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This service manual is a guide to servicing of Cat Lift Trucks. 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. Cat lift truck reserves the right
to change specifications or design without notice and without incurring obligation.
The trucks are powered by K25 gasoline engines. For the engine servicing, please refer to the
applicable engine service manual.
SAFETY
! WARNING ! WARNING
The proper and safe lubrication and Do not operate this truck unless you have read
maintenance for this Lift Truck, recommended and understand the instructions in the
by Cat lift truck, are outlined in the OPERATION OPERATION & MAINTENANCE MANUAL.
& MAINTENANCE MANUAL for these trucks. Improper truck operation is dangerous and
Improper performance of lubrication or could result in injury or death.
maintenance procedures is dangerous and
could result in injury or death. Read and 4. Lower the forks or other implements to the ground
understand the OPERATION & MAINTENANCE before performing any work on the truck. If this
MANUAL before performing any lubrication or cannot be done, make sure the forks or other
maintenance. implements are blocked correctly to prevent them
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
The serviceman or mechanic may be unfamiliar with mounting or dismounting a truck. Clean any mud
many of the systems on this truck. This makes it or debris from steps, walkways or work platforms
important to use caution when performing service before using. Always face truck when using steps,
work. A knowledge of the system and/or components ladders and walkways. When it is not possible to
is important before the removal or disassembly of any use the designed access system, provide ladders,
component. scaffolds, or work platforms to perform safe repair
Because of the size of some of the truck components, operations.
the serviceman or mechanic should check the weights 6. To avoid back injury, use a hoist when lifting
noted in this Manual. Use proper lifting procedures components which weigh 23 kg (50 lb.) or more.
when removing any components. Make sure all chains, hooks, slings, etc., are in
Following is a list of basic precautions that should good condition and are of the correct capacity. Be
always be observed. sure hooks are positioned correctly. Lifting eyes
1. Read and understand all warning plates and decals are not to be side loaded during a lifting operation.
on the truck before operating, lubricating or 7. To avoid burns, be alert for hot parts on trucks
repairing the product. which have just been stopped and hot fluids in
2. Always wear protective glasses and protective lines, tubes and compartments.
shoes when working around trucks. In particular, 8. Be careful when removing cover plates. Gradually
wear protective glasses when pounding on any part back off the last two bolts or nuts located at
of the truck or its attachments with a hammer or opposite ends of the cover or device and pry cover
sledge. Use welders gloves, hood/goggles, apron loose to relieve any spring or other pressure, before
and other protective clothing appropriate to the removing the last two bolts or nuts completely.
welding job being performed. Do not wear loose- 9. Be careful when removing filler caps, breathers and
fitting or torn clothing. Remove all rings from plugs on the truck. Hold a rag over the cap or plug
fingers when working on machinery. to prevent being sprayed or splashed by liquids
3. Do not work on any truck that is supported only by under pressure. The danger is even greater if the
lift jacks or a hoist. Always use blocks or jack truck has just been stopped because fluids can be
stands to support the truck before performing any hot.
disassembly.
10. Always use tools that are in good condition and be 19. Tighten connections to the correct torque. Make
sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat, vibration
11. Reinstall all fasteners with same part number. Do or rubbing against other parts during operation.
not use a lesser quality fastener if replacements are Shields that protect against oil spray onto hot
necessary. exhaust components in event of a line, tube or seal
failure, must be installed correctly.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not 20. Relieve all pressure in air, oil or water systems
roll while working on or under truck. before any lines, fittings or related items are
disconnected or removed. Always make sure all
13. Disconnect battery and discharge any capacitors
raised components are blocked correctly and be
(electric trucks) before starting to work on truck.
alert for possible pressure when disconnecting any
Hang “Do not Operate” tag in the Operator’s
device from a system that utilizes pressure.
Compartment.
21. Do not operate a truck if any rotating part is
14. Repairs, which require welding, should be
damaged or contacts any other part during
performed only with the benefit of the appropriate
operation. Any high speed rotating component that
reference information and by personnel adequately
has been damaged or altered should be checked for
trained and knowledgeable in welding procedures.
balance before reusing.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or 22. When handling the parts containing asbestos, be
wire to provide a weld metal strength equivalent at careful not to inhale the asbestos. Doing so is
least to that of parent metal. hazardous to your health.
15. Do not damage wiring during removal operations. If the shop dust may contain asbestos, follow the
Reinstall the wiring so it is not damaged nor will it precautions described below.
be damaged in operation by contacting sharp a. Do not use compressed air for cleaning.
corners, or by rubbing against some object or hot b. Do not brush or apply grinder on asbestos
surface. Place wiring away from oil pipe. containing materials.
16. Be sure all protective devices including guards and c. To clean asbestos containing materials, wipe
shields are properly installed and functioning with moistened cloth or use a vacuum cleaner
correctly before starting a repair. If a guard or with particle filter.
shield must be removed to perform the repair work,
d. If you have to handle the parts containing
use extra caution.
asbestos for a long time, be sure to do it in a
17. Always support the mast and carriage to keep well-ventilated area.
carriage or attachments raised when maintenance
e. If the asbestos in the air cannot be removed,
or repair work is performed, which requires the
wear a mask.
mast in the raised position.
f. Be sure to observe the working rules and
18. Loose or damaged fuel, lubricant and hydraulic
regulations.
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which g. When disposing of materials with asbestos, be
have been bent or damaged. Inspect lines, tubes sure to observe the environmental protection
and hoses carefully. Do not check for leaks with regulations of your area.
your hands. Pin hole (very small) leaks can result h. Avoid working in the atmosphere where
in a high velocity oil stream that will be invisible asbestos particles may be suspended.
close to the hose. This oil can penetrate the skin
and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
HOW TO USE THIS MANUAL
(Removal, Installation, Assembly and Disassembly)
209603
Sequence
1 Cover , Bolt, Washer (part name)
2 Snap ring ................ (part name)
209604
Service Data
0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.
COOLING SYSTEM Fan Removal and Installation, Fan Belt Inspection and Adjustment
2
REAR AXLE Rear Tires, Rear Axle, Toe-in, Minimum Turning Radius
9
BRAKE SYSTEM Master Cylinder, Wheel Cylinders, Wheel Brakes, Brake Booster
10
Hydraulic Tank, Gear Pump, Control Valve, Lift and Tilt Cylinders,
HYDRAULIC SYSTEM Flow Regulator Valve, Down Safety Valve 12
1
Model View ............................................................................................... 1– 1
Truck Models Covered ........................................................................... 1– 2
Serial Number Locations ...................................................................... 1– 3
Dimensions ............................................................................................... 1– 4
Technical Data ......................................................................................... 1– 5
GENERAL INFORMATION
Model View
MC Truck
209605
1-1
GENERAL INFORMATION
This Service Manual provides servicing and maintenance information for the following trucks:
Gasoline-engine models
Truck class
Truck model Serial number Engine mounted
GC20N AT90-00011-up K25
2 ton class
GC25N AT90-00011-up K25
GC28N AT83F-00011-up K25
3 ton class
GC30N AT83F-00011-up K25
LPG-engine models
Truck class
Truck model Serial number Engine mounted
GC20N AT90-00011-up K25
2 ton class
GC25N AT90-00011-up K25
GC28N AT83F-00011-up K25
3 ton class
GC30N AT83F-00011-up K25
1-2
GENERAL INFORMATION
210693
1-3
GENERAL INFORMATION
Dimensions
G C K L
H
I
P
B
D N M O
F
209608
1-4
GENERAL INFORMATION
Technical Data
Unit: mm (in.)
Truck Model
Ref.
GC20N GC25N GC28N GC30N
No.
Item
A Maximum lift 3340 (131.5) 3315 (130.5)
B Free lift 130 (5.1) 135 (5.3)
C Fork spread (outside) 220 to 920 (8.7 to 36.2) 200 to 960 (7.9 to 37.8)
1-5
COOLING SYSTEM
Specification ............................................................................................ 2– 1
Structure .................................................................................................... 2– 2
2
Removal and Installation ...................................................................... 2– 3
Inspection and Adjustment .................................................................. 2– 5
Fan Belt Inspection .................................................................................... 2 – 5
Fan Belt Tension ........................................................................................ 2 – 5
Connecting Radiator Hoses ....................................................................... 2 – 5
Unit Layout ................................................................................................ 2 – 6
Coolant ...................................................................................................... 2 – 6
Radiator Cap ............................................................................................. 2 – 6
COOLING SYSTEM
Specification
Truck Models
2 ton class 3 ton class
Items
2-1
COOLING SYSTEM
Structure
209610
210696
2-2
COOLING SYSTEM
Engine
Fan
1 2
209612
Sequence
1 Tension pulley assembly, Bolt
2 Fan belt
Start by:
Remove the radiator cover.
Tension
NOTE pulley
Do not loosen the lock bolt to such an extent that the
bolt would be removed.
(2) Move the tension pulley fully toward the fan, then
remove the belt. 209613
2-3
COOLING SYSTEM
Installation
To install, follow the removal sequence in reverse. Also
follow the instructions given below.
(1) Before installing the belt, turn the fan to check for
smooth rotation. Replace the bearing if it generates
abnormal sound.
(2) After installing the belt, push it to make sure that the
tension pulley moves, then tighten the pulley lock bolt
firmly.
2-4
COOLING SYSTEM
! WARNING
When inspecting the fan belt tension, always stop
the Engine.
209615
2-5
COOLING SYSTEM
Unit Layout
210700
Coolant
Fill the radiator with coolant. Start and operate the engine
to let it warm up while checking for abnormal noise. Make
sure that the quantity of coolant is as specified by checking
the level in the reserve tank.
Quantity of coolant
Unit: liter (U.S. gal.)
Truck Models
2 ton class 3 ton class
Items
Engine (K21, K25) 3.95 (1.04) 3.95 (1.04)
Radiator 2.7 (0.71) 2.7 (0.71)
Reserve tank (FULL level) 0.65 (0.17) 0.65 (0.17)
Total quantity of coolant
7.4 (1.96) 8.7 (2.30)
(including coolant in hoses)
Oil cooler 0.094 (0.02) 0.094 (0.02)
Radiator Cap
90±15 kPa
Opening pressure (0.92±0.15 kgf/cm2)
[13.1±2.2 psi]
0 to 5 kPa
Vacuum valve (0 to 0.05 kgf/cm2)
[0 to 0.73 psi]
2-6
ELECTRICAL SYSTEM
Main harness
Harness, rear
combination
Harness, front
combination
Harness, front
combination
209620
3-1
ELECTRICAL SYSTEM
Starter switch
Key
Main harness
Harness,
Rear combination
Select switch
Warning buzzer
Back buzzer
Harness, Front
combination
Controller
Clip
Harness, Front
combination
Fuse box,
Fuse
Relay box,
Relay
Vehicle speed sensor
(Pulse generator)
Transmission
209621
3-2
ELECTRICAL SYSTEM
Structure
4 3
1
Console Box
1 Engine coolant temperature gauge 2
2 Fuel gauge 6
3 Hour Meter/Warning blinks
4 Instrument panel
5 Starter switch
6 Light switch, turn signal switch
7 Direction lever 7
5
210703
3-3
ELECTRICAL SYSTEM
210704
Description of function
When illuminated
Code Name of monitor When not illuminated Remarks
or flashing
Parking brake warning lamp Parking brake released Parking brake applied
A
Brake fluid level warning lamp /normal level /low level
Powershift transmission oil temperature
B Normal temperature Overheat
warning lamp
C Engine oil pressure warning lamp Normal oil pressure Low oil pressure
D Seat belt warning lamp Fastened Not fastened
Multi-purpose warning lamp (illuminates when
E warnings indicated by printed symbols occur or Normal Malfunction Printed symbol
minor failures occur)
Abnormal charging
F Alternator not charging warning lamp Normal charging
system
H Mast interlock indicator lamp Free Locked
Driving interlock indicator lamp Free Locked (flashing)
I
Neutral indicator lamp F or R Neutral
J Fuel gauge Indicate remaining fuel amount with key in “ON.”
K Engine coolant temperature gauge Overheat if pointer enters the red zone.
L Liquid crystal (normally acting as hour meter) Indicate operating hours with key in “ON.”
printed symbols
L1 Engine coolant level warning lamp Normal level Low level Option
Position and
content of
3-4
ELECTRICAL SYSTEM
(OFF)
(ON)
G1
M
B2
(START)
G2
B1
S
208540
Connection Table
Gasoline-engine truck
Terminal B1, B2 G1 G2 M S
Connected to Battery,
alternator, Fuse box Direction lever
Key position fuse box
OFF
ON (when driving)
START (when starting engine)
3-5
ELECTRICAL SYSTEM
Light and
turn signal lever
Boot
Horn contact
Boot
Direction lever
Forward of truck
Lighting switch, turn signal switch
209625
Forward of truck
Light switch,
turn signal switch
F L
N N
R R
Forward-reverse
selector switch 1 2
3
OFF
209626A
T-2 L-5
L-1 L-3
5 Steering angle sensor
1 3
Horn contact
4
1 2
Horn
3 5
209627
3-6
ELECTRICAL SYSTEM
Horn
Check that the horn sounds when applying the specified Up
voltage to both terminals of the horn, T1 and T2.
Replace the horn with a new one if it does not sound or its
sound is abnormal.
T1
Operating voltage: DC 12 V
NOTICE: Refer to the illustration for the horn installed
position. T2
Down
Vent hole
Contact
Coil
209628
Tank Unit
Referential Standards
210710
3-7
ELECTRICAL SYSTEM
Rated voltage: DC 12 V
3-8
ELECTRICAL SYSTEM
Forward of vehicle
F Forward
(10°) (10°)
N Neutral
R Reverse
Connection table
Terminal 1 2 3 4 5
Wire color
Lever position GR/L B G/R B L/W
F (Forward)
N (Neutral)
R (Reverse)
209632A
3-9
ELECTRICAL SYSTEM
Gasoline-engine truck
Temperature 50 70 100 110 120 208546
[°C (°F)] (122) (158) (212) (230) (248)
Standard resistance
136 66 27.2 20.5 17.2
value (ohm)
3-10
ELECTRICAL SYSTEM
1 M ohm or more
Insulation resistance value (with contact OFF)
(at 500 V megger)
NOTE
When installing the thermoswitch, tighten it to the 208547
specified torque.
! CAUTION
Replace the thermoswitch with a new one if an
impact is given to it or if it is dropped.
Main specifications
122±3 °C
OFF→ON
(251.6±37.4 °F)
Operating temperature
115 °C (239 °F)
ON→OFF
or higher
Insulation resistance
1 M ohm or more
(with contact OFF)
3-11
ELECTRICAL SYSTEM
Inspection of coil
Apply a tester to terminal 1 and terminal 2 and measure the
resistance value of the relay coil. Replace the relay with a
new one if there is no continuity or the resistance value
measured is outside the standard resistance value.
Resistance value of coil 80 ohm ±10%
Inspection of contact
(1) Measure the insulation resistance value between
terminal 3 and terminal 4. Replace the relay with a
new one if the measured insulation resistance value is 2 4
less than the value below.
10 M ohm or more
Insulation resistance value
(at 500 V megger)
Connection diagram
1 3
(2) Apply the tester to terminal 3 and terminal 4.
(3) Apply a voltage of 12 V ON and OFF across terminal 1 2 4
Diode
and terminal 2, and check to see if the relay activates to
cause continuity or not between terminal 3 and
1 3
terminal 4. Replace the relay with a new one if it does
not activate properly.
208548
! CAUTION
This part operates on DC 12 V power supply.
! CAUTION
As the relay has an integrated diode between
terminals, be careful about the polarity when
inspecting. Replace the relay with a new one if an
impact is given to it or if it is dropped.
3-12
ELECTRICAL SYSTEM
Fuel pump
Fuel pump
209640
3-13
ELECTRICAL SYSTEM
3-14
ELECTRICAL SYSTEM
Fuse Box
209645
WORKING
LAMP
BACK UP/OTHERS 15A
15A WIPER
ETC 15A
METER PANEL 15A STOP LANP
10A HEAD 10A
QGS/OTHERS A/C LAMP HORN
10A SPARE 20A 10A EGI
15A
30A EGI
VCM 20A 30A
30A
20A
FUSE
PULLER
10A 15A
SBF 100A SBF 100A SBF 50A
SPARE BATTERY ALTNR GLOW
209646
3-15
ELECTRICAL SYSTEM
Item Watts
No. of
Color of lens Shape Remarks
bulbs
Type of lamp 12 volt
Turn
2 Amber 27
signals
Standard:
Combination
Installed on
lamps (front)
overhead guard
Clearance
2 Amber 10
lamps
Turn
2 Amber 27
signals
Combination Tail/stop
2 Red 8/23
lamps (rear) lamps
Backup
2 Colorless 10
lamps
Working lamps
4 Colorless 45 Optional
(front and rear)
210713
3-16
ELECTRICAL SYSTEM
Console Box
Disassembly
210714
Reassembly
Follow the disassembly sequence in reverse.
3-17
ELECTRICAL SYSTEM
Instrument Panel
Disassembly
206480
Sequence
1 Meter cover 6 Meter case
2 Dial 7 Rigid board
3 Water temperature gauge 8 Bulb
4 Liquid crystal 9 Socket
5 Fuel gauge
! CAUTION
Be careful not to damage the rigid board when
disassembling the instrument panel.
3-18
ELECTRICAL SYSTEM
Battery
2. Charging precautions
(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery to be charged.
(2) In quick charging, the battery capacity in ampere
should not be exceeded.
(3) During charging, adjust the charging current to
prevent the electrolyte temperature from rising
beyond 45°C (113°F).
(4) When connecting the cables to the battery, begin
with the cable for the positive (+) terminal. When 210716
disconnecting them from the battery, begin with the
cable for the negative (−) terminal.
3-19
ELECTRICAL SYSTEM
Wire Color
Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first
color shows a base color and the second color a marking color.
Example: The wire color of BW shows that its base color is B with a marking W.
BW
Marking color
Base color
NOTE
For wiring identification, the same color, in principle, must be used for the circuit from the power supply to the
load.
! CAUTION
Be careful that allowable current differs between solid wires and stranded wires even if they are of the
same gauge.
3-20
ELECTRICAL SYSTEM
Troubleshooting
Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Starter will not crank
Poor continuity in starter switch Replace.
engine
Starter or starter relay defective Replace.
Forward-reverse lever not in neutral Move lever to neutral
Starter switch position position.
Gauges
Printed circuit board defective Replace.
Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Water Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
temperature
accurately
gauge Loose terminal connection Repair.
Will indicate higher Circuit between gauge and gauge unit Repair.
than actual grounded
temperature Gauge internally defective Replace.
3-21
ELECTRICAL SYSTEM
Lighting System
Weak or dead battery Recharge or replace.
Fuses blown out Check and replace.
Open or short circuit Repair or replace.
Will not light Poor grounding Clean ground spot and
re-make connection.
Switch defective Replace.
Lamps - general Bulbs burnt out Replace.
Weak battery Check and recharge.
Contact points in switches defective Repair or replace.
Loose terminals Repair.
Will light dimly
Dirty lenses Clean.
Waterdrops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.
Lighting switch defective Replace.
Head lamps Will not light
Bulbs burnt out Replace.
Turn signal switch defective Replace.
Will not flicker
Turn signal relay defective Replace.
Turn signal relay defective Replace.
Will not light
Bulbs burnt out Replace.
Turn signals
Will flicker too Low wattage of bulbs Replace to a correct one.
slow Turn signal relay defective Replace.
Will flicker too High wattage of bulbs Replace to a correct one.
fast Turn signal relay defective Replace.
Alarm Unit
Fuse blown out Check and replace.
Will not give Open or short circuit Repair or replace.
blast of sound Horn switch defective Replace.
Horn defective Replace.
Horn Horn switch defective Replace.
Will give ugly
blast of sound Horn defective Replace.
3-22
ELECTRICAL SYSTEM
Battery
Drive belt slipping Readjust.
❋ Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.
Tends to run down ❋ Regulator
rapidly
Regulated voltage setting too low Replace.
❋ Battery
Terminal connections loose Clean and retighten.
❋ Wiring
Open or loose connection between starter switch and Repair.
regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator
❋ Wiring
Regulator IC and F terminals shorted or miswired Repair.
Poor grounding of regulator F terminal Repair.
Tends to get
overcharged ❋ Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Replace.
3-23
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