Caterpillar GC25HP Lift Trucks Service Manual – PDF DOWNLOAD

Description

Caterpillar GC25HP Lift Trucks Service Manual – PDF DOWNLOAD

DESCRIPTION:

Caterpillar GC25HP Lift Trucks Service Manual – PDF DOWNLOAD

Liquefied Petroleum Gas Supplement
4G63 AA0001-ZZ9999
4G64 AA0001-ZZ9999
6G72 0A0001-0Z9999

For use with 4G63, 4G64 & 6G72 Engine Service Manuals. 99729-85100

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.

TABLE OF CONTENTS:

Caterpillar GC25HP Lift Trucks 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
ii
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 GC25HP LIFT TRUCKS SERVICE MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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