Caterpillar Cat DP25K MC Forklift Lift Trucks Service Repair Manual SN:ET18B-55001 and up

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  99719-61120Service Manual GP15K, GP18K, GP20K, GP25K, GP30K, GP35K DP15K, DP18K, DP20K, DP25K, DP30K, DP35K Chassis, Mast & Options GP15K GP18K GP20K GP25K GP30K…
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99719-61120Service Manual GP15K, GP18K, GP20K, GP25K, GP30K, GP35K DP15K, DP18K, DP20K, DP25K, DP30K, DP35K Chassis, Mast & Options GP15K GP18K GP20K GP25K GP30K GP35KET31A-50001-up ET31A-75001-up ET17B-05001-up ET17B-55001-up ET13D-35001-up ET13D-55001-upDP15K ET16B-55001-up DP18K ET16B-75001-up DP20K ET18B-05001-up DP25K ET18B-55001-up DP30K ET14C-35001-up DP35K ET14C-55001-upMCFor use with 4G63/4G64, S4Q2, 4DQ7/S4S Engine Service ManualFOREWORD This service manual is a guide to servicing of Caterpillar® Lift Trucks for 1.5 thru 3.5 ton models. The instructions are grouped by systems to serve the convenience of your ready reference. Long productive life of your lift trucks depends to a great extent on correct servicing — the servicing 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. The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing. Caterpillar reserves the right to change specifications or design without notice and without incurring obligation. For the items pertaining to the engines, refer to the following service manuals: • 4G63/4G64 Gasoline Engine Service Manual (Pub. No. 99729-84120) • S4Q2 Diesel Engine Service Manual (Pub. No. 99719-73100) • 4DQ7/S4S Diesel Engine Service Manual (Pub. No. 99719-51110)SAFETY RELATED SIGNS The following safety related signs are used in this service manual to emphasize important and critical instructions: WARNINGIndicates a specific potential hazard resulting in serious bodily injury or death.CAUTIONIndicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of, the machine.NOTEIndicates a condition that can cause damage to, or shorten service life of, the machine.Pub. No. 99719-61120HOW TO READ THIS MANUAL Disassembly Diagram (example)21 4Each disassembly diagram is followed by disassembly sequence and suggestions disassembly.3▲1 Cover [bolt, washer] (part name) 2 Output shaft (part name)▲Disassembly sequence▲Suggestion for disassembly (1) Output shaft removal Unit: mm (in.) Clearance between cylinder and pistonA0.020 to 0.105 (0.00079 to 0.00413)B0.15 (0.0059)A: Assembly standard B: Repair or service limitWARNINGSAFETY WARNING The proper and safe lubrication and maintenance for this lift truck, recommended by Caterpillar, 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. 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 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. 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 sledge. Use welder’s 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. 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.WARNING 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.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 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 which 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 which 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 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 Operateâ€? 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.GENERAL INFORMATIONVehicle Exterior • This Service Manual deals with all components or systems of the Caterpillar Lift Trucks; except for the engine and attachment, which are covered in the respective manuals.207151Models • This Service Manual furnishes servicing and maintenance information for the following trucks: Truck Model GP15K DP15K GP18K DP18K GP20K DP20K GP25K DP25K GP30K DP30K GP35K DP35KSerial Number ET31A-50001-up ET16B-55001-up ET31A-75001-up ET16B-75001-up ET17B-05001-up ET18B-05001-up ET17B-55001-up ET18B-55001-up ET13D-35001-up ET14C-35001-up ET13D-55001-up ET14C-55001-up1-1Engine Mounted Mitsubishi 4G63 Gasoline Engine Mitsubishi S4Q2 Diesel Engine Mitsubishi 4G63 Gasoline Engine Mitsubishi S4Q2 Diesel Engine Mitsubishi 4G63 Gasoline Engine Mitsubishi S4S Diesel Engine Mitsubishi 4G63 Gasoline Engine Mitsubishi S4S Diesel Engine Mitsubishi 4G64 Gasoline Engine Mitsubishi S4S Diesel Engine Mitsubishi 4G64 Gasoline Engine Mitsubishi S4S Diesel EngineGENERAL INFORMATIONSerial Number Locations NameplateChassis Serial NumberEngine Serial Number (gasoline models) 1 ton models 1 ton models2 to 3 ton models 2 – 3 ton modelsEngine Serial Number (diesel models) 1 ton models2 to 3 ton modelsMast Serial NumberTransmission Serial Number 2073441-2GENERAL INFORMATIONChassis and Mast Model Identification[Chassis] GP35KGeneration designatorMaximum capacity 35: 3500 kg (7640 lb) Engine type GP: gasoline engine type DP: diesel engine type[Mast] A35A33Maximum lifting height (“33” stands for 3300 mm.) Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 35: 3.3 ton classKind of mast A: simplex mast B: duplex mast C: triplex mast1-3Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITINGNOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.GENERAL INFORMATIONDimensionsG CLKEJA HIP BDMNOF 2071701-4GENERAL INFORMATIONUnit: mm (in.) Ref. No. Items ATruck ModelsMaximum lift Simplex mastGP15K DP15KGP18K DP18KGP20K DP20KGP25K DP25KGP30K DP30KGP35K DP35K3300 (130)3300 (130)3300 (130)110 (4.3)140 (5.5)150 (5.9)BFree lift Duplex mast (floor to fork top) Triplex mastCFork spread220 to 920 (8.7 to 36.2)250 to 1000 (9.8 to 39.4)250 to 1000 (9.8 to 39.4)DFork length1070 (42)1070 (42)1070 (42)ETilt angle (forward – backward)6° – 10°6° – 10°6° – 10°FOverall length3280/3315 (129.1/130.5)3515/3585 (138.4/141.1)3775/3830 (143/150.8)Overall width (w/single tires)1065 (41.9)1150 (45.3)1275/1290 (50.2/50.8)Overall width (w/double tires) (outside)1330 (52.4)1480 (58.3)1490 (58.7)HOverall height (to top of mast lowered)2145 (84.4)2210 (87)2210/2320 (87/91.3)IOverall height (to top of overhead guard)2055 (80.9)2070 (81.5)2095/2105 (82.5/82.9)Simplex mast4030 (158.7)4030 (158.7)Duplex mast Triplex mast4350 (171.3) 5805 (228.5)4355 (171.5) 5805 (228.5)4305 (169.5) 4355 (171.5) 5755 (226.6)Tread (front-single tires)890 (35.0)960 (37.8)1060 (41.7)Tread (front-double tires)1025 (40.4)1140 (44.9)1140 (44.9)LTread (rear)450 (17.7)980 (38.6)980 (38.6)MWheelbase1390 (54.7)1600 (63.0)1750 (68.9)NFront overhang402 (15.8)457 (18)490 (19.3)ORear overhang418/453 (16.5/17.8)388/458 (15.3/18)465/520 (18.3/20.5)PUnderclearnace (at frame)150 (5.9)160 (6.3)GJKOverall height (mast extended)1120 (44.1)1125 (44.3)1-51125 (44.3)1130 (44.5)1160 (45.7)1295 (51)4135 (180.1)190 (7.5)200 (7.9)GENERAL INFORMATIONTechnical Data (Standard Models) GP15KDP15KGP18KDP18KGP20KDP20KDesignationET31AET16BET31AET16BET17BET18BWork performanceTruck ModelCapacity/load centerkg/mm (lb/in.)1500/500 (3000/24)Maximum lift heightmm (in.)Lift speed (rated load)mm/secLowering speed (rated load)(fpm)500 (98)500 (98)500 (98)Mast tilt (forward – backward)degree6 – 106 – 106 – 10110 (4.3)110 (4.3)140 (5.5)1120 (44.1)1125 (44.3)1125 (44.3)1120 (44.1)1125 (44.3)1125 (44.3)0 to 19 (0 to 11.8)0 to 19 (0 to 11.8)0 to 18 (0 to 11.2)0 to 19 (0 to 11.8)0 to 19 (0 to 11.8)1990 (78.3)2020 (79.5)3300 (130) 490 (96)Simplex mast Free liftDuplex mastmm (in.)Traveling performanceTriplex mast Travel speedPowershift transmission modelsForward Reversekm/h (mph)Minimum turning radius Minimum intersecting isle Gradeability (reted load)Single wheelsmm (in.)Double wheels Powershift transmission models% (tan)Overall length Overall widthOverall heightDimensions600 (118)2000/500 (4000/24)3300 (130) 490 (96)600 (118)3300 (130) 510 (100)0 to 18 (0 to 11.2)640 (126)0 to 19 (0 to 11.8)2185 (86)1780 (70.1)1800 (70.9)1900 (74.8)1880 (74.0)1900 (74.8)2020 (79.5)3028282528353280 (129.1)3315 (130.5)3515 (138.4)Single wheels1065 (41.9)1065 (41.9)1150 (45.3)Double wheels1330 (52.4)1330 (52.4)1480 (58.3)To top of mast lowered2145 (84.4)2145 (84.4)2210 (87)To top of mast extended4030 (158.7)4030 (158.7)4030 (158.7)2055 (80.9)2055 (80.9)2070 (81.5)To top of overhead guardmm (in.)Wheel base1390 (54.7)1390 (54.7)1600 (63.0)Single wheels890 (35.0)890 (35.0)960 (37.8)Double wheels1025 (40.4)1025 (40.4)1140 (44.9)Rear900 (35.4)900 (35.4)980 (38.6)Overhang Front402 (15.8)402 (15.8)457 (18)Rear418 (16.5)453 (17.8)388 (15.3)150 (5.9)150 (5.9)160 (6.3)6.50 – 10 – 10 686 (7) [100]6.50 – 10 – 10 686 (7) [100]7.00 – 12 – 12 686 (7) [100]4.50 – 12 – 8 686 (7) [100]4.50 – 12 – 8 686 (7) [100]5.00 – 15 – 8 686 (7) [100]5.00 – 8 – 8 686 (7) [100]5.00 – 8 – 8 686 (7) [100]6.00 – 9 – 10 686 (7) [100]Front TreadUnderclearance (at frame) Single wheels Tire size and pressureFront Double wheelskPa (kgf/cm2) [psi]Rear2470 (5450)2550 (5620)2640 (5820)2720 (6000)3260 (7190)3380 (7450)Front axle kg (lb)1040 (2290)1070 (2360)1000 (2210)1030 (2270)1460 (3220)1500 (3310)Rear axle1430 (3150)1480 (3260)1640 (3620)1690 (3730)1770 (3900)1850 (4080)Service weight Weight1750/500 (3500/24)Single wheels (without load)Load distribution1-6GENERAL INFORMATION GP25KDP25KGP30KDP30KGP35KDP35KET17BET18BET13DET14CET13DET14C2500/500 (5000/24)3000/500 (6000/24)3500/500 (7000/24)3300 (130)3300 (130)3300 (130)550 (108)660 (130)470 (93)510 (100)400 (79)430 (85)500 (98)530 (104)440 (87)6 – 106 – 106 – 10140 (5.5)150 (5.9)150 (5.9)1130 (44.5)1160 (45.7)1295 (51)1130 (44.5)1160 (45.7)1295 (51)0 to 18 (0 to 11.2)0 to 19 (0 to 11.8)0 to 19 (0 to 11.8)0 to 18 (0 to 11.2)0 to 19 (0 to 11.8) (0 to 11.8)0 to 19 (0 to 11.8)0 to 19 (0 to 11.8)0 to 18 (0 to 11.2)0 to 19 (0 to 11.8) 2245 (88.4)2445 (96.2)2485 (97.8)1970 (77.6)2090 (82.3)2120 (83.5)2090 (82.3)2170 (85.4)2190 (86.2)2329232419203585 (141.1)3775 (143)3830 (150.8)1150 (45.3)1275 (50.2)1290 (50.8)1480 (58.3)1490 (58.7)1490 (58.7)2210 (87)2210 (87)2320 (91.3)4030 (158.7)4135 (162.8)4135 (162.8)2070 (81.5)2095 (82.5)2105 (82.9)1600 (63.0)1750 (68.9)1750 (68.9)960 (37.8)1060 (41.7)1060 (41.7)1140 (44.9)1140 (44.9)1140 (44.9)980 (38.6)980 (38.6)980 (38.6)457 (18)490 (19.3)490 (19.3)458 (18)465 (18.3)520 (20.5)160 (6.3)190 (7.5)200 (7.9)7.00 – 12 – 12 686 (7) [100]28 × 9 – 15 – 12 686 (7) [100]250 – 15 – 16 834 (8.5) [120]5.00 – 15 – 8 686 (7) [100]6.50 – 10 – 10 686 (7) [100]6.50 – 10 – 10 686 (7) [100]6.00 – 9 – 10 686 (7) [100]6.50 – 10 – 10 686 (7) [100]6.50 – 10 – 12 883 (9.0) [128]3620 (7990)3740 (8250)4220 (9310)4340 (9570)4600 (10140)4720 (10410)1400 (3090)1440 (3180)1760 (3880)1710 (3770)1790 (3950)1830 (4040)2220 (4900)2300 (5070)2460 (5420)2530 (5580)2810 (6200)2890 (6370)1-7GENERAL INFORMATION Truck ModelGP15KDP15KGP18KDP18KGP20KDP20K2500 (5510)2580 (5690)2670 (5890)2750 (6060)3330 (7340)3450 (7610)Front axle kg (lb)1070 (2360)1100 (2430)1030 (2270)1060 (2340)1530 (3370)1570 (3460)Rear axle1430 (3150)1480 (3260)1640 (3620)1690 (3730)1770 (3900)1850 (4080)Engine model4G63S4Q24G63S4Q24G63S4SManufacturerMitsubishi MotorsMHIMitsubishi MotorsMHIMitsubishi MotorsMHIGasolineDieselGasolineDieselGasolineDieselWeightService weight Double wheels (withuot load)Load distributionType Cooling System No. of cylinders - arrangementWaterWaterWater4 -in-line4 -in-line4 -in-line444No. of strokes Types of combustion chambers Valve arrangementType of cylinder liners Cylinder bore × strokemm (in.)Displacementcc (cu. in.)EngineCompression ratioSemisphericalSwirlSemisphericalSwirlSemisphericalSwirlOHCOHVOHCOHVOHCOHVIntegral with cylinder blockDryIntegral with cylinder blockDryIntegral with cylinder blockDry85 × 88 88 ×103 85 × 88 88 ×103 85 × 88 94 ×120 (3.346 × 3.465) (3.465 × 4.055) (3.346 × 3.465) (3.465 × 4.055) (3.346 × 3.465) (3.701 × 4.724) 1997 (121.8)2505 (152.8)1997 (121.8)2505 (152.8)1997 (121.8)3331 (203.2)8.5 :122 : 18.5 : 122 : 18.5 : 122 : 142/240040/220042/240040/220042/240060/2200136 (13.9) [101]/1600134 (13.7) [99]/1600136 (13.9) [101]/1600134 (13.7) [99]/1600201 (20.5) [148]/1400Rated outputPS/rpmMaximum torqueN·m (kgf·m) 134 (13.7) [lbf·ft]/rpm [99]/1600Dimensions (length × width × height)mm (in.)Weight (service)kg (lb)653 × 604 686 × 493 653 × 604 686 × 493 653 × 604 647 × 552 × 759 × 623 × 759 × 623 × 759 × 712 (25.7 × 23.8 (27.0 × 19.4 (25.7 × 23.8 (27.0 × 19.4 (25.7 × 23.8 (25.5 × 21.7 × 29.9) × 24.5) × 29.9) × 24.5) × 29.9) × 28) 150 (330)Location Intake valves150 (330)Rear Open BTDC180 (397)150 (330)Rear260 (570)Rear123012301230405040504050Open BBDC547454745474Close ATDC630630630Intake valves0.00 (hot)0.25 (0.0098) 0.25 (0.0098) 0.25 (0.0098) 0.00 (hot) 0.00 (hot) (cold) (cold) (cold)0.00 (hot)0.25 (0.0098) 0.25 (0.0098) 0.25 (0.0098) 0.00 (hot) 0.00 (hot) (cold) (cold) (cold)Close ABDC Exhaust valves180 (397)Valve clearancedegreemm (in.) Exhaust valvesIgnitionSparkFiring orderCompressionSpark1-3-4-2Ignition timing BTDCdegree/rpmInjection timing BTDCdegreeFuel tank rated capacityliter (U.S. gal)CompressionSpark1-3-4-2Compression1-3-4-26/650–6/650–6/650––18–18–2053 (14)1-853 (14)76 (20)GENERAL INFORMATION GP25KDP25KGP30KDP35KGP35KDP35K3690 (8140)3810 (8400)4240 (9350)4360 (9610)4620 (10190)4740 (10450)1470 (3240)1520 (3550)1780 (3920)1830 (4040)1810 (3990)1850 (4080)2220 (4900)2290 (5050)2460 (5420)2530 (5580)2810 (6200)2890 (6870)4G63S4S4G64S4S4G64S4SMitsubishi MotorsMHIMitsubishi MotorsMHIMitsubishi MotorsMHIGasolineDieselGasolineDieselGasolineDieselWaterWaterWater4 -in-line4 -in-line4 -in-line444SemisphericalSwirlSemisphericalSwirlSemisphericalSwirlOHCOHVOHCOHVOHCOHVIntegral with cylinder blockDryIntegral with cylinder blockDryIntegral with cylinder blockDry85 × 88 (3.346 × 3.465)94 × 120 (3.701 × 4.724)86.5 × 100 (3.406 × 3.937)94 × 120 (3.701 × 4.724)86.5 × 100 (3.406 × 3.937)94 × 120 (3.701 × 4.724)1997 (121.8)3331 (203.2)2350 (143.4)3331 (203.2)2350 (143.4)3331 (203.2)8.5 : 122 : 18.6 : 122 : 18.6 : 122 : 142/240060/220050/240060/220050/240060/2200134 (13.7) [99]/1600201 (20.5) [148]/1400167 (17) [123]/1600201 (20.5) [148]/1400167 (17) [123]/1600201 (20.5) [148]/1400653 × 604 × 759 (25.7 × 23.8 × 29.9)647 × 552 × 712 (25.5 × 21.7 × 28)653 × 604 × 759 (25.7 × 23.8 × 29.9)647 × 552 × 712 (25.5 × 21.7 × 28)653 × 604 × 759 (25.7 × 23.8 × 29.9)647 × 552 × 712 (25.5 × 21.7 × 28)150 (330)260 (570)150 (330)260 (570)150 (330)260 (570)1230123012304050405040505474547454746306306300.00 (hot)0.25 (0.0098) (
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