Caterpillar 4G63 4G64 6G72 Liquefied Petroleum Gas Supplement Service Manual – PDF DOWNLOAD

Description

Caterpillar 4G63 4G64 6G72 Liquefied Petroleum Gas Supplement Service Manual – PDF DOWNLOAD

DESCRIPTION:

Caterpillar 4G63 4G64 6G72 Liquefied Petroleum Gas Supplement Service Manual – PDF DOWNLOAD

4G63 AA0001-ZZ9999
4G64 AA0001-ZZ9999
6G72 0A0001-0Z9999

INTRODUCTION :

• LP-gas (Liquefied Petroleum gas) lift trucks are superior to gasoline lift trucks in many ways including cleaner emissions and higher fuel efficiency. LP-gas is, however, more dangerous than gasoline when handled improperly.
• This Service Manual contains operating instructions and maintenance procedures for the LP-gas device of Caterpillar LP-gas fuel lift trucks. To ensure safety and maximize the superb features of your lift truck, read this manual thoroughly. The following mark and designation are used in this manual to call your attention to important instructions and cautions.

TABLE OF CONTENTS:

Caterpillar 4G63 4G64 6G72 Liquefied Petroleum Gas Supplement Service Manual – PDF DOWNLOAD

Types of LP-gas 1
Guideline for selecting LP-gas for lift-truck engines 1
LP-gas knock rating and octane number 2
Adverse effects of olefins on LP-gas fuel system 2
Vapor pressure vs temperature for mixture of propane
and normal butane 2
Structure and Function 4
1 Outline of LP-gas device 4
2 LP-gas device layout 5
3 Main component structures 6
3 1 LP-gas tank 6
3 1 1 Pressure relief valve 6
3 1 2 Fixed liquid level gauge 7
3 1 3 Service valve (LP-gas outlet valve) 7
3 1 4 Fuel level indicator 8
3 2 Filter (Vacuum fuel lock filter) 9
3 3 Hydrostatic relief valve 10
3 4 Converter (vaporizer) and LP-gas carburetor 11
3 4 1 Converter (vaporizer) 11
3 4 2 LP-gas carburetor 11
Actions to be taken in the event of a failure 12
Troubleshooting 14
Disassembly and reassembly 17
1 Main components of LP-gas device (4G63, 4G64) 17
2 Main components of LP-gas device (6G72) 18
3 Disassembly and reassembly of LP-gas carburetor /mixer 19
4 Disassembly and reassembly of converter/regulator (vaporizer) 21
5 Disassembly and reassembly of LP-gas filter, Fuel lock 27
Inspection and adjustment 33
1 LP-gas tank inspection 33
2 Filter inspection 33
3 Converter (vaporizer) inspection and adjustment 34
4 Idle speed adjustment 35
5 Output power adjustment 36
6 Gas leak check procedure 36
i
CARB Tier 1 Emissions Control System (S-15G, 2001-2002 Model Year)
Introduction 37
1 Outline of CARB Tier 1 LP-gas system 38
2 CARB Tier 1 LP-gas layout 39
3 Main Component Illustrations 40
3 1 Electronic Control Units (ECU) (Version 1 & 2) 40
3 2 Electronic Control Unit Illustration 40
3 3 Oxygen Sensor 41
3 4 Pedal Sensor 41
3 5 Engine Block Temperature Sensor 41
3 6 Mixer and Throttle Body Illustration 42
3 7 Three Way Catalytic Convertor 42
3 8 Dash Light Illustration 43
3 9 Exploded view for use with Pneumatic type models 44
3 10 Exploded view for use with cushion type models 45
Systems Operations
1 Explanation of Operation 46
2 Terminology 46
Sub-system Operating Principles
1 Fuel Control 46
2 Fuel Control Operation 48
3 Throttle and Governor 49
4 Throttle and Governor Operation 50
5 Operating Specifications 50
System Adjustments
1 Diagnostic Kit Installation 51
2 Adjustments 51
3 S15G Screen Layout 54
3 1 Adjustment Details 55
3 2 Diagnostic Screen Layout 56
S-15G Troubleshooting
1 Troubleshooting Problem Detail 57
2 Troubleshooting Tree Detail 60
3 Check Engine Light Blink Codes 62
4 System Fault Codes 62
5 Effects of Fault Conditions 63
Vacuum System Diagram and Wiring Schematics
1 Vacuum System Diagram 65
2 S-15G Fuel System Wiring Schematic 66
3 ECU Pin Location and Function 67
Inspection and Adjustment
1 Periodic Inspection Schedule 68

CATERPILLAR 4G63 4G64 6G72 LIQUEFIED PETROLEUM GAS SUPPLEMENT SERVICE MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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