Caterpillar GC30N Lift Trucks Service Manuals – PDF DOWNLOAD

Description

Caterpillar GC30N Lift Trucks Service Manuals – PDF DOWNLOAD

DESCRIPTION:

Caterpillar GC30N Lift Trucks Service Manuals – PDF DOWNLOAD

FOREWORD:

This service manual is a guide for servicing Cat® lift trucks. The long productive life of your lift truck(s) depends on regular and proper servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair, or rebuild the lift truck. The descriptions, illustrations, and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience the instructions are grouped by systems as an easy reference.

For engine servicing, please refer to the applicable engine service manual.
K25 Gasoline engine

Safety:

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 lift truck components, the serviceman or mechanic should check the weights noted in this manual.

Use proper lifting procedures when removing any components.
The following is a list of basic precautions that should always be observed:

1. Read and understand all warning plates and decals on the lift truck before operating, lubricating or repairing the product.
2. Always wear protective glasses and protective shoes when working around lift trucks. In particular, wear protective glasses when using a hammer or sledge on any part of the lift truck or its attachments.
3. 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.
4. DO NOT work on any lift truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the lift truck before performing any disassembly.
5. Lower the forks or other implements to the ground before performing any work on the lift truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from falling unexpectedly.

TABLE OF CONTENTS:

Caterpillar GC30N Lift Trucks Service Manuals – PDF DOWNLOAD

Chapter 1 GENERAL INFORMATION
1 Model View 1-1
2 Truck Models Covered 1-2
3 Serial Number Locations 1-3
4 Dimensions 1-4
5 Technical Data 1-5
Chapter 2 COOLING SYSTEM
1 Specification 2-1
2 Structure 2-2
3 Removing Fan Belt 2-3
3 1 Preparation 2-3
3 2 Removal Sequence 2-3
3 3 Suggestions for Removal 2-3
4 Installing Fan Belt 2-4
5 Inspecting and Adjusting Cooling System 2-4
5 1 Inspecting Fan Belt 2-4
5 2 Adjusting Fan Belt Tension 2-4
5 3 Connecting Radiator Hoses 2-5
5 4 Coolant 2-5
5 5 Radiator Cap 2-5
Chapter 3 ELECTRICAL SYSTEM
1 Electrical Components and Wiring Outline 3-1
2 Console Box 3-3
2 1 Console Box Outline 3-3
2 2 Disassembling Console Box 3-4
2 3 Assembling Console Box 3-4
3 Meter Panel 3-5
3 1 Disassembling Meter Panel 3-5
3 2 Assembling Meter Panel 3-5
3 3 Bulb Replacement 3-5
4 Main Electrical Components 3-6
4 1 Meter Panel 3-6
4 2 Key Switch (Anti-Restart Switch) 3-7
4 3 Light Switch and Turn Signal Switch 3-8
4 4 Direction (FNR) Switch 3-9
4 5 Select Switch 3-10
4 6 Horn 3-12
4 7 Tank Unit 3-13
4 8 Brake Oil Sensor 3-13
4 9 Stop Light Switch 3-14
4 10 Thermoswitch (Engine Coolant Temperature) 3-14
4 11 Thermoswitch (T/C Oil) 3-15
TABLE OF CONTENTS
TOC-2
4 12 Speed Sensor (Pulse Generator) 3-16
4 13 Parking Brake Switch 3-17
4 14 Relay Box 3-18
4 15 Fuse Box 3-21
4 16 List of Lights 3-22
5 Battery and Maintenance 3-23
5 1 State of Charge and Electrolyte Specific Gravity (S G ) Adjustment 3-23
5 2 Specific Gravity Reading and State of Charge 3-23
5 3 Precautions for Battery Charging 3-23
6 Wire Color 3-24
6 1 List of Wire Color Codes 3-24
7 Troubleshooting 3-25
7 1 Starter System 3-25
7 2 Gauges 3-25
7 3 Lighting System 3-26
7 4 Alarm Unit 3-27
7 5 Battery 3-27
8 Electrical Wiring Diagram 3-29
Chapter 4 CONTROLLER
1 Outline 4-1
2 Main Functions of Controllers 4-2
2 1 Meter Panel 4-2
2 2 VCM (Vehicle Control Module) 4-2
2 3 ECM (Engine Control Module) 4-2
2 4 GSE Connector 4-3
3 Service Tool 4-5
3 1 Service Tool Menus 4-5
3 2 Toolbox 4-7
4 Mast Interlock System 4-20
4 1 Mast Interlock Function 4-20
4 2 Checking Procedure of Mast Interlock System 4-21
4 3 Active Test Inspection Procedure 4-24
5 Driving Interlock System 4-27
5 1 Controller Function 4-27
5 2 Checking the Operation of Driving Interlock Function 4-28
5 3 Active Test Inspection Procedure 4-31
6 Seat Belt Warning Light 4-32
6 1 Operation of Seat Belt Warning Light 4-32
6 2 Checking the Operation of Seat Belt Warning Light 4-33
7 Parking Brake Warning Buzzer and Light 4-34
7 1 Operation of Parking Brake Warning Buzzer and Light 4-34
7 2 Parking Brake Warning Buzzer 4-35
7 3 Checking the Operation of Parking Brake Warning Buzzer/Light with
Key in OFF Position 4-37
8 Harness Codes 4-38
TABLE OF CONTENTS
TOC-3
9 Controller Output Details 4-40
9 1 VCM (Vehicle Control Module) 4-40
9 2 Seat Switch 4-46
9 3 Parking Brake Switch 4-46
9 4 Direction Lever Switch 4-46
9 5 Vehicle Speed Sensor 4-47
9 6 T/M Solenoid 4-47
9 7 Unload Solenoid 4-47
9 8 Lift Lock Solenoid 4-48
9 9 Warning Buzzer 4-48
9 10 Warning Buzzer Relay 4-49
9 11 Warning Buzzer Circuit 4-50
9 12 Meter Panel 4-51
10 Truck Status Display and Troubleshooting 4-53
10 1 Truck Status Display 4-53
10 2 Diagnosis Table (F Code) 4-54
10 3 LED Blink Pattern 4-60
10 4 Probable Warning Cause on Diagnostic Code and Troubleshooting 4-61
11 Common Diagnostic Codes 4-71
11 1 F85(T/M Forward Travel Solenoid Warning) and
F87 (T/M Backward Travel Solenoid Warning) Displayed 4-71
11 2 E-23 (Throttle Sensor Warning) 4-75
11 3 E-24 (Accelerator Sensor Warning) 4-79
11 4 E-27 (POS Sensor Warning) 4-82
11 5 E-30 (ECCS C/U System Warning) 4-95
11 6 E-31 (Throttle Control Warning) 4-98
11 7 E-35 (LPG Fuel Injection Disconnection Warning) 4-100
11 8 E-38 (LPG Vaporizer Diagnostic Result Warning) 4-102
11 9 E-42 (Gas Air-Fuel Ratio Malfunction) and
E-43 (LPG Air-Fuel Ratio MalFunction) 4-104
Chapter 5 POWER TRAIN
1 Removing and Installing Engine and Transmission Assembly 5-1
1 1 Removal Sequence of Overhead Guard, Covers, and Air Cleaner 5-1
1 2 Suggestions for Removal of Overhead Guard, Cover, and Air Cleaner 5-2
1 3 Removal Sequence of Controls 5-3
1 4 Suggestion for Removal of Controls 5-3
1 5 Installation Sequence of Overhead Guard, Covers, Air Cleaner,
and Controls 5-3
1 6 Preparation for Removing LPG System
(Dual Fuel Gasoline and LPG Model) 5-4
1 7 Removal Sequence of LPG System (Dual Fuel Gasoline and LPG Model) 5-4
1 8 Preparation for Removal of Cooling, Exhaust and Hydraulic Systems 5-5
1 9 Removal Sequence of Cooling, Exhaust and Hydraulic Systems 5-5
1 10 Suggestion for Removal of Cooling, Exhaust and Hydraulic Systems 5-5
1 11 Installation Sequence of Cooling, Exhaust and Hydraulic Systems 5-5
1 12 Removal Sequence of Front Wheel and Front Axle Shaft 5-6
1 13 Preparation for Removal of Engine and Transmission Assembly 5-6
1 14 Removal Sequence of Engine and Transmission Assembly 5-7
TABLE OF CONTENTS
TOC-4
1 15 Suggestions for Removal of Engine and Transmission Assembly 5-7
1 16 Suggestions for Installation of Engine and Transmission Assembly 5-8
Chapter 6 POWERSHIFT TRANSMISSION
1 Structure 6-1
1 1 Transmission 6-1
1 2 Torque Converter Components 6-2
1 3 Control Valve 6-3
1 4 Schematic Diagram of Powershift Transmission Hydraulic System 6-4
2 Removing Transmission 6-7
2 1 Suggestions for Removal 6-7
3 Installing Transmission 6-7
3 1 Suggestions for Installation 6-7
4 Disassembling Control Valve 6-8
4 1 Disassembly Sequence 6-8
5 Inspection and Repair After Disassembling Control Valve 6-8
6 Assembling Control Valve 6-9
6 1 Assembly Sequence 6-9
6 2 Suggestions for Assembly 6-10
7 Disassembling Input Shaft Assembly 6-11
7 1 Disassembly Sequence 6-11
7 2 Suggestions for Disassembly 6-11
8 Inspection and Repair After Disassembling Input Shaft Assembly 6-12
9 Disassembling Oil Pump Assembly 6-13
9 1 Disassembly Sequence 6-13
9 2 Suggestion for Disassembly 6-13
10 Inspection and Repair After Disassembling Oil Pump Assembly 6-14
11 Assembling Oil Pump 6-15
12 Inspection and Adjustment 6-16
12 1 Oil Pressure Measurement 6-16
12 2 Adjusting Brake (Inching) Pedal 6-18
12 3 Adjusting Inching Cable 6-20
12 4 Increasing the Inching Pedal Return Spring Tension 6-21
13 Troubleshooting 6-22
14 Tightening Torque 6-28
15 Service Data 6-29
15 1 Control Valve 6-30
Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
1 Structure 7-1
2 Removing and Installing Front Wheels 7-2
2 1 Preparation 7-2
2 2 Removal 7-2
2 3 Installation 7-3
TABLE OF CONTENTS
TOC-5
3 Removing Front Axle 7-4
3 1 Preparation 7-4
3 2 Removal 7-4
3 3 Suggestions for Removal 7-5
3 4 Installation 7-6
4 Disassembling and Assembling Front Axle 7-8
4 1 Disassembly 7-8
4 2 Suggestions for Disassembly 7-9
4 3 Inspection after Disassembly 7-10
4 4 Assembly 7-11
5 Removing and Installing Reduction Differential 7-13
5 1 Removal 7-13
5 2 Installation 7-13
6 Disassembling and Assembling Reduction Differential 7-14
6 1 Disassembly (2 Ton Class) 7-14
6 2 Disassembly (3 Ton Class) 7-15
7 Disassembling and Assembling Reduction Differential 7-16
7 1 Disassembly 7-16
7 2 Inspection After Disassembling Reduction Differential 7-19
7 3 Assembly 7-20
7 4 Adjustment 7-22
8 Troubleshooting 7-23
9 Service Data 7-24
Chapter 8 REAR AXLE
1 Structure 8-1
1 1 Main Components of Rear Axle 8-1
1 2 Specifications for Wheel Alignment and Steering Angle 8-2
1 3 Main Components of Wheel Hub 8-3
1 4 Main Components of King Pin 8-3
1 5 Main Components of Tie Rod 8-4
1 6 Main Components of Steering Cylinder 8-5
2 Removing Rear Wheels 8-6
3 Installing Rear Wheels 8-6
4 Removing Rear Wheels and Rear Axle Assembly 8-7
4 1 Removal Sequence 8-7
4 2 Suggestions for Removal 8-7
5 Installing Rear Wheels 8-8
6 Disassembling Wheel Hub 8-8
6 1 Disassembly Sequence 8-8
6 2 Suggestions for Disassembly 8-8
7 Inspection and Repair After Disassembly 8-9
8 Assembling Wheel Hub 8-9
8 1 Adjusting Procedure of Wheel Hub Assembly 8-9
9 Disassembling Knuckle (King Pin) 8-11
TABLE OF CONTENTS
TOC-6
9 1 Preparation 8-11
9 2 Suggestion for Disassembling 8-11
10 Inspection and Repair After Disassembling Knuckle (King Pin) 8-12
11 Assembling Knuckle (King Pin) 8-12
12 Removing Steering Cylinder 8-13
12 1 Preparation 8-13
12 2 Suggestions for Removal 8-13
12 3 Disassembly Sequence 8-14
12 4 Suggestions for Disassembly 8-15
13 Inspection and Repair After Disassembling Steering Cylinder 8-15
14 Assembling Steering Cylinder 8-15
15 Disassembling and Assembling Tie Rod 8-16
15 1 Disassembly Sequence 8-16
16 Assembling Tie Rod 8-16
17 Troubleshooting 8-17
18 Service Data 8-17
Chapter 9 BRAKE SYSTEM
1 Structure of Brake System 9-1
2 Structure of Wheel Brakes 9-2
2 1 2, 3 Ton Class 9-2
3 Disassembling Master Cylinder 9-3
3 1 Disassembly Sequence 9-3
4 Inspection and Repair After Disassembling Master Cylinder 9-4
5 Assembling Master Cylinder 9-4
5 1 Suggestions for Assembly 9-4
6 Disassembling Wheel Brakes 9-5
6 1 Preparation 9-5
6 2 Disassembly Sequence 9-5
6 3 Suggestions for Disassembly 9-6
7 Inspection After Disassembling Wheel Brakes 9-7
8 Assembling Wheel Brakes 9-8
8 1 Assembly Sequence 9-8
8 2 Suggestions for Assembly 9-9
9 Assembling Wheel Cylinder 9-11
9 1 Assembly Sequence 9-11
10 Inspection and Repair After Disassembling Wheel Cylinder 9-12
11 Assembling Wheel Cylinder 9-12
12 Inspecting and Adjusting Brake System 9-13
12 1 Automatic Adjuster Test 9-13
12 2 Manual Adjustment 9-13
12 3 Parking Brake Cable Adjustment 9-14
12 4 Brake Pedal Adjustment 9-15
12 5 Bleeding Brake Oil Lines 9-16
TABLE OF CONTENTS
TOC-7
12 6 Braking Performance Test 9-16
12 7 Parking Brake Lever 9-17
13 Troubleshooting 9-19
13 1 Service Brake 9-19
13 2 Parking Brake 9-20
14 Service Data 9-21
14 1 Master Cylinder 9-21
14 2 Wheel Brakes 9-22
Chapter 10 STEERING SYSTEM
1 Structure and Function 10-1
1 1 General 10-1
1 2 Steering Valve 10-2
1 3 Steering Column 10-4
2 Disassembling and Assembling Pipes and Hoses 10-5
2 1 Suggestions for Disassembly and Assembly 10-5
3 Disassembling Steering Wheel and Steering Valve 10-6
3 1 Disassembly Sequence 10-6
3 2 Suggestions for Disassembly 10-6
3 3 Installing Steering Wheel and Steering Valve 10-7
4 Installation 10-8
4 1 Inspection After Installation 10-9
5 Removing Steering Valve 10-9
6 Installing Steering Valve 10-9
7 Disassembling Tilt Lock Lever 10-10
8 Assembling Tilt Lock Lever 10-10
9 Disassembling Steering Valve 10-11
9 1 Disassembly Sequence 10-11
9 2 Suggestions for Disassembly 10-12
10 Inspection After Disassembly 10-13
11 Assembling Steering Valve 10-13
11 1 Assembly Sequence 10-13
11 2 Suggestions for Assembly 10-14
12 Troubleshooting 10-17
13 Service Data 10-18
Chapter 11 HYDRAULIC SYSTEM
1 Structure 11-1
1 1 Outline of Hydraulic System 11-1
1 2 Hydraulic Line Diagram 11-2
1 3 Structure of Hydraulic Tank 11-3
1 4 Structure of Hydraulic Pump (Gear Pump) 11-4
1 5 Structure of Control Valve 11-5
1 6 Down Safety Valve 11-6
TABLE OF CONTENTS
TOC-8
1 7 Structure of Lift Cylinder
(First Lift Cylinder for Duplex Mast and Triplex Mast) 11-7
1 8 Structure of Lift Cylinder
(Second Lift Cylinder for Simplex Mast and Triplex Mast) 11-8
1 9 Structure of Lift Cylinder (Second Lift Cylinder for Duplex Mast) 11-9
1 10 Structure of Tilt Cylinder 11-10
2 Removing Hydraulic Pump 11-11
2 1 Removal Sequence 11-11
2 2 Suggestion for Removal 11-11
3 Installing Hydraulic Pump 11-11
3 1 Suggestion for Installation 11-11
4 Disassembling Hydraulic Pump 11-12
4 1 Disassembly Sequence 11-12
4 2 Suggestions for Disassembly 11-12
5 Inspection and Repair After Disassembling Hydraulic Pump 11-13
6 Assembling Hydraulic Pump 11-13
6 1 Suggestions for Disassembly 11-13
7 Inspection and Adjustment After Assembling Hydraulic Pump 11-13
7 1 Test Operation 11-13
8 Removing Lift Cylinders (Simplex Mast) 11-14
8 1 Removal Sequence 11-14
8 2 Suggestions for Removal 11-14
9 Installing Lift Cylinder (Simplex Mast) 11-16
9 1 Suggestions for Installation 11-16
10 Removing Lift Cylinder (Duplex and Triplex Mast) 11-16
10 1 Removal Sequence 11-16
10 2 Suggestions for Removal 11-17
11 Installing Lift Cylinder (Duplex and Triplex Mast) 11-19
11 1 Suggestions for Installation 11-19
12 Disassembling Lift Cylinder
(First Lift Cylinder for Duplex Mast and Triplex Mast) 11-20
12 1 Disassembly Sequence 11-20
12 2 Suggestions for Disassembly 11-20
13 Inspection After Disassembly
(First Lift Cylinder for Duplex Mast and Triplex Mast) 11-20
14 Assembling Lift Cylinder
(First Lift Cylinder for Duplex Mast and Triplex Mast) 11-21
14 1 Assembly Sequence 11-21
14 2 Suggestions for Assembly 11-21
15 Disassembling Lift Cylinder
(Second Cylinder for Simplex Mast and Triplex Mast) 11-22
15 1 Disassembly Sequence 11-22
15 2 Suggestions for Disassembly 11-22
16 Inspection After Disassembling Lift Cylinder
(Second Cylinder for Simplex Mast and Triplex Mast) 11-22
TABLE OF CONTENTS
TOC-9
17 RAssembling Lift Cylinder
(Second Cylinder for Simplex Mast and Triplex Mast) 11-23
17 1 Assembly Sequence 11-23
17 2 Suggestions for Assembly 11-23
18 Disassembling Lift Cylinder
(Second Lift Cylinder for Duplex Mast) 11-24
18 1 Disassembly Sequence 11-24
18 2 Suggestion for Disassembly 11-24
19 Inspection After Disassembling Lift Cylinder
(Second Lift Cylinder for Duplex Mast) 11-24
20 Assembling Lift Cylinder
(Second Lift Cylinder for Duplex Mast) 11-25
20 1 Assembly Sequence 11-25
20 2 Suggestions for Assembly 11-25
21 Removing Tilt Cylinder 11-26
21 1 Preparation 11-26
21 2 Removal Sequence 11-26
21 3 Suggestions for Removal 11-26
22 Installing Tilt Cylinder 11-26
22 1 Suggestions for Installation 11-26
23 Disassembling Tilt Cylinder 11-27
23 1 Disassembly Sequence 11-27
24 Assembling Tilt Cylinder 11-28
24 1 Precaution 11-28
25 Piping 11-29
26 Removing Suction Strainer and Return Filter 11-30
26 1 Removal Sequence 11-30
26 2 Suggestions for Removal 11-30
27 Inspecting Suction Strainer and Return Filter 11-30
28 Installing Suction Strainer and Return Filter 11-30
28 1 Suggestions for Installation 11-30
29 Hydraulic System Adjustment 11-31
29 1 Hydraulic Tank 11-31
29 2 Inspecting Control Valve 11-32
29 3 Descent Test 11-34
29 4 Forward Tilt Test 11-34
30 Troubleshooting 11-35
30 1 Hydraulic Tank 11-35
30 2 Gear Pump 11-36
30 3 Control Valve 11-36
30 4 Lift and Tilt Cylinders 11-37
31 Service Data 11-38
31 1 First Cylinder for Duplex Mast and Triplex Mast 11-39
31 2 Second Cylinder for Simplex Mast and Triplex Mast 11-40
31 3 Second Cylinder for Duplex Mast 11-41
31 4 Tilt Cylinder 11-42
TABLE OF CONTENTS
TOC-10
32 MC Control Valve 11-43
32 1 Outline of MC Control Valve 11-43
32 2 Hydraulic Line Diagram of MC Control Valve 11-44
32 3 Structure of Inlet Cover Section 11-45
32 4 Structure of Lift Valve 11-48
32 5 Structure of Tilt Valve 11-51
32 6 Structure of Unloader Valve 11-53
33 Removing MC Control Valve 11-54
33 1 Suggestions for Removal 11-54
34 Installing MC Control Valve 11-54
34 1 Suggestions for Installation 11-54
35 Disassembly Sequence of Valve of Inlet Cover Section 11-55
35 1 Suggestions for Disassembly 11-55
36 Disassembly Sequence of Combination Section (Lift Valve) 11-56
36 1 Suggestions for Disassembling Combination Section 11-56
37 Disassembly Sequence of Combination Section (Tilt Valve) 11-57
37 1 Suggestions for Disassembly 11-57
38 Disassembly Sequence of End Cover Section (Unloader Valve) 11-58
39 Inspection and Repair After Disassembling MC Control Valve 11-58
40 Assembling MC Control Valve 11-59
40 1 Suggestions for Assembly 11-59
Chapter 12 MAST AND FORKS
1 Simplex Mast 12-1
1 1 Mast System 12-1
1 2 Structure and Functions (5A25C to 5A30C) 12-3
1 3 Removal Sequence of Mast and Lift Bracket Assembly 12-5
1 4 Suggestions for Removing Mast and Lift Bracket Assembly 12-5
1 5 Suggestions for Installing of Mast and Lift Bracket Assembly 12-7
1 6 Removal Sequence of Mast and Lift Bracket 12-8
1 7 Suggestions for Disassembling Mast and Lift Bracket 12-9
1 8 Inspecting Mast and Lift Bracket (All Mast Models) 12-10
1 9 Assembly Sequence of Lift Bracket Roller (All Mast Models) 12-11
1 10 Lift Bracket Clearance Adjustment (All Mast Models) 12-12
1 11 Installing Mast Rollers (All Mast Models) 12-15
1 12 Installing Mast Strips (All Mast Models) 12-16
1 13 Installing Lift Cylinders (All Mast Models) 12-17
1 14 Connecting Chains 12-18
1 15 Installing Hydraulic Lines 12-19
1 16 Removing and Installing Mast Rollers and Strips Without
Removing Mast From Truck 12-21
1 17 Inspection and Adjustment 12-22
1 18 Inspecting Forks (All Mast Models) 12-22
1 19 Inspecting and Adjusting Chain Tension (All Mast Models) 12-24
1 20 Measuring Chain Elongation (All Mast Models) 12-25
1 21 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(All Mast Models) 12-26
TABLE OF CONTENTS
TOC-11
1 22 Adjusting Mast Roller Clearance (All Mast Models) 12-28
1 23 Inspecting and Adjusting Mast Strip (All Mast Models) 12-29
1 24 Adjusting Mast Tilt Angle (All Mast Models) 12-30
1 25 Inspecting and Adjusting Right and Left Lift Cylinder Stroke
(All Mast Models) 12-31
1 26 Troubleshooting 12-32
1 27 Service Data 12-33
2 Duplex Mast 12-35
2 1 Mast System 12-35
2 2 Structure and Functions (5B25C to 5B30C) 12-37
2 3 Removal Sequence of Mast and Lift Bracket Assembly 12-39
2 4 Suggestions for Removing Mast and Lift Bracket Assembly 12-39
2 5 Suggestions for Installing Mast and Lift Bracket Assembly 12-41
2 6 Suggestions for Installing Mast and Lift Bracket Assembly 12-42
2 7 Disassembly Sequence of Mast and Lift Bracket 12-43
2 8 Preparation for Disassembling Mast and Lift Bracket 12-43
2 9 Suggestions for Disassembling Mast and Lift Bracket 12-44
2 10 Inspecting Mast and Lift Bracket (All Mast Models) 12-45
2 11 Assembly Sequence of Lift Bracket Roller (All Mast Models) 12-46
2 12 Lift Bracket Clearance Adjustment (All Mast Models) 12-47
2 13 Installing Mast Rollers (All Mast Models) 12-50
2 14 Installing Mast Strips (All Mast Models) 12-51
2 15 Installing Second Lift Cylinder (All Mast Models) 12-52
2 16 Installing First Lift Cylinder 12-53
2 17 Connecting Chains 12-54
2 18 Installing Hydraulic Lines 12-55
2 19 Removing and Installing Mast Rollers and Strips Without
Removing Mast From Truck 12-57
2 20 Inspection and Adjustment 12-58
2 21 Inspecting Forks (All Mast Models) 12-58
2 22 Inspecting and Adjusting Chain Tension (All Mast Models) 12-60
2 23 Measuring Chain Elongation (All Mast Models) 12-62
2 24 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(All Mast Models) 12-63
2 25 Adjusting Mast Roller Clearance (All Mast Models) 12-65
2 26 Inspecting and Adjusting Mast Strip Clearance (All Mast Models) 12-66
2 27 Adjusting Mast Tilt Angle (All Mast Models) 12-67
2 28 Inspecting and Adjusting Right and Left Lift Cylinder Stroke
(All Mast Models) 12-68
2 29 Troubleshooting 12-69
2 30 Service Data 12-70
3 Triplex Mast 12-72
3 1 Mast System 12-72
3 2 Structure and Functions (5C25C to 5C30C) 12-74
3 3 Removal Sequence of Mast and Lift Bracket Assembly 12-76
3 4 Suggestions for Removing Mast and Lift Bracket Assembly 12-76
3 5 Suggestions for Installing Mast and Lift Bracket Assembly 12-78
3 6 Disassembly Sequence of Mast and Lift Bracket 12-79
3 7 Preparation for Disassembling Mast and Lift Bracket 12-80
3 8 Suggestions for Disassembling Mast and Lift Bracket 12-80
TABLE OF CONTENTS
TOC-12
3 9 Inspecting Mast and Lift Bracket (All Mast Models) 12-81
3 10 Assembly Sequence of Lift Bracket Roller (All Mast Models) 12-82
3 11 Lift Bracket Clearance Adjustment (All Mast Models) 12-83
3 12 Installing Mast Rollers (All Mast Models) 12-86
3 13 Installing Mast Strips (All Mast Models) 12-87
3 14 Installing Second Lift Cylinder (All Mast Models) 12-88
3 15 Installing First Lift Cylinder 12-89
3 16 Connecting Chains 12-90
3 17 Installing Hydraulic Lines 12-91
3 18 Removing and Installing Mast Rollers and Strips Without
Removing Mast From Truck 12-93
3 19 Inspection and Adjustment 12-95
3 20 Inspecting Forks (All Mast Models) 12-95
3 21 Inspecting and Adjusting Chain Tension (All Mast Models) 12-97
3 22 Measuring Chain Elongation (All Mast Models) 12-99
3 23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(All Mast Models) 12-100
3 24 Adjusting Mast Roller Clearance (All Mast Models) 12-102
3 25 Inspecting and Adjusting Mast Strip Clearance (All Mast Models) 12-103
3 26 Adjusting Mast Tilt Angle (All Mast Models) 12-104
3 27 Inspecting and Adjusting Right and Left Lift Cylinder Stroke
(All Mast Models) 12-105
3 28 Troubleshooting 12-106
3 29 Service Data 12-107
Chapter 13 SERVICE DATA
1 Maintenance Schedule 13-1
2 Tightening Torques for Standard Bolts and Nuts 13-6
2 1 Metric Fine Thread 13-6
2 2 Metric Coarse Thread 13-8
3 Periodic Replacement Parts 13-10
3 1 Location of Periodic Replacement Parts 13-11
4 Lubrication Instructions 13-12
4 1 Lubrication Chart 13-12
4 2 Fuel and Lubricant Specifications 13-13
4 3 Adjustment Value and Oil Capacity 13-14
5 Special tools 13-15
5 1 Special Service Tools 13-15

CATERPILLAR GC30N LIFT TRUCKS SERVICE MANUALS – PDF DOWNLOAD:

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