Caterpillar GP15N, GP15ZN, GP18N, GP18ZN, GP20CN, GP20N, GP20ZN, GP25N, GP25ZN, GP30N, GP35N, GPE15N and 15 more Forklift Service Manual
631 pages · Publication 99719-3F110 · GP15N, GP15ZN, GP18N, GP18ZN, GP20CN, GP20N, GP20ZN, GP25N, GP25ZN, GP30N, GP35N, GPE15N, GPE18N, GPE20CN, GPE20N, GPE20ZN, GPE25N, GPE25ZN, GPE30N, GPE35N, DP15N, DP18N, DP20CN, DP20N, DP25N, DP30N, DP35N
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- Models
- GP15N, GP15ZN, GP18N, GP18ZN, GP20CN, GP20N, GP20ZN, GP25N, GP25ZN, GP30N, GP35N, GPE15N, GPE18N, GPE20CN, GPE20N, GPE20ZN, GPE25N, GPE25ZN, GPE30N, GPE35N, DP15N, DP18N, DP20CN, DP20N, DP25N, DP30N, DP35N
- Serial coverage
- CT25C-55001-up
- CT34-52001-up
- CT25C-75001-up
- CT34-72001-up
- CT34-22001-up
- CT17D-10001-up
- CT35-10001-up
- CT17D-60001-up
- CT35-60001-up
- CT13F-40001-up
- CT13F-60001-up
- CT34-00001-up
- CT34-40001-up
- CT34-30001-up
- CT17D-20001-up
- CT35-20001-up
- CT17D-70001-up
- CT35-70001-up
- CT13F-10001-up
- CT13F-80001-up
- CT16D-54001-up
- CT16D-74001-up
- CT16D-24001-up
- CT18C-20001-up
- CT18C-70001-up
- CT14E-10001-up
- CT14E-80001-up
- Manual type
- Service Manual
- Pages
- 631
- Publication
- 99719-3F110
- Condition
- Brand new
What's inside
From the manual's own table of contents: 433 topics. See sample pages (PDF, 618 KB)
- Model View
- Applicable Truck Model
- Serial Number Locations
- Dimensions
- Technical Data
- Performance
- Specifications
- Structure
- Fan Belt, Removing
- Preparation
- Removal Sequence
- Suggestions for Removal
- Fan Belt, Installing
- Suggestions for Installation
- Cooling System, Inspecting and Adjusting
- Fan Belt Inspection
- Fan Belt Tension Adjustment
- Hoses, Connecting
- Cooling Water
- Radiator Cap
- Chassis Electrical Components and Wiring Outline
- Console Box
- Console Box Outline
- Meter Panel, Removing
Show all 433 topics
- Meter Panel, Installing
- Main Electrical Components
- Meter panel
- Direction (FNR) Switch
- Light Switch and Turn Signal Switch
- Key Switch (Anti-Restart Switch)
- Select Switch
- Steering Angle Sensor
- Backup Buzzer
- QGS Controller (Diesel Model)
- VCM (Vehicle Control Module)
- ECM (Gasoline Engine Control Module)
- Relay Box
- Fuse Box
- Tank Unit
- Horn
- Rear Combination Light
- Rear Combination Harness
- Front Combination Light
- Front Combination Harness
- Stop Light Switch
- Backup Light Switch (Manual T/M Truck)
- Neutral Switch
- Thermoswitch (Engine Coolant Temperature)
- Thermoswitch (T/C Oil)
- List of Lights
- Battery and Maintenance
- State of Charge in Specific Gravity and Adjustment
- Relationship Between Electrolyte Specific Gravity and State of Charge 3-32
- Precautions for Battery Charging
- Meter Panel Layout
- Basic Display
- Basic Operation
- When A Warning Occurs
- Diagnostic Code
- Warning Lights
- Optional Functions
- Hour Meter
- Troubleshooting
- Wire Color
- List of Wire Color Codes
- Engine Startup Problem
- Gauge-related Problem
- Lightning-related Problem
- Warning System Problem
- Battery-related problem
- Electrical Wiring Diagram
- Outline
- Main Functions of Controllers
- VCM -1M (Vehicle Control Module)
- GSE Connector
- Service Tool
- Service Tool Menus
- Toolbox
- Mast Interlock System
- Mast Interlock Function
- VCM-1M Controller, Mast Interlock System Checking Procedure
- Active Test Inspection Procedure
- Driving Interlock System
- Controller Function
- Driving Interlock Function, Checking the Operation
- Seat Belt Warning Light
- Seat Belt Warning Light, Checking the Operation
- Parking Brake Warning Buzzer and Light
- Parking Brake Warning Buzzer
- Checking the Operation with Key in OFF Position
- Harness Codes
- Controller Output Details
- VCM-1M Controller
- Seat Switch
- Park Brake Switch
- Direction Lever Switch
- Vehicle Speed Sensor
- T/M Solenoid
- Unload Solenoid
- Lift Lock Solenoid
- Warning Buzzer
- Warning Buzzer Relay
- Warning Buzzer Circuit
- Truck Status Display and Troubleshooting
- Truck Status Display
- Diagnosis Table (F Code)
- LED Blink Pattern
- Probable Warning Cause on Diagnostic Code and Troubleshooting
- (for Gasoline Models)
- Removal Sequence of Overhead Guard, Air Cleaner and Others
- Suggestions for Removal of Overhead Guard, Air Cleaner and Others
- Removal Sequence of Controls (Manual T/M Truck)
- Suggestions for Removal of Controls (Manual T/M Truck)
- Suggestions for Installing Controls (Manual T/M Truck)
- Removal Sequence of Controls (Power Shift T/M Truck)
- Suggestions for Removing Controls (Power Shift T/M Truck)
- Suggestions for Installing Controls (Power Shift T/M Truck)
- Preparation for Removing Pipes and Radiator (Manual T/M Truck)
- Removal Sequence of Pipes and Radiator (Manual T/M Truck)
- Suggestions for Installing of Pipes and Radiator (Manual T/M Truck)
- Preparation for Removing Pipes and Radiator (Power Shift T/M Truck) 5-6
- Suggestions for Installing Pipes and Radiator (Powershift T/M Truck) . 5-6
- Preparation for Removing Engine and Transmission Assembly
- Removal Sequence of Engine and Transmission Assembly
- Suggestions for Removing Engine and Transmission Assembly
- (Manual T/M truck)
- (Power Shift T/M Truck)
- (for Diesel Truck)
- Suggestions for Removing Overhead Guard, Air Cleaner and Others
- Suggestions for Installing Pipes and Radiator (Manual T/M Truck)
- Preparation for Removing Pipes and Radiator (Power Shift T/M Truck) 5-13
- Removal Sequence of Pipes and Radiator (Power Shift T/M Truck)
- Suggestions for Removing Pipes and Radiator (Power Shift T/M Truck) 5-13
- Suggestions for Installing Pipes and Radiator (Power Shift T/M Truck) . 5-13
- Suggestions for Installing Engine and Transmission Assembly
- Advantages and Disadvantages of Clutches by Type of Drive System
- Main Differences Between Dry-Type and Wet-Type Clutches
- Structure and Function of Clutch
- Clutch Assembly, Disassembling
- Disassembly Sequence
- Suggestions for Disassembly
- Clutch Assembly, Inspection and Repair After Disassembly
- Clutch Disc Assembly
- Clutch Assembly, Assembling
- Assembly Sequence
- Suggestions for Assembly
- Pressure Plate Assembly, Disassembling
- Pressure Assembly, Inspection and Repair After Disassembly
- Pressure Assembly, Assembling
- Clutch Master Cylinder (Dry Type Clutch), Disassembling
- Clutch Master Cylinder (Dry Type Clutch), Assembling
- Clutch Release Cylinder, Disassembling
- Clutch Release Cylinder, Assembling
- Clutch System, Adjustment
- Bleeding Clutch Hydraulic System
- Precautions
- Clutch Pedal (Dry Type), Adjustment
- Clutch Pedal (Wet Type), Adjustment
- Checking Clutch Disc for Wear
- Service Data
- Dry Type Clutch
- Wet Type Clutch
- Components of Transmission
- Transmission, Removal
- Transmission, Installation
- Transmission External Parts, Disassembly
- Control Covers, Shift Rails and Forks, Disassembly
- Shifter Case and Input Shaft, Disassembly
- Transmission Housing and Shaft Assemblies, Disassembly
- Synchro-shaft Assembly, Disassembly
- Input Gear Assembly, Disassembly
- Output Gear, Disassembly
- Inspection and Repair
- Synchromesh Device
- Assembly
- Shifter Case, Assembly Sequence
- Output Gear, Assembly Sequence
- Input Gear and Idler Gear, Assembly Sequence
- Main Shaft Assembly, Assembly
- Selection of Shims
- Transmission Housing, Assembly
- Fork and Shift Rails and Control Cover, Assembly
- Shift Rail
- Input Gear
- Main Shaft
- Gear
- External View of Torque Converter Transmission
- External View of Control Valve
- Transmission Components
- Torque Converter Components
- Torque Converter Drive Control Components
- Schematic Diagram of Powershift Transmission Hydraulic System
- Transmission, Removing
- Transmission, Installing
- Torque Converter Transmission, Disassembling
- Transmission Accessories, Removing
- Oil Pump, Removing
- Transmission Housing, Removing
- Input Shaft, Idler Shaft and Output Gear, Removing
- Transmission Housing, Disassembling
- Torque Converter Housing, Disassembling
- Idler Shaft, Disassembling
- Output Gear, Disassembling
- Forward Side Input Shaft Gear Assembly, Disassembling
- Reverse Side Input Shaft Gear, Disassembling
- Oil Pump, Disassembling
- Torque Converter Transmission, Assembling
- Transmission Housing, Assembling
- Idler Shaft Assembly, Assembling
- Output Gear Assembly, Assembling
- Input Shaft Gear Assembly, Inspecting
- Forward Side Input Shaft Gear Assembly, Assembling
- Reverse Side Input Shaft Gear Assembly, Assembling
- Oil Pump Assembly, Assembling and Installing
- Torque Converter Housing, Assembling
- Transmission Housing, Installing
- Servo Case Assembly, Installing
- Transmission Accessories, Installing
- Control Valve, Disassembling
- Control Valve Accessories, Removing
- Valve Body Plate, Removing
- Plugs, Removing
- Strainer, Removing
- Regulator Valve Section, Disassembling
- Accumulator Valve Section, Disassembling
- Inching Valve Section, Disassembling
- Oil Seal and Plug, Removing
- Control Valve, Assembling
- Control Valve, Assembly Sequence
- Washing and Inspecting
- Valve Plug and Oil Seal, Installing
- Inching Valve Section, Assembling
- Accumulator Valve Section, Assembling
- Regulator Valve Section, Assembling
- Strainer, Installing
- Plug, Installing
- Valve Body Plate and Breather Cover, Installing
- Control Valve Accessories, Assembling
- Inspection and Adjustment
- Oil Pressure Measurement
- Brake (Inching) Pedal, Adjusting
- Inching Cable, Adjusting
- Pump Boss
- Pilot Boss
- Oil Pump
- Flexible Plate
- Clutches
- Input Shaft
- Ton Class
- Front Wheel, Removing
- Front Wheels, Installing
- Front Axle and Reduction Differential, Removing
- Front Axle and Reduction Differential, Installing
- Front Axle, Disassembling
- Front Axle, Inspection and Repair After Disassembly
- Front Axle, Assembling
- Reduction Differential, Disassembling
- Reduction Differential, Assembling
- Reduction Differential, Inspecting and Adjusting After Assembly 9-25
- Reduction Gear Tooth Contact
- Rear Axle Structure
- Main Components
- Specifications for Wheel Alignment and Steering Angle
- Wheel Hub Section, Main Components
- Left Side Kingpin Section, Main Components
- Right Side Kingpin Section, Main Components
- Main Components of Sensor
- Tie Rod Section, Main components
- Steering Cylinder, Main Components
- Rear wheels, Removing
- Rear Wheels, Installing
- Rear Axle Assembly, Removing
- Axle Assembly, Inspection and Repair After Disassembly
- Axle Assembly, Installing
- Wheel Hub, Disassembling
- Wheel Hub Section, Inspection and Repair After Disassembly
- Wheel Hub Section, Assembling
- Wheel Bearing, Assembling and Adjusting
- Knuckle Section (Kingpin), Disassembling
- Knuckle Section (Kingpin), Inspection After Disassembly
- Knuckle Section (Kingpin), Assembling
- Steering Cylinder, Removing
- Steering Cylinder, Disassembling
- Steering Cylinder, Assembling
- Tie Rod, Disassembling
- Tie Rod, Assembling
- Structure of Brake System
- Master Cylinder, Disassembling
- Master Cylinder, Inspection and Repair after Disassembly
- Master Cylinder, Assembling
- Structure of Wheel Brakes
- 2, 3 Ton Classes
- Wheel Brakes, Disassembling
- Wheel Brakes, Inspection and Repair After Disassembly
- Wheel Brakes, Assembling
- Assembly Sequence (1 Ton Class)
- Assembly Sequence (2, 3 Ton Class)
- Wheel Cylinder, Disassembling
- Wheel Cylinder, Inspection and Repair After Disassembly
- Wheel Cylinder, Assembling
- Brake System, Inspecting and Adjusting
- Automatic Adjuster, Operation Test
- Manual Adjustment Procedure
- Parking Brake Cable, Adjusting
- Brake Pedal, Adjusting
- Brake Oil Line, Bleeding
- Braking Performance Test
- Parking Brake Lever, Adjusting
- Structure and Functions
- General
- Steering Valve
- Knob Deviation Correction Control
- Steering Column
- Pipes and Hoses, Disassembling and Assembling
- Suggestions for Disassembly and Assembly
- Steering Wheel and Steering Valve, Disassembling
- Steering Wheel and Steering Valve, Installing
- Installation
- Inspection After Installation
- Steering Valve, Removing
- Steering Valve, Installing
- Tilt Lock Lever, Disassembling
- Tilt Lock Lever, Assembling
- Steering Valve, Disassembling
- Inspection After Disassembly
- Steering Valve, Assembling
- Hydraulic Lines Diagram
- Hydraulic Tank
- Hydraulic Pump (Gear Pump)
- Control Valve
- Down Safety Valve
- Lift Cylinder (First Cylinder for Duplex and Triplex Masts)
- Lift Cylinder (Second Lift Cylinder for Simplex Mast and Triplex Mast)
- Lift Cylinder (Second Lift Cylinder for Duplex Mast)
- Tilt Cylinder
- Hydraulic Pump, Removing
- Hydraulic Pump, Installing
- Hydraulic Pump, Disassembling
- Hydraulic Pump, Inspection and Repair
- Hydraulic Pump, Assembling
- Operation Test
- Lift Cylinders (Simplex Mast), Removing
- Lift Cylinders (Simplex Mast), Installing
- Lift Cylinders (Duplex and Triplex Masts), Removing
- Removing First Lift Cylinders
- Removing Second Lift Cylinders
- Lift Cylinders (Duplex and Triplex Masts), Installing
- (First Cylinder for Duplex and Triplex Masts)
- (Second Cylinder for Simplex Mast and Triplex Mast)
- Lift cylinders, Removing (Second Cylinder for Duplex Mast)
- Lift Cylinder (Second for Duplex Mast), Inspecting
- Lift Cylinders, Assembling (Second Cylinder for Duplex Mast)
- Removing tilt cylinders
- Tilt Cylinders, Installing
- Tilt Cylinder, Disassembling
- Tilt Cylinder, Inspecting
- Tilt Cylinder, Assembling
- Piping
- Piping for Control Valve on Diesel Engine Models
- Suction Strainer and Return Filter, Removing
- Suction Strainer and Return Filter, Inspecting
- Suction Strainer and Return Filter, Installing
- Hydraulic Tank, Inspecting and Adjusting
- Control Valve, Inspecting
- Vertical Drift Test
- Tilt Drift Test
- Gear Pump
- Lift and Tilt Cylinders
- First Cylinder for Duplex and Triplex Masts
- Second Cylinder for Simplex and Triplex Masts
- Second Cylinder for Duplex Mast
- Control Valve, Outline
- Hydraulic Lines Diagram of Hydraulic Control Valve
- Inlet Cover Section
- Lift Valve
- Tilt Valve
- Unload Valve
- Control Valve, Removing
- Control Valve, Installing
- Control Valve - Inlet Cover Section, Disassembling
- Control Valve - Lift Valve, Disassembling
- Control Valve - Tilt Valve, Disassembling
- Control Valve - End Cover Section, Disassembling
- Control Valve - End Cover Section, Assembling
- Attachment Valves, Assembling
- Simplex Mast
- Mast System
- Structure and Functions (5V15D to 5V35D)
- Mast and Lift Bracket Assembly, Removal Sequence
- Suggestions for Removing of Mast and Lift Bracket Assembly
- Suggestions for Installing of Mast and Lift Bracket Assembly
- Mast and Lift Bracket, Removal Sequence
- Suggestions for Disassembly of Mast and Lift Bracket
- Mast and Lift Bracket, Inspection (All Mast Models)
- Lift Bracket Roller, Assembly Sequence (All Mast Models)
- Lift Bracket Clearance Adjustment (All Mast Models)
- Installing Mast Rollers (All Mast Models)
- Installing Mast Strips (All Mast Models)
- Installing Lift Cylinders
- Connecting Chains
- Installing Hydraulic Lines
- Without Removing Mast from Truck
- Inspecting Forks (All Mast Models)
- Chain Tension, Inspection and Adjustment (All Mast Models)
- Measuring Chain Elongation (All Mast Models)
- (All Mast Models)
- Adjusting Mast Roller Clearance (All Mast Models)
- Inspecting and Adjusting Mast Strip Clearance (All Mast Models)
- Adjusting Mast Tilt Angle (All Mast Models)
- Duplex Mast
- Structure and Functions (5F15C to 5F35CF)
- Suggestions for Installing Mast and Lift Bracket Assembly
- Mast and Lift Bracket, Disassembly Sequence
- Preparation for Disassembly of Mast and Lift Bracket
- Installing Second Lift Cylinder
- Installing First Lift Cylinder
- Triplex Mast
- Structure and Functions (5M15D to 5M35D)
- Suggestions for Removing Mast and Lift Bracket Assembly
- Mast and Lift Bracket, Disassembly Sequence (All Mast Models)
- Maintenance Schedule
- Tightening Torques for Standard Bolts and Nuts
- Metric Fine Thread
- Metric Coarse Thread
- Periodic Replacement Parts
- Safety Critical Parts
- Lubrication Schedule
- Lubrication Chart
- Fuel and Lubricant Specifications
- Adjustment Value and Oil Capacity
- Special tools
- Special Service Tools
- Special Service Tools (For Powershift Transmission)
Inside this manual
Real pages from this service manual (631 pages). Open the sample pages (PDF, 617 KB)
- Diagram, page 172: CHAPTER 4 CONTROLLER
- Troubleshooting, page 415: CHAPTER 11 BRAKE SYSTEM
- Specifications, page 451: CHAPTER 13 HYDRAULIC SYSTEM
- Color page, page 122: CHAPTER 4 CONTROLLER
- Color page, page 325: CHAPTER 8 POWERSHIFT TRANSMISSION
- Foldout diagram, page 105: SENSOR
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This manual: Service Manual 99719-3F110$69.89
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 631 pages
Quantity one is the manual described above.
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Other editions and similar models
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