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Service Manual
This service manual is a guide to servicing of Caterpillar® 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. Caterpillar reserves the right
to change specifications or design without notice and without incurring obligation.
GP40K, GP40KL, GP45K, and GP50K are powered by G6 (GM4.3L) gasoline engine.
DP40K, DP40KL, DP45K, and DP50K are powered by Mitsubishi S6S diesel engine.
Disassembly sequence
Sequence
1. Cover [Bolt, Washer] (part name)
2. Output shaft (part name)
Unit: mm (in.)
0.020 to 0.105
A
(0.00079 to 0.00413)
Clearance between
cylinder and piston 0.15
B
(0.0059)
A: Standard value B: Repair or service limit
Symbols or abbreviations
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)
WARNING
SAFETY
WARNING WARNING
The proper and safe lubrication and Do not operate this truck unless you have
maintenance for this lift truck, recommended read and understand the instructions in the
by Caterpillar, are outlined in the OPERATION & MAINTENANCE MANUAL.
OPERATION & MAINTENANCE MANUAL for Improper truck operation is dangerous and
these trucks. could result in injury or death.
Improper performance of lubrication or
maintenance procedures is dangerous and 4. Lower the forks or other implements to the ground
could result in injury or death. Read and before performing any work on the truck. If this
understand the OPERATION & cannot be done, make sure the forks or other
MAINTENANCE MANUAL before performing implements are blocked correctly to prevent them
any lubrication or maintenance. 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
work. A knowledge of the system and/or components steps, ladders and walkways. When it is not
is important before the removal or disassembly of any possible to use the designed access system,
component. provide ladders, scaffolds, or work platforms to
perform safe repair operations.
Because of the size of some of the truck components,
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
good condition and are of the correct capacity. Be
Following is a list of basic precautions that should
sure hooks are positioned correctly. Lifting eyes
always be observed.
are not to be side loaded during a lifting
1. Read and understand all warning plates and decals 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.
wear protective glasses when pounding on any
Gradually back off the last two bolts or nuts
part of the truck or its attachments with a hammer
located at opposite ends of the cover or device and
or sledge. Use welders gloves, hood/goggles,
pry cover loose to relieve any spring or other
apron and other protective clothing appropriate to
pressure, before removing the last two bolts or
the welding job being performed. Do not wear
nuts completely.
loose-fitting or torn clothing. Remove all rings
from fingers when working on machinery. 9. Be careful when removing filler caps, breathers
and plugs on the truck. Hold a rag over the cap or
3. Do not work on any truck that is supported only
plug to prevent being sprayed or splashed by
by lift jacks or a hoist. Always use blocks or jack
liquids under pressure. The danger is even greater
stands to support the truck before performing any
if the truck has just been stopped because fluids
disassembly.
can be hot.
10. Always use tools that are in good condition and 18. Loose or damaged fuel, lubricant and hydraulic
be sure you understand how to use them before lines, tubes and hoses can cause fires. Do not
performing any service work. bend or strike high pressure lines or install ones
11. Reinstall all fasteners with same part number. which have been bent or damaged. Inspect lines,
Do not use a lesser quality fastener if tubes and hoses carefully. Do not check for
replacements are necessary. Do not mix metric leaks with your hands. Pin hole (very small)
fasteners with standard nuts and bolts. leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can
12. If possible, make all repairs with the truck
penetrate the skin and cause personal injury. Use
parked on a level, hard surface. Block truck so it
cardboard or paper to locate pin hole leaks.
does not roll while working on or under truck.
19. Tighten connections to the correct torque. Make
13. Disconnect battery and discharge any capacitors
sure that all heat shields, clamps and guards are
(electric trucks) before starting to work on truck.
installed correctly to avoid excessive heat,
Hang “Do not Operate” tag in the Operator’s
vibration or rubbing against other parts during
Compartment.
operation. Shields that protect against oil spray
14. Repairs, which require welding, should be onto hot exhaust components in event of a line,
performed only with the benefit of the tube or seal failure, must be installed correctly.
appropriate reference information and by
20. Relieve all pressure in air, oil or water systems
personnel adequately trained and knowledgeable
before any lines, fittings or related items are
in welding procedures. Determine type of metal
disconnected or removed. Always make sure all
being welded and select correct welding
raised components are blocked correctly and be
procedure and electrodes, rods or wire to provide
alert for possible pressure when disconnecting
a weld metal strength equivalent at least to that
any device from a system that utilizes pressure.
of parent metal.
21. Do not operate a truck if any rotating part is
15. Do not damage wiring during removal
damaged or contacts any other part during
operations. Reinstall the wiring so it is not
operation. Any high speed rotating component
damaged nor will it be damaged in operation by
that has been damaged or altered should be
contacting sharp corners, or by rubbing against
checked for balance before reusing.
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.
GROUP INDEX
COOLING SYSTEM Fan removal and installation, Fan belt inspection and adjustment 2
Dry type clutch, Wet type clutch, Pressure plate assembly, Clutch booster,
CLUTCHES Clutch master cylinder, Clutch release cylinder, Adjustment 5
FRONT AXLE AND Front tires, Front axle, Reduction and differential
REDUCTION DIFFERENTIAL 8
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
Radiator screen kit, Radiator plate-fin type kit, Elevated exhaust kit.
OPTIONS Head lamp kit (installed on mast), Tail lamp upper relocate kit, etc. 15
GENERAL INFORMATION
1
Model View ................................................................................................ 1–1
Truck Models Covered ........................................................................... 1–1
Serial Number Locations ....................................................................... 1–2
Chassis and Mast Model Identification ............................................. 1–3
Dimensions ............................................................................................... 1–4
Technical Data .......................................................................................... 1–6
GENERAL INFORMATION
Model View
103190
1-1
GENERAL INFORMATION
202761A
1-2
GENERAL INFORMATION
[Chassis]
GP 40 K
Generation designator
1-3
GENERAL INFORMATION
Dimensions
G K C L
E
J
I
H
B
D N M O
202762A
1-4
GENERAL INFORMATION
Unit: mm (in.)
H Overall height (to top of mast lowered) 2170 (85.4) 2250 (88.6)
O Rear overhang 513 (20.2) 563 (22.2) 613 (24.1) 573 (22.6)
1-5
GENERAL INFORMATION
Technical Data
Truck Model
GP40K GP40KL GP45K GP50K
DP40K DP40KL DP45K DP50K
Item
Type Standard
Lift speed (rate load) GP: 510 (100) GP: 440 (87) GP: 430 (85)
General
mm/sec (fpm) DP: 500 (98) DP: 430 (85) DP: 420 (83)
Travel speed of Forward 19.5 (12.1) 19.5 (12.1) 19.5 (12.1) 23.5 (14.6)
powershift
transmission models
km/h (mph) Reverse 19.5 (12.1) 23.5 (14.6)
Performance
Inside 83°
Steering angle
Outside 56°33’
Minimum Single tire 2360 (92.9) 2400 (94.5) 2450 (96.5) 2510 (98.8)
intersecting aisle
mm (in.) Dual tire 2490 (98) 2520 (99.2) 2570 (101.2) 2740 (107.9)
Single drive tire (unloaded) GP: 5540 (12200) GP: 5950 (13100) GP: 6510 (14300) GP: 7010 (15400)
kg (lb) DP: 5630 (12400) DP: 6030 (13300) DP: 6590 (14500) DP: 7080 (15600)
Dual drive tire (unloaded) GP: 5730 (12600) GP: 6080 (13400) GP: 6640 (14600) GP: 7170 (15800)
kg (lb) DP: 5810 (12800) DP: 6160 (13600) DP: 6730 (14800) DP: 7250 (15900)
1-6
GENERAL INFORMATION
Truck Model
GP40K GP40KL GP45K GP50K
Item
Type Gasoline
No. of strokes 4
Rated torque
310 (31.0) [224]/1200
N·m (kgf·m) [lbf·ft]/rpm
Ignition Spark
1-7
GENERAL INFORMATION
Truck Model
GP40K GP40KL GP45K GP50K
Item
Type Mold
Ignition
coil
Manufacturer AC Delco
Type Pointless
Manufacturer AC Delco
Ignition system
Distributor
Type of spark
Internal solid state circuit
advance control
Model #41-932
Manufacturer AC Delco
Spark plug
Size mm (in.) 14 (0.55)
Type 1FZ
Carburetor
Fuel system
Type Electromagnetic
Fuel pump
Manufacturer Jidosha Kiki
Air cleaner
Oil pan
4.2 (1.1)
liter (U.S. gal)
Total
5.0 (1.3)
liter (U.S. gal)
1-8
GENERAL INFORMATION
Truck Model
GP40K GP40KL GP45K GP50K
Item
Voltage V 12
Capacity AH (5 Hr) 50
Type 3-phase AC
Alternator
Manufacturer MANDO
Type Electromagnetic
Starter
1-9
GENERAL INFORMATION
Truck Model
DP40K DP40KL DP45K DP50K
Item
Compression ratio 22 : 1
Maximum torque
250 (25.5) [184]/1600
N·m (kgf·m) [lbf·ft]/rpm
Engine (diesel)
Intake valves
Valve mm (in.)
clearance 0.25 (0.0098)
(at cold) Exhaust valves
mm (in.)
Ignition Compression
Truck Model
DP40K DP40KL DP45K DP50K
Item
115 (30)
liter (U.S.gal)
Type Bosch
Type Throttle
injection mm (in.)
nozzles
Injection pressure
1372 (140) [1992]
kPa (kg/cm2) [psi]
Type Sheathed
Glow plugs
Voltage – current
22 – 4.4
V– A
Type Plunger
Fuel pump
Manufacturer Nippon Denso
1-11
GENERAL INFORMATION
Truck Model
DP40K DP40KL DP45K DP50K
Item
Refill capacity
10.35 (2.7)
liter (U.S. gal)
Voltage V 24
Capacity Ah 50
Alternator and regulator
Capacity V–A 24 – 35
Type Electromagnetic
Starter
Voltage – output V – kW 24 – 5
Operating voltage
16 to 30
V
Engine stop device
Stop
solenoid
Rated current
11.3
(at 24 V) V
Mitsubishi Electric
Manufacturer
Corporation
Detector
(magnetic Output mA 180 minimum
pickup)
0.7 ± 0.2
Gap mm (in.)
(0.028 ± 0.008)
1-12
GENERAL INFORMATION
Truck Model
GP40K GP40KL GP45K GP50K
DP40K DP40KL DP45K DP50K
Item
Torque Manufacturer’s
Okamura M15
converter model
Control and
Hydraulic and column shift
shift
R1: 5.735
Reverse 4.057
R2: 3.239
Type Synchro-mesh
Shift Floor-shift
Manual
1st 8.462
transmission Forward
(DP40K thru ratio
2nd 4.145
DP45K)
1st 8.489
Reverse
ratio
2nd 4.159
Housing Banjo
Differential
1-13
GENERAL INFORMATION
Truck Model
GP40K GP40KL GP45K GP50K
DP40K DP40KL DP45K DP50K
Item
Type Semi-integral
Effective stroke
Power 275 (10.8)
mm (in.)
steering
Relief pressure + 490 +5 + 71
8336 0 (85 0 ) [1209 0 ]
kPa (kgf/cm2) [psi]
Toe-in mm (in.) 0
Camber 1.0°
Wheel
alignment Caster 0°
1-14
GENERAL INFORMATION
Truck Model
GP40K GP40KL GP45K GP50K
DP40K DP40KL DP45K DP50K
Item
Type Gear
Manufacturer Shimazu
Type KVS-120VPF-2
0 0 0
kPa (kgf/cm2) [psi]
80 + 00.1 90 + 00.1
ID mm (in.) + 0.004 + 0.004
Tilt (3.15 0 ) (3.54 0 )
cylinders
Stroke mm (in.) 185 (7.28)
L: 56.5 (14.9)
Hydraulic tank capacity N: 58.7 (15.5)
liter (U.S. gal) H: 64.4 (17.0)
1-15
COOLING SYSTEM
Structure
1
6
5
8
5
4
10
1
2
3
2 3
207009 208411
8 8
9
7
7
6 6
9
208412 208413
2-1
COOLING SYSTEM
1
2
(Only loosen.)
208414
Sequence
1 Universal joint
2 Tension pulley assembly, Bolt
3 Fan belt
Start by:
Remove the radiator cover.
2-2
COOLING SYSTEM
Installation
Perform installation by following 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 at a point midway
between the driven and drive pulleys to make sure that
the tension pulley moves, then tighten the pulley lock
bolt firmly.
3
2
208416
Sequence
1 Fan cover
2 Fan assembly
3 Tension pulley assembly
Start by:
Remove the radiator cover.
2-3
COOLING SYSTEM
Installation
Perform installation by following the removal sequence in
reverse. Also follow the instruction given below.
(1) With the tension pulley lock bolt loosened, attach the
belt to the driven pulley (fan assembly pulley), then
screw in the bolt at the bottom of the fan support; do
not tighten the bolt yet. Holding the fan support by its
top, move the support until it reaches the boss (frame),
then tighten all the fan support bolts.
(2) Adjust the tension of the fan belt.
2-4
COOLING SYSTEM
2.94 to 4.9 N
Cooler hose (0.3 to 0.5 kgf)
[2.2 to 3.6 lbf]
2-5
COOLING SYSTEM
Coolant
Fill the radiator with coolant containing antifreeze. 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 Model GP40K, GP40KL, GP40K, DP40KL,
DP40K, DP40KL, DP45K
GP45K, GP50K DP45K, DP50K
Manual transmission
Powershift transmission Powershift transmission
models
Item models models
Engine 11 (2.9) 7.1 (1.9) 7.1 (1.9)
Reserve tank (FULL level) 0.65 (0.17) 0.65 (0.17) 0.65 (0.17)
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
Console Box
1 Engine coolant temperature gauge
2 Travel speed select switch
3 Fuel gauge
4 Service hourmeter
5 OK monitor
6 Starter switch
7 Lighting switch
8 Fuse box
103195
3-1
ELECTRICAL SYSTEM
OK Monitor
102794A
Function
3-2
ELECTRICAL SYSTEM
ECU (Electronic
control unit) Power
source
Solenoid valve
Fuse box
Pressure
switch
Horn Fusible link Travel speed sensor (pulse generator)
To front
combination To rear
lamps combination
lamps
Spare terminal Backup buzzer
Ground on body Spare
terminal
Ground on body
A To console
box
To front To rear
combination combination
lamps lamps
T/C oil thermounit Brake fluid Fuel tank unit Starter relay
level sensor
Stop lamp switch
207548
3-3
ELECTRICAL SYSTEM
Diesel-engine models
203782
3-4
ELECTRICAL SYSTEM
Sensors
207549
3-5
ELECTRICAL SYSTEM
Diesel-engine models
203783
3-6
ELECTRICAL SYSTEM
(OFF)
(ON)
G1
B2 M
(START)
G2
B1 S
203561A
Connection chart
Terminal B1, B2 G1 G2 M S
Starter, neutral
Fuse box,
Component Fuse box, switch (powershift
battery,
Key fuel-cut solenoid transmission
alternator
position models)
(OFF)
(ON)
(START)
Terminal B1, B2 G1 G2 M S
(OFF)
(ON)
(START)
NOTE
The starter switches for both gasoline and diesel engines are same in design. With a gasoline engine, therefore,
turning the key to a position on the left of the OFF position is possible but does not cause any effect as there is
no electric circuit connected there.
3-7
ELECTRICAL SYSTEM
Lighting Switch
206481
Connection chart
Terminal B T H P
Tail lamps,
Component Battery license plate lamp,
Head lamps Clearance lamps
Knob (fuse) instrument panel
position lamp
(OFF)
1st position
2nd position
If the insulation resistance between any two terminals is not up to the specification indicated below when the knob is
in the OFF position, the lighting switch must be replaced with a new one.
Connection chart
L Terminal F RF LF
R R (Right)
RF LF
N (Straight)
F
L (Left)
203573 Cord color Green Yellow Black
If the insulation resistance between any two terminals is not up to the specification indicated below when the lever is
in the N position, the turn signal switch must be replaced with a new one.
To fuel gauge
141.4 mm
(5.57 in.)
3/4
To ground
Indication accuracy
1/2
212.4 mm
(8.36 in.)
Terminal
E 1/4 1/2 3/4 F
Item
1/4
Standard resistance (ohm) 80 49.5 32 19 10
+ 12 + 1.0
E Tolerance (ohm) +2 − ±3 − − 0.5
203574
Neutral Switch
Connection chart
Position
Battery Battery Neutral Reverse Forward
I II N R F
Terminal
(0.98 in.)
25 mm
a
b R
a
c
d N
e
F
b
11 mm
(0.43 in.) c
18 mm
(0.71 in.) d
N (BR) R (BrB) e
B I (WL) B II (GW)
206750
3-9
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