions in theOPERATION & MAINTENANCE MANUAL.Improper truck operation is dangerous andcould result in injury or death.

WARNING!

10. Always use tools that are in good condition and besure you understand how to use them beforeperforming any service work.

11. Reinstall all fasteners with same part number. Donot use a lesser quality fastener if replacements arenecessary.

12. If possible, make all repairs with the truck parkedon a level, hard surface. Block truck so it does notroll 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’sCompartment.

14. Repairs, which require welding, should beperformed only with the benefit of the appropriatereference information and by personnel adequatelytrained and knowledgeable in welding procedures.Determine type of metal being welded and selectcorrect welding procedure and electrodes, rods orwire to provide a weld metal strength equivalent atleast to that of parent metal.

15. Do not damage wiring during removal operations.Reinstall the wiring so it is not damaged nor will itbe damaged in operation by contacting sharpcorners, or by rubbing against some object or hotsurface. Place wiring away from oil pipe.

16. Be sure all protective devices including guards andshields are properly installed and functioningcorrectly before starting a repair. If a guard orshield must be removed to perform the repair work,use extra caution.

17. Always support the mast and carriage to keepcarriage or attachments raised when maintenanceor repair work is performed, which requires themast in the raised position.

18. Loose or damaged fuel, lubricant and hydrauliclines, tubes and hoses can cause fires. Do not bendor strike high pressure lines or install ones whichhave been bent or damaged. Inspect lines, tubesand hoses carefully. Do not check for leaks withyour hands. Pin hole (very small) leaks can resultin a high velocity oil stream that will be invisibleclose to the hose. This oil can penetrate the skinand cause personal injury. Use cardboard or paperto locate pin hole leaks.

19. Tighten connections to the correct torque. Makesure that all heat shields, clamps and guards areinstalled correctly to avoid excessive heat, vibrationor rubbing against other parts during operation.Shields that protect against oil spray onto hotexhaust components in event of a line, tube or sealfailure, must be installed correctly.

20. Relieve all pressure in air, oil or water systemsbefore any lines, fittings or related items aredisconnected or removed. Always make sure allraised components are blocked correctly and bealert for possible pressure when disconnecting anydevice from a system that utilizes pressure.

21. Do not operate a truck if any rotating part isdamaged or contacts any other part duringoperation. Any high speed rotating component thathas been damaged or altered should be checked forbalance before reusing.

HOW TO USE THIS MANUAL

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

• Gasoline Engine Truck (GPE, GP) . . . . . . . . . . . . . Equipped with K15/K21 or K25 Gasoline Engine

• Diesel Engine Truck (DP) . . . . . . . . . . . . . . . . . . . . Equipped with S4Q2 or S4S Diesel Engine

• Powershift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipped with Powershift Transmission

• Manual Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipped with Manual Transmission (2 Types of Clutch; Dry and Wet)

Electric wiringController

FC lever box

Lever

Electromagnetic control valve

Hydraulic transducer

Same as MC Truck except electronic control system

209602

Lever

Control valve

Flow regulator valve

209601

MC Truck

FC Truck

HOW TO USE THIS MANUAL (continued)(Removal, Installation, Assembly and Disassembly)

Disassembly diagram (example)

Suggestion for disassembling

1. Output shaft, Removing

Remove output shaft using a special tool.

Service Data

A: Standard ValueB: Repair or Service Limit

1

2

209603

Sequence

1 Cover, Bolt, Washer (part name)2 Snap ring ................ (part name)

A0.11 to 0.28 mm

Gear Backlash (0.0043 to 0.0110 in.)

B 0.5 mm (0.020 in.)

209604

Disassembling sequence

Procedures are described in the text.

Symbols or abbreviation

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)

Units

1. SI Units are used in this manual.

2. The following table shows the conversion of SI unit and customary unit.

Item SI unit Customary unit

Force1 N 0.1020 kgf

1 lbf 0.4536 kgf

Pressure1 kPa 0.0102 kgf/cm2

1 psi 0.0703 kgf/cm2

Torque1 N·m 0.1020 kgf·m

1 lbf·ft 0.1383 kgf·m

GROUP INDEX Items

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

GROUP INDEX

GENERAL INFORMATION

COOLING SYSTEM

ELECTRICAL SYSTEM

CONTROLLERS

POWER TRAIN

CLUTCHES

MANUAL TRANSMISSION

POWERSHIFT TRANSMISSION

FRONT AXLE ANDREDUCTION DIFFERENTIAL

REAR AXLE

BRAKE SYSTEM

STEERING SYSTEM

HYDRAULIC SYSTEM

Specification, Structure, Removal and installation, Inspection andadjustment

Chassis electrical devices wiring outline, Structure, Console box, Batterymaintenance, Wire color, Troubleshooting, Electrical schematics

Outline, Main functions, Service tool functions, Locations of sensorsand switches

Removal and installation (MC models), Removal and installation (FCmodels)

Advantages and disadvantages of clutches by type of drive system, Principaldifferences between dry-type and wet-type clutches, Structure and function ofclutch, Adjustment, Troubleshooting, Service data

Structures, Removal and installation, Disassembly, Inspection andrepair, Reassembly, Troubleshooting, Service data

Structure and function, Removal and installation, Disassembly andreassembly, Inspection and adjustment, Troubleshooting, Service data

Structure, Removal and installation, Disassembly and reassembly,Troubleshooting, Service data

Model view, Truck models covered, Serial number locations,Dimensions, Technical data

Structure and functions, Removal and installation, Disassembly andreassembly

Structure, Disassembly and reassembly, Inspection and adjustment,Troubleshooting, Service data

Structure and function, Disassembly and reassembly, Steering valve,Troubleshooting, Service data

Structure and functions, Disassembly and reassembly, Inspection andadjustment, Troubleshooting, Service data, MC control valve, FC controlvalve

MAST AND FORKS

Mast system, Structure and function, Removal and installation,Disassembly and reassembly, Removal and installation of mast rollers andstrips without removing mast from truck, Inspection and adjustment,Troubleshooting, Service data

SERVICE DATAMaintenance schedule, Tightening torque for standard bolts and nuts,Periodic replacement parts, Lubrication instructions, Special servicetools

Model View ............................................................................................... 1 – 1

Truck Models Covered ........................................................................... 1 – 2

Serial Number Locations ...................................................................... 1 – 4

Dimensions ............................................................................................... 1 – 5

Technical Data ......................................................................................... 1 – 6

1

GENERAL INFORMATION

1-1

GENERAL INFORMATION

Model View

MC Truck

209605

FC Truck

210780

1-2

GENERAL INFORMATION

Truck Models Covered

This Service Manual provides servicing and maintenance information for the following trucks:

(FC type is used in torque converter model only.)

Notice: Characters at the end of truck model should be read as follows:

(F) : Finger-tip-controlled model

None: Mechanically-controlled model

Z : High-power engine model

C : Short body model

Engine control Gasoline engine Diesel engine LPG engine

StandardMC/— MC/FC —

(Non-electronic control)

Electronic control MC/FC — MC/FC

Standard gasoline engine models Diesel engine models

Truck classTruck model

Model code - EngineTruck model

Model code - Engineserial number mounted serial number mounted

GP15N T25C-50001~ K15 DP15N T16D-50001~ S4Q2— — — DP15N(F) T16D-60001~ S4Q2

1 ton classGP18N T25C-70001~ K15 DP18N T16D-70001~ S4Q2GP15ZN T34-50011~ K21 DP18N(F) T16D-80001~ S4Q2GP18ZN T34-70001~ K21 DP20CN T16D-85001~ S4Q2GP20CN T34-20001~ K21 DP20CN(F) T16D-87001~ S4Q2

GP20N T17D-00011~ K21 DP20N T18C-00011~ S4SGP25N T17D-50001~ K21 DP20N(F) T18C-10001~ S4S

2 ton classGP20ZN T35-00011~ K25 DP25N T18C-50001~ S4SGP25ZN T35-50001~ K25 DP25N(F) T18C-60001~ S4S

GP30N T13F-30011~ K25 DP30N T14E-30011~ S4S

3 ton class— — — DP30N(F) T14E-40001~ S4S

GP35AN T13F-50001~ K25 DP35AN T14E-50001~ S4S— — — DP35AN(F) T14E-60001~ S4S

1-3

GENERAL INFORMATION

Electronically-controlled gasoline engine models Electronically-controlled LPG engine models

Truck classTruck model

Model code - EngineTruck model

Model code - Engineserial number mounted serial number mounted

GPE15N T25C-58001~ K15GPE15N(F) T25C-68001~ K15GPE18N T25C-78001~ K15GPE18N(F) T25C-88001~ K15 — — —

1 ton classGPE15ZN T34-58011~ K21GPE15ZN(F) T34-68001~ K21GPE18ZN T34-78001~ K21GPE18ZN(F) T34-88001~ K21GPE20CN T34-28001~ K21GPE20CN(F) T34-38001~ K21

GPE20N T17D-08011~ K21GPE20N(F) T17D-18001~ K21GPE25N T17D-58001~ K21

2 ton classGPE25N(F) T17D-68001~ K21 — — —GPE20ZN T35-08011~ K25GPE20ZN(F) T35-18001~ K25GPE25ZN T35-58001~ K25GPE25ZN(F) T35-68001~ K25

GPE30N T13F-38011~ K25 — — —

3 ton classGPE30N(F) T13F-48001~ K25 GPE30N(F) T13F-49001~ K25GPE35AN T13F-58001~ K25 — — —GPE35AN(F) T13F-68001~ K25 — — —

1-4

GENERAL INFORMATION

Serial Number Locations

Name Plate Chassis Serial Number Gasoline Engine Serial Number

Diesel Engine Serial Number(2, 3 ton classes)

Diesel Engine Serial Number(1 ton class and DP20N–25N)

Transmission Serial Number(Powershift Transmission Truck)

Transmission Serial Number(Manual Transmission Truck)

Mast Serial Number

209607

1-5

GENERAL INFORMATION

Dimensions

A

B

H

J

E

D N

P

M

F

I

L

O

KCG

210781

1-6

GENERAL INFORMATION

Technical Data

Ref. Model Gasoline-engine GP15N GP18NNo. Truck GP15ZN GP18ZN

GPE15N GPE18NGPE15ZN GPE18ZN

Diesel-engine Truck (DP15N) (DP18N)

Item

A Maximum lift 3000 (118)

B Free lift 115 (4.5)

C Fork spread (outside)200 to 920

(7.9 to 36.2)

D Fork length 920 (36.2)

E Tilt angle (forward – backward) 6° – 12°

F Overall length 3180 (125.2) 3220 (126.8)

G Overall width (outside of tires)Single tire 1065 (41.9)

Dual tire 1330 (52.4)

H Overall height (to top of mast lowered) 1995 (78.5)

I Overall height (to top of overhead guard) 2065 (81.3)

J Overall height (mast extended) 4055 (159.6)

K Tread (front)Single tire 888.5 (35)

Dual tire 1025 (40.4)

L Tread (rear) 900 (35.4)

M Wheelbase 1400 (55.1)

N Front overhang 400 (15.7)

O Minimum turning radius 1950 (76.8) 1980 (78)

P Underclearance (at frame) 150 (5.9)

Unit: mm (in.)

1-7

GENERAL INFORMATION

GP20N GP25NGP20CN GP20ZN GP25ZN GP30N GP35AN

GPE20CN GPE20N GPE25N GPE30N GPE35ANGPE20ZN GPE25ZN

(DP20CN) (DP20N) (DP25N) (DP30N) (DP35AN)

3000 (118) 3030 (119) 3000 (118)

115 (4.5) 140 (5.5) 145 (5.7) 150 (5.9)

220 to 920 220 to 1000 250 to 1000 (8.7 to 36.2) (8.7 to 39.4) (9.8 to 39.4)

920 (36.2) 1070 (42.1)

6° – 12°

3280 (129.1) 3410 (134.3) 3625 (142.7) 3795 (149.4) 3860 (152)

1065 (41.9) 1150 (45.3) 1275 (50.2) 1290 (50.8)

— 1480 (58.3) 1490 (58.7)

1995 (78.5) 2045 (80.5) 2180 (85.8)

2065 (81.3) 2070 (81.5) 2095 (82.5) 2105 (82.9)

4055 (159.6) 4085 (160.8) 4055 (159.6)

890 (35) 960 (37.8) 1060 (41.7)

— 1140 (44.9)

900 (35.4) 980 (38.6)

1400 (55.1) 1600 (63) 1700 (66.9)

415 (16.3) 455 (17.9) 490 (19.3)

2020 (79.5) 2200 (86.6) 2230 (87.8) 2380 (93.7) 2440 (96.1)

150 (5.9) 160 (6.3) 190 (7.5) 200 (7.9)

Unit: mm (in.)

1-8

GENERAL INFORMATION

Model Gasoline-engine GP15N GP18NTruck GP15ZN GP18ZN

GPE15N GPE18NGPE15ZN GPE18ZN

Diesel-engine Truck (DP15N) (DP18N)

Item

Capacity/load center kgf/mm (lbf/in.)1500/500 1750/500(3310/20) (3860/20)

GP15N: 500 (98) GP18N: 500 (98)

rate loadGP15ZN: 570 (112) GP18ZN: 570 (112)GPE15N: 560 (110) GPE18N: 560 (110)

mm/sec (fpm)GPE15ZN: 640 (126) GPE18ZN: 640 (126)

Lift speedDP15N: 600 (118) DP18N: 600 (118)

GP15N: 560 (110) GP18N: 560 (110)

unloadGP15ZN: 640 (126) GP18ZN: 640 (126)GPE15N: 570 (112) GPE18N: 570 (112)

mm/sec (fpm)GPE15ZN: 650 (128) GPE18ZN: 650 (128)DP15N: 650 (128) DP18N: 650 (128)

rate load19/(11.8)

Travel speedkm/h (mph)

unload19.5/(12.1)

km/h (mph)

Unit: mm (in.)

Per

form

ance

1-9

GENERAL INFORMATION

GP20N GP25NGP20CN GP20ZN GP25ZN GP30N GP35AN

GPE20CN GPE20N GPE25N GPE30N GPE35ANGPE20ZN GPE25ZN

(DP20CN) (DP20N) (DP25N) (DP30N) (DP35AN)

2000/500 2000/500 2500/500 3000/500 3500/500(4410/20) (4410/20) (5510/20) (6610/20) (7720/20)

GP20N: 510 (100) GP25N: 510 (100)GP20CN: 570 (112) GP20ZN: 590 (116) GP25ZN: 590 (116) GP30N: 470 (93) GP35AN: 400 (79)

GPE20CN: 640 (126) GPE20N: 590 (116) GPE25N: 590 (116) GPE30N: 520 (102) GPE35AN: 430 (85)DP20CN: 600 (118) GPE20ZN: 680 (134) GPE25ZN: 680 (134) DP30N: 510 (100) DP35AN: 430 (85)

DP20N: 640 (126) DP25N: 640 (126)

GP20N: 600 (118) GP25N: 600 (118)GP20CN: 640 (126) GP20ZN: 680 (134) GP25ZN: 680 (134) GP30N: 515 (101) GP35AN: 430 (85)

GPE20CN: 650 (128) GPE20N: 610 (120) GPE25N: 610 (120) GPE30N: 530 (104) GPE35AN: 440 (87)DP20CN: 650 (128) GPE20ZN: 690 (136) GPE25ZN: 690 (136) DP30N: 545 (107) DP35AN: 460 (91)

DP20N: 670 (132) DP25N: 670 (132)

19/(11.8)

19.5/(12.1)

Unit: mm (in.)

Specification ............................................................................................ 2 – 1

Structure .................................................................................................... 2 – 2

Removal and Installation ...................................................................... 2 – 3

Inspection and Adjustment .................................................................. 2 – 5

Fan Belt Inspection .................................................................................... 2 – 5

Fan Belt Tension ........................................................................................ 2 – 5

Connecting Radiator Hoses ....................................................................... 2 – 5

Unit Layout ................................................................................................ 2 – 5

Coolant ...................................................................................................... 2 – 6

Radiator Cap ............................................................................................. 2 – 6

2

COOLING SYSTEM

2-1

COOLING SYSTEM

Specification

Truck Models 1 ton class 2 ton class 3 ton classItems

Type Water-cooled, forced circulation

Radiator Corrugated fin (pressure) type

Water pump Centrifugal type

Thermostat Wax Pellet Type

CoolingSystem

2-2

COOLING SYSTEM

Structure

Lower hose

Hose layout

S4Q2 engine

K15, K21,

K25 engines

S4S engine

Radiator

Reservoir tank

K15, K21, K25S4Q2

S4S

Shroud

Fan guard

Upper hose

212800

Fan (directly coupled to engine)

209610

2-3

COOLING SYSTEM

Removal and Installation

Fan Belt Removal

Start by:

Remove the radiator cover.

Suggestion for Removal

(1) Loosen the tension pulley lock bolt by three or fourturns. If the bolt is loosened insufficiently, the tensionpulley will not move.

(2) Move the tension pulley fully toward the fan, thenremove the belt.

Engine

Fan

21209612

Sequence

1 Tension pulley assembly, Bolt2 Fan belt

Fan

Tensionpulley

209613

Do not loosen the lock bolt to such an extent thatthe bolt would be removed.

CAUTION!

2-4

COOLING SYSTEM

Installation

To install, follow the removal sequence in reverse. Alsofollow the instructions given below.

(1) Before installing the belt, turn the fan to check forsmooth rotation. Replace the bearing if it generatesabnormal sound.

(2) After installing the belt, push it to make sure that thetension pulley moves, then tighten the pulley lock boltfirmly.

2-5

COOLING SYSTEM

Inspection and Adjustment

Fan Belt Inspection(1) Check the belt for contamination from oil, grease or

dust. Replace the belt if required. When thecontamination is slight, clean the belt with a rag orpaper towel. Do not use gasoline, oil or any othersolvent to clean the belt.

(2) During the engine overhaul or belt tension adjustment,check the condition of the belt. Replace the belt if ithas any damage.

Fan Belt TensionApply a force of 98 N (10 kgf) [22 lbf] perpendicularly tothe belt at a point midway between the fan pulley andtension pulley. Adjust the tension until belt deflection isbetween 11 to 13 mm (0.43 to 0.51 in.) for the gasoline-engine truck and 10 to 12 mm (0.39 to 0.47 in.) for thediesel-engine truck.

Connecting Radiator HosesWhen connecting the hoses to the radiator, fit their endsfully on the fittings and secure them with clamps. Tightenthe clamp bolts to the torque indicated below. Make surethat each hose is correctly connected and over the flare ofthe fitting.

Clamp bolt tightening torque

Unit Layout

3.92 to 5.88 N·mUpper and lower hoses (0.4 to 0.6 kgf·m)

[2.9 to 4.3 lbf·ft]

2.94 to 4.9 N·mCooler hose (0.3 to 0.5 kgf·m)

[2.2 to 3.6 lbf·ft]

Fan pulley

Tensionpulley

209614

Hose

209615

Standard typeElectronic control type

209616

2-6

COOLING SYSTEM

Coolant

Fill the radiator with coolant containing antifreeze. Afterstarting the engine and letting it warm up during operation,check for abnormal noises. Check the coolant level in thereserve tank to ensure it meets the specification.

Quantity of coolant

Radiator Cap

Truck Models1 ton class 2 ton class 3 ton class

Items

Reserve tank (FULL level) 0.65 (0.17) 0.65 (0.17) 0.65 (0.17)

Total quantity of coolant6.8 (1.80) 7.4 (1.96) 8.7 (2.30)

(including coolant in hoses)

Unit: liter (U.S. gal.)

88 ± 14.7 kPaOpening pressure (0.90 ± 0.15 kgf/cm2)

[12.8 ± 2.1 psi]

0 to 4.9 kPaVacuum valve (0 to 0.05 kgf/cm2)

[0 to 0.71 psi]

Chassis Electrical Devices Wiring Outline ....................................... 3 – 1

Structure .................................................................................................... 3 – 3

Console box .............................................................................................. 3 – 3

Major Electrical Components ..................................................................... 3 – 5

Lamp Bulb Specifications .......................................................................... 3 – 16

Console Box ............................................................................................. 3 – 17

Disassembly .............................................................................................. 3 – 17

Instrument Panel ....................................................................................... 3 – 18

Battery Maintenance .............................................................................. 3 – 19

Wire Color .................................................................................................. 3 – 20

Troubleshooting........................................................................................ 3 – 21

Electrical Schematics ........................................................................... 3 – 25

3

ELECTRICAL SYSTEM

3-1

ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline (No. 1)

Main harness

Harness, front combination

Harness, front combination

Harness, rear combination

209620

3-2

ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline (No. 2)

Battery seat

Fuse box,Fuse

Harness,rear combination

Back buzzer

Clip

Relay box,Relay

Harness, frontcombination

Connectorbracket

Horn

Controller

QGS controller(Diesel truck only)

Warning buzzer

Harness, frontcombination

Vehicle speed sensor(Pulse generator)

Transmission

Select switch

Starter switch

Key

212801

3-3

ELECTRICAL SYSTEM

Structure

Console box

1 Water temperature gauge2 Fuel gauge3 Various warning lights4 Instrument panel5 Starter switch6 Lighting switch, turn signal switch7 Forward-reverse lever

1

6

5

34

2

7

213005

3-4

ELECTRICAL SYSTEM

Function of Instrument Panel

Description of function

Inspection method of blown bulbs for Instrument panel

All warning and indicator lamps are normal, if they illuminate, when the starter switch is turned to ON position.

A B C D E F G H

I

KJ LL1 L2 L3 212802

Code Name of monitor When not illuminated When illuminated Remarksor flashing

A Brake fluid level warning lamp Normal level Low level

BATM: Torque converter fluid temperature warning lamp Normal temperature Overheat ATM truck

MTM: Clutch wear lamp Normal Clutch worn MTM truck

C Engine oil pressure warning lamp Normal oil pressure Low oil pressure

D Seat belt reminder warning lamp Fastened Not fastened

Multi-purpose warning lamp (illuminates when E warnings indicated by printed symbols occur or minor Normal Malfunction Printed symbol

failures occur)

F Charge warning lamp Normal charging Abnormal charging system

G Glow pilot lamp Preheating completed Engine being Diesel-engine truckpreheated

H Load/unload interlock lamp Free Locked

IFr, Re interlock lamp Free Locked (flashing)

Neutral lamp F or R Neutral

J Fuel gauge Indicates remaining fuel amount with key in “ON” position.

K Water temperature gauge Indicates “Overheat” condition if pointer enters the red zone.

L Liquid crystal (normally acting as hour meter) Indicates operating hours with key in “ON” position.

L1 Fuel filter warning lamp Normal Water drain required Diesel-engine truck

L2 Coolant level warning lamp Normal level Low level Option

L3 Clogged air cleaner element warning lamp Normal element Clogged Option

When major failures occur, bulbs A, C, D, E, and H simultaneously flash.

Pos

itio

n an

d co

nten

tof

pri

nted

sym

bols

3-5

ELECTRICAL SYSTEM

Major Electrical Components

Starter switch

The diesel-engine truck, which uses a distributor type injection pump, is provided with an engine automatic stopmechanism of the fuel cut system by the starter switch.

The gasoline-engine truck is also provided with an engine automatic stop mechanism of the fuel cut system.

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 whilethe engine is running. This prevents starter breakage or flywheel damage caused by an operator restarting the truckwhen the engine is running The gasoline- and diesel-engine models use the same starter switch. In the diesel-enginemodels, (ON) position of the switch is for energizing the glow plugs.

Connection Table

Gasoline-engine truck (12 V)

Diesel-engine truck (12 V)

MG1

G2

SB1

B2

(OFF)(ON)

(START)

208540

Terminal B1, B2 G1 G2 M S

Connected to Battery,alternator, Fuse box FNR lever

Key position fuse box

OFF

ON (when driving)

START (when starting engine)

Terminal B1, B2 G1 G2 M S

Connected to Battery, Neutral switchalternator, Fuse box (starter),

Key position fuse box QGS controller

OFF

ON (when preheating) (when driving)

START (when starting engine)

3-6

ELECTRICAL SYSTEM

Lighting switch and turn signal switch

Lighting switch and turn signal switch

Horn contact

Horn

Steering angle sensor

Forward-reverse selector switch

T-3 L-2L-4

L-5L-3L-1T-2

T-1

421

3 5

42

315

209627

Lighting and turn signal lever

Boot

Horn contact

Steering angle sensor

Boot

Forward-reverse lever

Lighting switch, turn signal switchForward of truck

209625

Lighting switch, turn signal switch

Forward of truck

Forward-reverse selector switch

F

N

R

212804

3-7

ELECTRICAL SYSTEM

Horn

Check that the horn sounds when applying the specifiedvoltage to both terminals of the horn, T1 and T2.

Replace the horn if it does not sound or its sound isabnormal.

Operating voltage: DC 12 V

Notice: The installed position in an actual truck is as perthe illustration.

Tank Unit (gasoline-engine truck)

Up

Down

Coil

T1

T2

Vent hole

Contact

209628

1/2

3/4

F

1/4

E

Fuel pump

Pressure reliefvalve

Fuel filter

210782

Float position E 1/4 1/2 3/4 F

Standard resistance value (ohm) 80 49.5 32 19 10

Tolerance (ohm)+12

– ±3 –+1.0

+2 -0.5

Referential Standards

3-8

ELECTRICAL SYSTEM

Brake fluid sensor

Refer to the brake system.

Stop lamp switch

Connect a tester across the terminals and check that thelamps turn ON and OFF when the push rod extendedprojection is to the specified value.

Measure the insulation resistance value across the terminalswhen the push rod is pushed in.

Replace the switch if the measured insulation resistancevalue is not more than the value listed below.

Rated voltage: DC 12 V

Indi

cato

r O

N a

ctiv

atin

g po

sitio

n

(em

erge

ncy

ener

giza

tion)

3 ±

2 m

m(0

.12

± 0.

08 in

.)

206672

OFF ON(illuminates)

4 (0.16)

2 (0.08)

Push rod

M10x1.25

Unit : mm (in.)

208543Insulation resistance value

1 M ohm or more (at 500 V megger)

3-9

ELECTRICAL SYSTEM

Forward-reverse lever assembly (ATM truck)

Backup lamp switch (MTM truck)

(10

)(1

0 )

F Forward

N Neutral

R Reverse

Forward of vehicle

212805

Transmission case

Shift rail (for forward-reverse)

Backup lamp switch

200013

19.5 mm (0.77 in.)

2 mm(0.08 in.)

2 mm(0.08 in.)

M12x1.75

ON OFF

208545

Terminal 1 2 3 4 5

Wire colorLever position *1 B G/R B L/W

F (Forward)

N (Neutral)

R (Reverse)

Connection table

*1 G/W: Gasoline-engine truck

GY/L: Diesel-engine truck

3-10

ELECTRICAL SYSTEM

Sender unit (engine coolant temperature)

1. Apply an ohmmeter between the terminal and body ofthe sender unit and check for continuity (resistancevalue).

2. Replace the sender unit if there is no continuity or themeasured resistance value is outside the standardresistance value.

Notice: The illustration is for a gasoline-engine truck.

Gasoline-engine truck

Diesel-engine truck

TerminalBody

208546

Temperature 60±0.2 65±0.2 80±0.2 100±0.3 115±0.3 125±0.3 130±0.3[°C (°F)] (140±0.4) (149±0.4) (176±0.4) (212±0.5) (239±0.5) (257±0.5) (266±0.5)

Standard resistance80±10 64±7.8 40.6±3.7 22.2±1.4 14.6±0.6 11.3±0.6 10±0.6

value (ohm)

Temperature 50±0.2 60±0.2 80±0.2 100±0.3 106±0.3 120±0.3[°C (°F)] (122±0.4) (140±0.4) (176±0.4) (212±0.5) (223±0.5) (248±0.5)

Standard resistance80±10 56.3±5 29.5±2.5 16.5±0.9 14.3±0.5 10±0.3

value (ohm)

3-11

ELECTRICAL SYSTEM

Thermoswitch (T/C oil)

Apply an ohmmeter between the terminal and body andcheck for continuity (resistance value). Replace thethermoswitch if the measured insulation resistance value isnot more than the value listed in the table below.

Internal resistance: 0.5 ohm or less (with contact ON)

Allowable load: 0.5 A

BodyTerminal

208547

1 M ohm or moreInsulation resistance value (with contact OFF)

(at 500 V megger)

Main specifications

OFF→ON122 ± 3 °C

Operating temperature(251.6 ± 5.4 °F)

ON→OFF115 °C (239 °F)

or higher

Insulation resistance 1 M ohm or more

(with contact OFF)

31.4 to 47.1 N·mTightening torque (3.2 to 4.8 kgf·m)

[23.2 to 34.7 lbf·ft]

Replace the thermoswitch if it was dropped orabused.

CAUTION!

NOTE

When installing the thermoswitch, tighten it to thespecified torque.

3-12

ELECTRICAL SYSTEM

Power relay (ATM truck, for backup lamps)

Inspection of coil

Apply an ohmmeter across terminal 1 and terminal 2 andmeasure the resistance value of the relay coil. If there is nocontinuity or the resistance value measured is outside thestandard resistance value, replace the coil.

Inspection of contact

1. Measure the insulation resistance value betweenterminal 3 and terminal 4. Replace the contact if themeasured insulation resistance value is not more thanthe value listed in the table below.

2. Apply an ohmmeter across terminal 3 and terminal 4.

3. When applying a voltage of 12 V ON and OFF acrossterminal 1 and terminal 2 under the above condition,check to see if the relay activates to cause continuitybetween terminal 3 and terminal 4. Replace the relayif it does not activate properly.

Coil rating [at 20 °C (68°F)]

1 4

2

3 1

4

2

3

Connection diagram

213066

Insulation resistance value20 M ohm or more(at 500 V megger)

Resistance value of coil

Gasoline/Diesel-engine 80 ohm ± 10 %

Truck type Gasoline/Diesel-engine truckItem

Rated operating voltage DC 12 V

Working voltage DC 3 to 7 V

Open-circuit voltage DC 1.2 to 3.9 V

Coil resistance 80 ohm ± 10 %

Rated exciting current 168 mA ± 10 %

As the relay has an integrated diode betweenterminals, be careful about the polarity wheninspecting. Replace the relay if it was dropped orabused.

CAUTION!

3-13

ELECTRICAL SYSTEM

QGS controller (diesel-engine truck)

The QGS controller turns on the glow lamp and glow plugsduring the time indicated in the following table, when thestarter switch is turned from OFF to ON position.

It turns on the glow lamp and glow plugs while the starterswitch is turned to START position.

Rated operating voltage: DC 12 V

Fuel pump (gasoline-engine truck)

Water temperatureItem (Sensor resistance Time turned on

value)

-15 °C [+5 °F]10.0 ± 2.0 sec.

(12.1 kΩ)

Glow lamp, 0 °C [32 °F]6.4 ± 1.3 sec.

Glow plugs (5.9 kΩ)

+10 °C [50 °F]3.0 ± 0.6 sec.

(3.8 kΩ)

3 1

4

5 6

A

B

Connector A Connector B

Connection diagram

Starter switch

ONOFF

ST

BatteryDC12V

Glowplug

QGScontroller

Water temperaturesensor

Glow lamp

212806

Fuel pump

209640

3-14

ELECTRICAL SYSTEM

Solenoid valve (for SR-SF selector valve)

This is an ON/OFF valve (normal open type).

The valve opens the IN/OUT circuit in a non-energizedcondition.

Rated operating voltage: DC 12 V

Solenoid valve

ConnectorSOL a

SOL b

ab

P T

A B

P

B

T

A

213067

The valve for DC 12 V has an identification mark“12 V NO” on the body side.

CAUTION!

Fuse Box

VCM20A

QGS/Others10A

Meter panel10A

Back up/Others15A

Spare

20A 30A

Working lamp15A ETC

15A

A/C20A

Wiper15A

Head lamp15A

Horn10A

Stop lamp10A

EGI30A

EGI30A

Fuse puller

SBF 50AGlow

SBF 100AAlternator

SBF 100ABatterySpare

15A10A

212807

209645

Fuse box, Fuse

3-15

ELECTRICAL SYSTEM

3-16

ELECTRICAL SYSTEM

Lamp Bulb Specifications

ItemNo. of

WattsColor of lens Shape Remarks

Type of lampbulbs

12 volt

Head lamps 2 Colorless 55

Turn2 Amber 27

Combinationsignals

Standard:Installed on

lamps (front)Clearance

overhead guard2 Amber 10

lamps

Turn2 Amber 20

signals

Combination Tail/stop2 Red 8/23

lamps (rear) lamps

Backup2 Colorless 18.4

lamps

213068

6

4

2

5

1

5

3

209648

3-17

ELECTRICAL SYSTEM

Console Box

Disassembly

(1) Disconnect the electrical wiring from connector 1.

(2) Remove the screw using a flatblade screwdriver andremove cover 2.

(3) Remove the screw and then, remove cover 3.

(4) Remove the screw and then, remove cover 4.

(5) Remove the forward-reverse lever (FNR lever) and turnsignal lever 5.

(6) Remove the bolt and then, remove console boxassembly 6.

Reassembly

Follow the disassembly sequence in reverse.

3-18

ELECTRICAL SYSTEM

Instrument Panel

Disassembly

Sequence

1 Meter cover2 Dial3 Water temperature gauge4 Liquid crystal5 Fuel gauge

6 Meter case7 Rigid board8 Bulb9 Socket

1

2

3

6

7

8

9

5

4

206480

Reassembly

To reassemble the instrument panel, follow the reverseof disassembly procedure.

Bulb replacement

For bulb replacement, remove the socket from the rigidboard by turning it counterclockwise. For configurationof the indicator lights, refer to page 3-4.

Be careful not to damage the rigid board whendisassembling the instrument panel.

CAUTION!

3-19

ELECTRICAL SYSTEM

Battery Maintenance

1. State of charge and electrolyte specific gravity (S.G.) adjustment

2. Specific gravity reading and state of charge

To check the battery for state of charge, takehydrometer readings on its electrolyte. The battery maybe fully charged if the S.G. reading is 1.280 to 1.265 at20°C (68°F). The state of charge can be told from theway the electrolyte level goes down to expose the cellplates. If addition of distilled water is necessary everymonth or so, the battery is overcharged. If addition isnot required for more than 3 months, it is likely that thebattery is inadequately charged.

3. Charging precautions

(1) In slow charging, the charging current should beabout 1/10 the capacity of the battery to be charged.

(2) In quick charging, the battery capacity in ampereshould not be exceeded.

(3) During charging, adjust the charging current toprevent the electrolyte temperature from risingbeyond 45°C (113°F).

(4) When connecting the cables to the battery, begin byinstalling the cable to the positive (+) terminal.When disconnecting them from the battery, beginby removing the cable from the negative (−)terminal.

Specific gravity readingState of charge Adjustmentat 20°C (68°F)

1.280 to 1.265 Fully charged If difference in S.G. between any two cells is 0.020 or more,discharge the battery to minimize the difference and thenrecharge 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 connection.

1.220 or below Discharged Recharge battery. If difference in S.G. is large, adjust itduring recharging.

If difference in S.G. is A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remainedmore than 0.040 is in shorted condition. constant for more than 2 hours.

Electrolyte leakage, During recharging, adjust S.G. to 1.280 to 1.265.or excessive/diluted If difference in S.G. is more than 0.040 and a low S.G. iselectrolyte. found in certain cells only, replace battery. After leaving

battery for 12 to 96 hours, conduct a high current dischargetest.

IDENTIFICATION34B19L55D23L (Gasoline-engine truck)

75D26L95D31L (Diesel-engine truck)

209650

Be sure to turn OFF the starter switch andlighting switch before disconnecting orconnecting the battery cables to prevent the ICregulator from suffering damage.

CAUTION!

3-20

ELECTRICAL SYSTEM

Wire Color

Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the firstcolor shows a base color and the second color a marking color.

Example: The wire color of BW shows that its base color is B with a marking W.

B WMarking color

Base color

Notice: For wiring identification, the same color, in principle, must be used for the circuit from the power supply tothe load.

List of wire colors

Wire color Color

B BLACK

W WHITE

R RED

G GREEN

Y YELLOW

Br BROWN

L BLUE

Lg LIGHT GREEN

O ORANGE

P PINK

Gr GRAY

Lb LIGHT BLUE

Dg DARK GREEN

ch CHOCOLATE

Be careful that allowable current differs between solid wires and stranded wires even if they are of thesame gauge.

CAUTION!

3-21

ELECTRICAL SYSTEM

Troubleshooting

Starter System

Weak or dead battery Recharge or replace.

Short or open circuit Repair or replace.

Poor continuity in starter switch Replace.

Starter or starter relay defective Replace.

Forward-reverse lever not in neutral Move lever to neutralposition (ATM truck) position.

Open or short circuit Repair or replace.

Engine stop solenoid defective Replace or readjust.

Control timer defective Replace.

Gauges

Rigid board defective Replace.


Gauge internally defective Replace.

Gauge unit defective Replace.

Gauge or gauge unit not of the type Replace to a correct called for one.

Loose terminal connection Repair.

Circuit between gauge and gauge unit Repair.grounded


Rigid board defective Replace.




Gauge or gauge unit not of the type Replace to a correct called for one.

Loose terminal connection Repair.

Circuit between gauge and gauge unit Repair.open or short



Circuit between gauge and gauge unit Repair.grounded



Starter will not crankengine

Starter switch

Watertemperaturegauge

Fuel gauge

Turning off starterswitch will not stopengine

Will not indicate atall

Will not indicateaccurately

Will indicate higherthan actualtemperature

Will not indicate atall

Will not indicateaccurately

Will indicate “full”regardless of amountof fuel left in tank

Will indicate“empty” regardlessof amount of fuelleft in tank

3-22

ELECTRICAL SYSTEM

Lighting System

Weak or dead battery Recharge or replace.

Fuses blown out Check and replace.


Poor grounding Clean ground spot andre-make connection.

Switch defective Replace.

Bulbs burnt out Replace.

Weak battery Check and recharge.

Contact points in switches defective Repair or replace.

Loose terminals Repair.

Dirty lenses Clean.

Water drops inside lenses Dry and replace packings.

Bulbs expired in service life Replace.

Lighting switch defective Replace.


Turn signal switch defective Replace.

Turn signal relay defective Replace.



Low wattage of bulbs Replace to a correct one.



High wattage of bulbs Replace to a correct one.


Backup lamp switch defective Repair or replace.


Lighting switch defective Replace.

Bulb burnt out Replace.

Alarm UnitFuse blown out Check and replace.


Horn switch defective Replace.

Horn defective Replace.

Horn button defective Repair or replace.

Horn switch defective Replace.

Horn defective Replace.

Will not light

Will not light

Lamps - general

Head lamps

Will light dimly

Turn signals

Other lamps

Horn

Will not flicker

Will not go out

Will flicker tooslow

Will flicker toofast

Backup lampswill not light

License numberplate lamp willnot light

Will not sound

Will give anoffensive blastof sound

3-23

Battery

Drive belt slipping Readjust.

❋ Alternator

Stator coil grounded or open-circuited Repair or replace.

Rotor coil open Replace.

Brushes poorly seating on slip rings Replace brushes if worn.Clean holder and polish slip rings.

Diode ruptured Replace.

❋ Regulator

Regulated voltage setting too low Replace.

❋ Battery

Not enough electrolyte or wrong concentration of acid Refill and check specific to water gravity.

Battery cell plates deteriorated (forming, possibly Replace.internal short-circuit)

Terminal connections loose Clean and retighten.

❋ Wiring

Open or loose connection between starter switch and Repair.regulator IC terminal

Fuse blown, or loosely set in holder Replace and repair.

Open or loose connection between F terminals of Repair.regulator and alternator

❋ Wiring

Regulator IC and F terminals shorted or miswired Repair.

Poor grounding of regulator F terminal Repair.

❋ Regulator

Pressure coil open-circuited Replace.

Regulated voltage too high Replace.

Tends to run downrapidly

Tends to getovercharged

ELECTRICAL SYSTEM

3-25

ELECTRICAL SYSTEM

Electrical Schematics

Electrical Schematic (1/6): GP15N to GP35AN (MC Truck) ................................ 3 – 27

Fuse, Starter, Alternator, License Lamp ............................................................. 3 – 29

Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 – 31

Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 – 33

Strobe Lamp, Working Lamp, Front Wiper .......................................................... 3 – 35

Meter Panel ........................................................................................................ 3 – 37

Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 – 39

Steering, Hydraulic Sensor................................................................................. 3 – 41

Electrical Schematic (2/6): GPE15N to GPE35AN (MC Truck)............................ 3 – 43





Meter Panel ........................................................................................................ 3 – 53



Electrical Schematic (3/6): GPE15N to GPE35AN (FC Truck)............................. 3 – 59





Meter Panel ........................................................................................................ 3 – 69



Armrest .............................................................................................................. 3 – 75

Electrical Schematic (4/6): GPE15N to GPE35AN (MC/FC Truck) ECM ............ 3 – 77

Gas Injection, Ignition Coil.................................................................................. 3 – 79

LPG Injection, GLE Engine................................................................................. 3 – 81

Electrical Schematic (5/6): DP15N to DP35AN (MC Truck) ................................ 3 – 83





3-26

ELECTRICAL SYSTEM

Meter Panel ........................................................................................................ 3 – 93



Electrical Schematic (6/6): DP15N to DP35AN (FC Truck) ................................. 3 – 99

Fuse, Starter, Alternator, License Lamp .............................................................3 – 101

Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ...............................................3 – 103

Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................3 – 105

Strobe Lamp, Working Lamp, Front Wiper ..........................................................3 – 107

Meter Panel ........................................................................................................3 – 109

Seat Switch, Lift Cylinder, Tilt Cylinder ...............................................................3 – 111

Steering, Hydraulic Sensor.................................................................................3 – 113

Armrest ..............................................................................................................3 – 115

Thank you very much for your reading.

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Caterpillar Cat GP15ZN Forklift Lift Trucks Service Repair Manual SN:T34-50011 and up

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