CATERPILLAR CAT DP40 DP40L DP45 DP50 FORKLIFT LIFT TRUCKS Service Repair Manual Instant Download

1
GP40, GPL40
DP40, DPL40, DP45, DP50
99739-84100
Chassis Mast
For use with 6G72 Gasoline, S6S Diesel Engine
Service Manual
2
FOREWORD 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 servicingthe 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. The gasoline models (GP40/GPL40) are
powered by Caterpillar 6G72-32FD gasoline
engine. The diesel models (DP40/DPL40/DP45/DP50
) are powered by Caterpillar S6S diesel engine.
Pub.No. 99739-84100
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GROUP INDEX
Group Items involved
General Serial number locations, Dimensions, Technical data
Cooling system Fan removal and installation, Fan belt adjustment
Electrical system Console box, Chassis electrical devices, Care of the battery, Schematic
Power train Removal and installation
Clutches Dry type clutch, Wet type clutch, Pressure plate assembly, Clutch booster, Clutch master cylinder, Clutch release cylinder, Adjustment
Manual transmission Description, Suggestions for removal and installation, Disassembly, Inspection and repair, Reassembly
Powershift transmission Torque converter, 1-speed transmission, Control valve, Automatic 2-speed transmission
Front axle and reduction differential Front tires, Front axle, Reduction and differential
Rear axle Rear axle, Rear tires
Brake system Master cylinder, Wheel brakes, Brake booster
Steering system Steering gear, Power cylinder, Flow divider
Hydraulic system Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve
Masts and forks Dual-stage panoramic mast
Troubleshooting
Service data Maintenance standards, Periodic service chart, Periodic replacement parts, Lubrication instructions, Special tools, Inspection guide
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HOW TO READ THIS MANUAL Disassembly diagram
(example)
Each disassembly diagram is followed by
Disassembly sequence and Suggestions for
disassembly. Disassembly sequence
Cover bolt, washer (part name) Output shaft
(part name) Suggestion for disassembly (1)
Output shaft removal
Reassembly diagram (example) Suggestions for
installation or assembly of item marked with
are given on the page which follows.
202760
Reassembly sequence
(The same index numbering as that for
disassembly is used.)
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6
GENERAL INFORMATION
7 7 8 9 11
MODEL VIEW . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . TRUCK MODELS
COVERED . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . SERIAL NUMBER LOCATIONS . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . DIMENSIONS . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TECHNICAL DATA . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
1
7
GENERAL INFORMATION
MODEL VIEW
100507 TRUCK MODELS COVERED This Service Manual
furnishes servicing and maintenance information
for the following trucks
7
8
GENERAL INFORMATION SERIAL NUMBER LOCATIONS
Chassis serial number
Gasoline engine serial number
Nameplate
206747
Diesel engine serial number
Transmission serial number
Mast serial number
8
9
GENERAL INFORMATION
DIMENSIONS
202762
9
10
GENERAL INFORMATION
Unit mm in.
10
11
GENERAL INFORMATION
TECHNICAL DATA
11
12
GENERAL INFORMATION
12
13
GENERAL INFORMATION
13
14
GENERAL INFORMATION
14
15
GENERAL INFORMATION
15
16
GENERAL INFORMATION
16
17
GENERAL INFORMATION
17
18
COOLING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 21 REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 INSPECTION AND ADJUSTMENT Fan belt
inspection . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 26 Fan belt adjustment
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 26 2
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COOLING SYSTEM
DESCRIPTION
203823
203824
202765 Manual transmission models
202766
Powershift transmission models

1. Lower hose
2. Radiator
3. Oil cooler
4. Cooler hoses
5. Tension pulley

1. Engine
2. Universal joint
3. Gear pump
4. Fan belt
5. Cooling fan
6. Upper hose

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COOLING SYSTEM
REMOVAL AND INSTALLATION
Fan Belt Removal 1. Method by removing radiator
203825
Removal sequence

1. Radiator
2. Universal joint
3. Tension pulley bolt 8 Belt

• Drain cock
• Cap
• Hose
• Hose
• Start by

1. remove the radiator cover.
2. remove the engine cover and gas springs.

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COOLING SYSTEM
Suggestions for removal and installation
(1) Make sure coolant temperature is low before
opening the drain cock.
203460
(2) Using tensioner wrench A
(91268-04500)
through the space counterweight and
between the
frame (home base plate), loosen the tension
pulley bolt. To loosen this bolt, move
tensioner
wrench A in the direction of arrow 15 to
20 times. The pulley will not move unless
its bolt is not loosened enough. Over-loosening
of the bolt, however, would cause the
pulley to
203826
comes off, be removed
come off. If the pulley the counterweight
has to for installation of the pulley.
(3) Force the pulley all the way toward the
fan and remove fan belt.
Installation

• To install, follow the reverse of removal
  procedure and do the following steps
• Turn the fan by hand to make sure it rotates
  smoothly. If its bearing is noisy, replace it.
• After putting the belt on the drive and
  driven pulleys, push it midway between the
  pulleys to make sure the tension pulley moves
  freely. Then, tighten the pulley bolt.
• When installing the hoses to the radiator,
  push each hose over the flared portion of
  the hose connector of radiator and clamp
  it there securely.
• Pour antifreeze coolant into the radiator and
  start the engine. Run the engine and check
  for any abnormal noise. Check the coolant
  level in the reserve tank.

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COOLING SYSTEM 2. Method by removing
counterweight
203827
Removal sequence

1. Muffler
2. Fan assembly
3. Universal joint

1. Radiator
2. Belt

Start by (1) remove the radiator cover.
mounting to the
(2) remove the counterweight bolts. Attach a
hoist counterweight and lift it off.
NOTE Check the weight of counterweight in
attaching the hoist.
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COOLING SYSTEM Suggestions for removal and
installation (1) Unscrew the fan support
bolts. Slide the belt from the driven pulley,
then remove the fan assembly. Lay the fan
with the fan fan by hand Replace the
assembly on the bench support down. Turn the
to check the bearing. bearing if it is noisy.
bottom of at the top
(2) Remove two bolts at the radiator. Loosen
two bolts of radiator.
Only loosen
the engine
(3) Force the radiator toward
and slide the belt from the tension pulley,
letting it fall onto the universal joint.
203463
Installation To install, follow the reverse of
removal procedure and do the following
steps Fan assembly installation
Tension Pulley bolt
(1) Place the belt over the driven pulley
(fan assembly) and tighten one bolt only until
snug at the bottom of fan support. Loosen the
tension pulley bolt. Move the top of fan
support to the mounting boss (frame) and bolt
it there.
203828
the belt midway between the and driven
pulleys through the between fan blades to make
(2) Push drive space
sure the tension pulley moves freely, then
tighten the tension pulley bolt.
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COOLING SYSTEM INSPECTION AND ADJUSTMENT Fan
Belt Inspection
the belt is free
make sure grease or Replace
(1) Check to
of oil,
other foreign the belt if
matter. necessary.
A slightly dirty belt can
be re-used by cleaning with cloth or paper. Do
not attempt to clean the belt with gasoline
or the like. (2) At the time of overhauling
the engine or adjusting the belt tension,
closely check the belt and replace it if
defective. Fan Belt Adjustment
(1) Trucks with standard muffler Remove the grill
e counterweight.
from the
203465
(2) Using ratchet wrench B with extension
through the
vent in the loosen the tension
counterweight,
pulley bolt 3 to 4 turns.
(3) The belt will be properly tightened by
the tension spring. Tighten the tension
pulley bolt.
Trucks with non-standard muffler
2.
203826
Remove the radiator cover.
(1)
(2) Using tensioner wrench A through the space
between the counterweight and frame (home base
plate), loosen the tension pulley bolt 3 to 4
turns.
NOTE Refer to the topics, 1. Method by removing
radiator, Fan Belt Removal.
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COOLING SYSTEM

• The belt will be automatically tightened.
  Tighten the pulley bolt.
• Install the radiator cover.
• 3. Trucks having an access hole on left rear
  side
• (1) Remove the cover from the access hole.

203767
(2) Using ratchet wrench C through the access
hole, loosen the tension pulley bolt 3 to 4
turns.
(3) The belt will be properly tightened by
the tension spring. Tighten the tension pulley
bolt. following trucks have the access
The hole
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ELECTRICAL SYSTEM
DESCRIPTION
Console box . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . Chassis
electrical devices. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
31 33
MAJOR ELECTRICAL COMPONENTS
Starter switch (with anti-restart lock) . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . Lighting switch. .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . Turn signal switch . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Buckup light switch (manual
transmission models) . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . Fuel
tank unit . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . Neutral
switch (powershift transmission models). . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Fuse box . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. Spare terminals. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
35 36 36 37 37 38 39 39
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LIGHT BULB SPECIFICATIONS . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
40
BATTERY MAINTENANCE . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
41
DISASSEMBLY AND REASSEMBLY. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . Console box . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Components in console box . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . Combination
meter. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
43 44 45 47
ELECTRICAL SYSTEM SCHEMATIC (GASOLINE MODELS). .
. . . . . . . . . . . . . . . . . . . . . . .
49
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ELECTRICAL SYSTEM
DESCRIPTION
Console Box
102389A

1. Engine coolant temperature gauge
2. Choke control
3. Fuel gauge
4. Service hour meter
5. OK monitor
6. Starter switch
7. Light switch
8. Fuse box
9. Speed selector switch

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ELECTRICAL SYSTEM OK monitor
102392 How to check
indicator light bulbs The bulbs are normal if the
indicator lights 1, 2, 6 and 7 come ON when the
starter switch key is turned to (ON) position.
(The indicator lights will go OFF when the engine
starts.)
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ELECTRICAL SYSTEM
Chassis Electrical Devices
1ST SPEED/AUTO selector switch
Power source
Electronic control unit
Solenoid valve Backup light switch (for manual
tranmission models) (Backup lights for powershift
transmission models are controlled by neutral
switch located under dashboard.)
Fuse box
Fusible link
Travel speed sensor (pulse generator)
Horn
Backup buzzer Ground on body
Sender unit (powershift transmission oil
temperature sensor)
Spare terminal
Fuel tank unit
Brake fluid lever sensor
Ground on body
Stop light switch
The electrical system is divided into engine
electrical system and chassis electrical system.
Following are the components involved in the
chassis electrical system
(4) Instruments The circuit is a one-wire
negative-ground system.

• Wire and fuses
• Lighting system
• Head lights, working light and backup lights
• Signaling system
• Turn signals, clearance lights, tail/stop lights,
  license plate light and horn

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ELECTRICAL SYSTEM Sensors
Sender unit (powershift transmission oil
temperature sensor)
Dust indicator switch (option)
Coolant sensor (option)
Brake fluid level sensor
Travel speed sensor (pulse generator)
206749

• The gasoline and diesel models use the following
  sensors. Each sensor senses a change in physical
  quantity and converts that change into a useful
  input signal for the OK monitor built in the
  console box.
• Brake fluid level sensor
• Coolant sensor (option)
• Dust indicator switch (option)
• Travel speed sensor
• (standard for DP50, optional for GP40/GPL40 and
  DP40/DPL40/DP45)
• Powershift transmission oil temperature sensor
• 34

31
ELECTRICAL SYSTEM MAJOR ELECTRICAL
COMPONENTS Starter Switch (with Anti-Restart Lock)
the diesel models, I (ON) position of the switch
is for energizing the glow plugs.
This switch has a built-in anti-restart lock, so
the key cannot be turned from I (ON) to (START)
position while the engine is running. The
gasoline and diesel models use the same starter
switch. In
203561A
35
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ELECTRICAL SYSTEM Lighting Switch
206481
Turn Signal Switch
203573
36
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ELECTRICAL SYSTEM
Backup Light Switch (Manual Transmission Models)
ON OFF
Shift rail 2 mm (for FORWARD 0.08 in. and
REVERSE)
4 mm 0.16 in.
Backup light switch
Transmission case
M 12 x 1.75
200013
203576
Fuel Tank Unit
To fuel gauge To ground Indication
accuracy 203574
37
34
ELECTRICAL SYSTEM Neutral Switch (Powershift
Transmission Models)
Connection chart
N (BR)
R (BrB)
BI (WL)
BII (GW)
206750
38
35
ELECTRICAL SYSTEM
Fuse Box
102607
Spare Terminals The spare terminal cord extends
from the fuse box in the console box. (Another
spare terminal is located on the chassis-side
main harness.) Cord color Lg (yellowish
green) Removing the console box rear panel will
expose this spare terminal which is fastened to
the harness protector with vinyl tape.
Spare Terminal
206424
39
36
ELECTRICAL SYSTEM LIGHT BULB SPECIFICATIONS
206751
40
37
ELECTRICAL SYSTEM BATTERY MAINTENANCE
1.
State of charge and electrolyte specific gravity
adjustment
2. Specific gravity reading and state of
charge To check the battery for state of charge,
take hydrometer readings on its electrolyte. The
battery may be fully charged if the S.G. reading
is 1.280 to 1.265 at 20C 68F. The state of
charge can be told from the way the electrolyte
level goes down to expose the cell plates. If
addition of distilled water is necessary every
month or so, the battery is overcharged. If
addition is not required for more than 3 months,
it is likely that the battery is inadequately
charged.
(4) When connecting the cables to the battery,
begin with the cable for the positive ()
terminal. When disconnecting them from the
battery, begin with the cable for the negative
(-) terminal.
CAUTION
Be sure to turn OFF the starter switch and light
switch before disconnecting or connecting the
battery cables to prevent the IC regulator from
suffering damage.
Charging precautions
3.

• In slow charging, the charging current should be
  about 1/10 the capacity of the battery to be
  charged.
• In quick charging, the battery capacity in
  ampere should not be exceeded.
• During charging, adjust the charging current to
  prevent the elFectrolyte temperature from
• rising beyond 45C 113F.

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ELECTRICAL SYSTEM Precautions for servicing
charging system (with alternator)
The alternator is equipped with a built-in IC
(integrated circuit) voltage regulator. When
servicing the charging system, pay attention to
the following precautions
Terminal L Terminal R Terminal B 2027721
(1) Do not reverse the polarity of the battery.
(2) Do not disconnect the battery terminal while
the engine is running.
(3) Do not ground the terminal L.

1. Do not short the terminals L and R.
2. Do not direct a blast of steam cleaner to the
   alternator. Remember, a blast of steam will
   damage the IC regulator.

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ELECTRICAL SYSTEM DISASSEMBLY AND REASSEMBLY
Console Box
206422
Disassembly Reassembly
To reassemble the console box, follow the reverse
of disassembly procedure.
1. Disconnect the electrical wires at connectors
1. (In the gasoline models, disconnect the choke
cable on the engine side.)

• Remove screws 2 (four) securing the cover.
• Remove screws 3 (six) and separate the front and
  rear panels.
• Remove screws 4 (four) securing the instrument
  panel.
• NOTE
• To replace the instrument panel bulbs, remove
  screws 3 and 4.

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ELECTRICAL SYSTEM Components in Console Box
206423

1. Glow plug timer (diesel models)
2. Light switch
3. Starter switch
4. Fuses

1. Power relay
2. Power relay
3. Turn signal relay
4. Glow plug relay (diesel models)

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42
ELECTRICAL SYSTEM
Combination Meter Disassembly
206480
Sequence
1 Instrument panel 6 Meter case
2 Dial 7 Printed circuit
3 Engine coolant temperature gauge 8 Bulb
Service hour meter Fuel gauge 9 Socket
CAUTION Be careful not to damage the printed
circuit when disassembling the combination meter.
Bulb replacement For bulb replacement, remove the
socket from the printed circuit by turning it to
the left. For configuration of the indicator
lights, refer to OK Monitor.
Reassembly To reassemble the combination meter,
follow the reverse of disassembly procedure.
45
43
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com