CAT Gasoline and LPG Forklift Truck GP15N, GP18N, GP20CN, GP20N, GP25N, GP30N, GP35N Workshop Service Manual

99719-6W100 GP20N ET17DL-01001-up GP20HN ET17DL-01001-up GP25N ET17DL-53001-up GP25HN ET17DL-53001-up GP30N ET13FL-02001-up GP35N ET13FL-51001-up DP20N ET18C-01001-up DP25N ET18C-55001-up DP30N ET14E-04001-up DP35N ET14E-53001-up Wet Disc Brake System Supplement Service Manual

Pub. No. 99719-6W100 FOREWORD This service manual is a guide for servicing Cat®Lift Trucks. For your convenience the instructions 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 the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual are for 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 obliga- tions. For items other than the wet disc brakes, refer to service manuals for 1.5 - 3.5 tons models. <Safety Related Signs> Indicates a specific potential hazard that could result in seri- ous bodily injury or death. Indicates a specific potential hazard that may result in bodily injury, or damage to, or destruction of, the machine. Indicates a condition that can cause damage to, or shorten service life of, the machine. WARNING CAUTION NOTE

CHAPTER INDEX CHAPTER INDEX CHAPTER INDEX Items GENERAL Overview ELECTRICAL SYSTEM Electrical System, Vehicle Electronic System Wiring, Instrument Panel, Electrical Schematic CONTROLLERS Main Functions of Each Controller, List of Diagnosis Contents (D-code) POWER TRAIN Removal and Installation Procedure and Points (MC models) TORQUE CONVERTER DRIVE TRANSMISSION Brake Pedal (Inching Pedal) Adjustment FRONT AXLE AND REDUCTION DIFFERENTIAL Removal and Installation Procedure, Disassembly and Reassembly Procedure BRAKE SYSTEM Disassembly and Reassembly, Measurement of Hy- draulic Pressure, Forcible Release of Parking Brake SERVICE DATA Maintenance Schedule, Periodically Inspected Parts, Supply Oil Standard, List of Special Tools 1 3 4 5 8 9 11 15

1 Chapter 1 GENERAL 1. Overview .................................................................................................. 1-1

1-1 GENERAL Chapter 1 GENERAL 1. Overview The following figure shows the major components of the wet disc brake system. The brake oil sucked up from the tank by the gear pump passes through the parking brake valve and flows into the brake valve. brake oil, corresponding in amount to how far the brake pedal is pressed, will flow into the wet disc brake assembly, which presses the internal multi-disc brake to produce a braking force. At the time of parking, if the parking brake switch is operated, the parking brake valve is electrically operated and the brake oil in the wet disc brake assembly is discharged into the tank. As a result, the multi-disc brake is mechan- ically pressed by the internal spring force to produce a braking force for parking. 215997 Main tank Auto-deceleration valve (optional) Oil filter Wet disc brake assembly Parking brake switch Gear pump Pedal assembly Parking brake valve OCM (controller for options) (for wet disc brake specification models only) Shuttle valve (optional) Connector Brake valve

3 Chapter 3 ELECTRICAL SYSTEM 1. Outline of the Electrical System ............................................................ 3-1 2. Outline of Vehicle Electronic System Wiring ....................................... 3-2 3. Instrument Panel ..................................................................................... 3-3 3.1 Optional Functions................................................................................................... 3-3 4. Electrical Schematics ............................................................................. 3-5

CAT Gasoline and LPG Forklift Truck GP15N, GP18N, GP20CN, GP20N, GP25N, GP30N, GP35N Workshop Service Manual

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