99739-36100
Service Manual GP40K, GP40KL, GP45K, GP50K; DP40K, DP40KL, DP45K, DP50K Chassis & Mast GP40K GP40KL GP45K GP50K
T29B-00011-up T29B-50001-up T29B-80001-up T33A-50001-up
DP40K DP40KL DP45K DP50K
T19C-00011-up T19C-50001-up T19C-80001-up T28B-50001-up
For use with G6 (GM4.3L), S6S Engine Service Manual
GROUP INDEX GROUP INDEX
Items
GENERAL INFORMATION
Model view, Truck models covered, Serial number locations, Dimensions, Technical data
1
COOLING SYSTEM
Fan removal and installation, Fan belt inspection and adjustment
2
ELECTRICAL SYSTEM
Console box, Chassis electrical devices, Lamp bulb specifications, Battery maintenance, Electrical system schematic
3
POWER TRAIN
Removal and installation
4
CLUTCHES
Dry type clutch, Wet type clutch, Pressure plate assembly, Clutch booster, Clutch master cylinder, Clutch release cylinder, Adjustment
5
MANUAL TRANSMISSION
Description, Suggestions for removal and installation, Disassembly, Inspection and repair, Reassembly
6
POWERSHIFT TRANSMISSION
Torque converter, 1-speed transmission, Control valve, Automatic 2-speed transmission, Solenoid valve, Hydraulic control
7
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front tires, Front axle, Reduction and 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
STEERING SYSTEM
Steering gear, Power cylinder, Flow divider
11
HYDRAULIC SYSTEM
Hydraulic tank, Gear pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve
12
MASTS AND FORKS
Simplex mast, Duplex mast, Triplex mast
13
SERVICE DATA
Maintenance standards, Periodic service chart, Periodic replacement parts, Lubrication instructions, Special tools
14
OPTIONS
Radiator screen kit, Radiator plate-fin type kit, Elevated exhaust kit. Head lamp kit (installed on mast), Tail lamp upper relocate kit, etc.
15
GENERAL INFORMATION 1 Model View ................................................................................................ Truck Models Covered ........................................................................... Serial Number Locations ....................................................................... Chassis and Mast Model Identification ............................................. Dimensions ............................................................................................... Technical Data ..........................................................................................
1–1 1–1 1–2 1–3 1–4 1–6
GENERAL INFORMATION
Model View
103190
Truck Models Covered This Service Manual furnishes servicing and maintenance information for the following trucks: Truck model
Transmission
Model code – Serial number
Engine mounted
GP40K
Powershift
T29B – 00011- up
G6 (GM4.3L) gasoline engine
GP40KL
Powershift
T29B – 50001- up
G6 (GM4.3L) gasoline engine
GP45K
Powershift
T29B – 80001- up
G6 (GM4.3L) gasoline engine
GP50K
Powershift
T33A – 50001- up
G6 (GM4.3L) gasoline engine
T19C – 00011- up
Mitsubishi S6S diesel engine
T19C – 50001- up
Mitsubishi S6S diesel engine
T19C – 80001- up
Mitsubishi S6S diesel engine
T28B – 50001- up
Mitsubishi S6S diesel engine
DP40K
DP40KL
DP45K DP50K
Manual Powershift Manual Powershift Manual Powershift Powershift
1-1
GENERAL INFORMATION
Serial Number Locations
Chassis serial number Name plate
(Gasoline- and LP-Gasengine models)
(Diesel-engine models)
(Gasoline- and LP-Gas-engine models)
Mast serial number
Transmission serial number
(Diesel-engine models)
Engine serial number
202761A
1-2
GENERAL INFORMATION
Chassis and Mast Model Identification
[Chassis] GP
40
K
Generation designator
Maximum capacity/Load center 40: 4000 kg (8000 lb)/500 mm (20 in.) 40L: 4000 kg (8000 lb)/600 mm (24 in.) 45: 4500 kg (10000 lb)/600 mm (24 in.) 50: 5000 kg (11000lb)/600 mm (24 in.) Engine type GP: gasoline engine type DP: diesel engine type [Mast] 4
V
40
A
30
Maximum lifting height [“30” stands for 3000 mm (118 in.)] Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 40: 4 ton class 40L: 4 ton class 45: 4.5 ton class 50: 5 ton class Kind of mast V: simplex mast F: duplex mast M: triplex mast Major change (“2” for the original, “3” for the first change, and so on up to “9”)
1-3
GENERAL INFORMATION
Dimensions
G
K
C
L
E J
A
I
H B
P
D
N
M
O
F
202762A
1-4
GENERAL INFORMATION
Unit: mm (in.) Ref. No. Item
Truck Model
A
Maximum lift
B
Free lift
C
Fork spread (outside)
D
Fork length
E
Tilt angle (forward – backward)
F
Overall length
G
Overall width (outside of tires)
GP40K DP40K
150 (5.9)
4140 (163.0)
I
Overall height (to top of overhead guard)
J
Overall height (mast extended)
K
Tread (front)
N
Front overhang
O
Rear overhang
P
Underclearance (at frame)
1220 (48)
6° – 12°
Overall height (to top of mast lowered)
Wheelbase
160 (6.5)
1070 (42)
H
M
GP50K DP50K
300 to 1190 (12 to 47)
4190 (165.0)
1415 (55.7)
Dual tire
Tread (rear)
GP45K DP45K
3000 (118)
Single tire
L
GP40KL DP40KL
4245 (167.1)
4525 (178.2)
1460 (57.5) 1780 (70.1)
1965 (77.4)
2170 (85.4)
2250 (88.6) 2250 (88.6)
4270 (168.1)
4290 (168.9)
Single tire
1175 (46.3)
Dual tire
1310 (51.6) 1180 (46.5) 2000 (78.7) 557 (21.9) 513 (20.2)
563 (22.2)
2150 (84.6) 562 (22.1)
582 (22.9)
613 (24.1)
573 (22.6)
252 (9.9)
1-5
GENERAL INFORMATION
Technical Data Truck Model Item
GP40K DP40K
GP40KL DP40KL
Model code
GP45K DP45K
GP: T29B DP: T19C
GP: T33A DP: T28B
Type
Standard
Capacity/load center kgf/mm (lbf/in.)
General
Maximum lift
4000/600 (8000/24)
4500/600 (10000/24)
GP: 510 (100) DP: 500 (98)
Tilt angle (forward – backward)
6° – 12°
mm (in.)
150 (5.9) 19.5 (12.1)
19.5 (12.1)
19.5 (12.1) 2735 (107.7)
GP: 430 (85) DP: 420 (83)
160 (6.5)
19.5 (12.1)
23.5 (14.6) 23.5 (14.6)
2775 (109.3)
Inside
2820 (111)
2965 (116.7)
83°
Steering angle Outside Minimum Single tire intersecting aisle mm (in.) Dual tire Front tires (size and inflation pressure)
Tires
GP: 440 (87) DP: 430 (85) 500 (98)
Minimum turning radius mm (in.)
5000/600 (11000/24)
3000 (118)
Lowering speed (rate load) mm/sec (fpm)
Travel speed of Forward powershift transmission models km/h (mph) Reverse Performance
4000/500 (8000/20)
mm (in.)
Lift speed (rate load) mm/sec (fpm)
Free lift
Truck weight
GP50K DP50K
Single tire
56°33’ 2360 (92.9)
2400 (94.5)
2450 (96.5)
2510 (98.8)
2490 (98)
2520 (99.2)
2570 (101.2)
2740 (107.9)
8.25-15-12PR (I) 800 (8.2) [116]
300-15-18PR (I) 800 (8.2) [116] 7.50-16-12PR (I) 800 (8.2) [116]
8.25-15-12PR (I) 800 (8.2) [116]
Rear tires (size and inflation pressure) kPa (kgf/cm2) [psi]
7.00-12-12PR (I) 800 (8.2) [116]
7.00-12-12PR (I) 800 (8.2) [116]
Single drive tire (unloaded) GP: 5540 (12200) kg (lb) DP: 5630 (12400)
GP: 5950 (13100) DP: 6030 (13300)
GP: 6510 (14300) DP: 6590 (14500)
GP: 7010 (15400) DP: 7080 (15600)
Dual drive tire (unloaded) GP: 5730 (12600) kg (lb) DP: 5810 (12800)
GP: 6080 (13400) DP: 6160 (13600)
GP: 6640 (14600) DP: 6730 (14800)
GP: 7170 (15800) DP: 7250 (15900)
kPa (kgf/cm2) [psi]
Dual tire
1-6
GENERAL INFORMATION
Truck Model GP40K
GP40KL
GP45K
Item Engine model
G6 (GM4.3L)
Manufacturer
General Motors
Type
Gasoline
Cooling system
Water cooled
No. of cylinders – arrangement
6 – 90° V
No. of strokes
4
Type of combustion chamber
Semi -spherical
Valve arrangement
Overhead
Type of cylinder liners
Integral
Engine (gasoline and LP-gas)
Cylinder bore × stroke
Displacement
mm (in.)
101.6 × 88.39 (4.00 × 3.48)
cc (cu in.)
4293 (262)
Compression ratio Rated output
9.2 : 1 kW/rpm
68/2450
Rated torque N·m (kgf·m) [lbf·ft]/rpm
310 (31.0) [224]/1200
Minimum engine speed
rpm
750 to 800
Maximum engine speed
rpm
2600 to 2650
Dimensions (L × W × H) mm (in.) Weight
710 × 620 × 740 (28.0 × 24.4 × 29.1)
kg (lb)
260 (573)
Installation position
Rear
Ignition
Spark
Firing order
1–6–5–4–3–2
Initial ignition timing BTDC deg
0° Gasoline 8° L.P.G.
Fuel tank capacity liter (U.S. gal)
115 (30)
1-7
GP50K
GENERAL INFORMATION
Truck Model GP40K
GP40KL
GP45K
Item
Ignition system
Ignition coil
Distributor
Type
Mold
Manufacturer
AC Delco
Type
Pointless
Manufacturer
AC Delco
Type of spark advance control
Internal solid state circuit
Model
#41-932
Manufacturer
AC Delco
Size
mm (in.)
14 (0.55)
Gap
mm (in.)
1.24 (0.0488)
Spark plug
Fuel system
Type
1FZ
Carburetor Manufacturer
ASIAN Kogyo Co.
Type
Electromagnetic
Fuel pump
Air cleaner
Manufacturer
Jidosha Kiki
Type Ă— Number
Cyclone with paper element Ă— 1
Manufacturer
Nippon Rokaki
Engine lubrication system
Type
Pressure feed
Oil pump
Gear pump
Oil filter
Paper element
Oil cooler
Oil to water type
Refill capacities
Oil pan liter (U.S. gal)
4.2 (1.1)
Oil filter & cooler liter (U.S. gal)
0.8 (0.2)
Total liter (U.S. gal)
5.0 (1.3)
1-8
GP50K
GENERAL INFORMATION
Truck Model GP40K
GP40KL
GP45K
Item
Battery
Cooling system
Type
Forced circulation
Radiator Refill capacity
Corrugated fin with pressure type liter (U.S. gal)
11 (2.9)
Water pump
Centrifugal type driven by V-belt
Thermostat
Wax type
Type × number
48D26L
Voltage Capacity
V
12
AH (5 Hr)
50
Starter
Alternator
Type
3-phase AC
Manufacturer Rated output
MANDO V–A
12 – 50
Regulator
Built-in IC type
Type
Electromagnetic
Manufacturer Voltage – output
Delco Remy V – kW
12 – 0.75
1-9
GP50K
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GENERAL INFORMATION
Truck Model DP40K
DP40KL
DP45K
Item Engine model
S6S
Manufacturer
Mitsubishi Heavy Industries, Ltd.
Type
Water-cooled, 4-stroke cycle
No. of cylinders – arrangement
6 – in-line
Type of combustion chambers
Swirl
Valve arrangement
Overhead
Type of cylinder liners
Dry
Bore × stroke
mm (in.)
94 × 120 (3.70 × 4.72)
Displacement
cc (cu in.)
4996 (305)
Compression ratio
Engine (diesel)
Rated output
22 : 1 kW/rpm
62.5/2450
Maximum torque N·m (kgf·m) [lbf·ft]/rpm
250 (25.5) [184]/1600
Dimensions (L × W × H) mm (in.)
907.5 × 639 × 801 (35.7 × 25.2 × 31.5)
Weight (service)
kg (lb)
350 (771)
Installation position Intake valves
Exhaust valves
Valve clearance (at cold)
Open
Rear BTDC deg
30°
Close ABDC deg
50°
Open
BBDC deg
74°
Close ATDC deg
30°
Intake valves mm (in.) 0.25 (0.0098) Exhaust valves mm (in.)
Ignition
Compression
Firing order
1–5–3–6–2–4
Ignition or injection timing BTDC deg
19°
1-10
DP50K
GENERAL INFORMATION
Truck Model DP40K
DP40KL
DP45K
Engine (diesel)
Item Fuel tank capacity
115 (30)
liter (U.S.gal) No-load minimum speed
rpm
650 to 700
No-load maximum speed
rpm
2600 to 2650
Type
Bosch
Manufacturer
Fuel system
Fuel injection pump
Fuel injection nozzles
Glow plugs
Nippon Denso
Plunger diam. mm (in.)
6.5 (0.256)
Cam lift (one side) mm (in.)
6 (0.24)
Type
Throttle
Spray holes diam. mm (in.)
1.0 (0.04)
Injection pressure kPa (kg/cm2) [psi]
1372 (140) [1992]
Type
Sheathed
Voltage – current V– A
22 – 4.4
Type
Plunger
Fuel pump Manufacturer
Nippon Denso
Type × number
Cyclone with paper element × 1
Air cleaner
Lubrication system
Manufacturer
Nippon Rokaki
Type
Pressure feed
Oil pump
Trochoid type
Oil filter
Paper element type
Oil pan Refill capacities Oil filter liter (U.S. gal) Total
11 (2.9) 1 (0.3) 12 (3.2)
1-11
DP50K
GENERAL INFORMATION
Truck Model DP40K
DP40KL
DP45K
DP50K
Item
Cooling system
Type
Forced circulation
Radiator
Corrugated fin with pressure cap
Refill capacity
10.35 (2.7)
liter (U.S. gal) Water pump
Centrifugal type driven by V-belt
Thermostat
Wax type
Starter
Alternator and regulator
Battery
Type × number Voltage
V
24
Capacity
Ah
50
Alternator type
3-phase AC
Manufacturer
Mitsubishi Electric Corporation
Capacity
V–A
24 – 35
Voltage/current regulator
Built-in IC type
Type
Electromagnetic
Manufacturer Voltage – output Control timer
Engine stop device
48D26R × 2
Stop solenoid
Mitsubishi Electric Corporation V – kW
24 – 5
Manufacturer Setting
Shin Dengen Kogyo sec
5 to 7
Operating voltage V Rated current (at 24 V)
16 to 30
11.3
V
Mitsubishi Electric Corporation
Manufacturer Detector (magnetic pickup)
Output Gap
mA
180 minimum 0.7 ± 0.2 (0.028 ± 0.008)
mm (in.)
1-12
GENERAL INFORMATION
Truck Model Item
GP40K DP40K
GP40KL DP40KL
GP45K DP45K
Type
Dry, single disc (OP: wet type)
Clutch Facing (OD × ID), (DP40K thru mm (in.) DP45K)
325 × 210 (12.8 × 8.3) [wet: 325 × 225 (12.8 × 8.9)]
Material
DR-8 (wet: cork)
Type Torque converter
3-element, 1-stage, 2-phase
Manufacturer’s model
Okamura M15
Stall torque ratio
3.2
Control and shift Powershift transmission
GP50K DP50K
Hydraulic and column shift
Forward
4.044
F1: 5.735 F2: 3.239
Reverse
4.057
R1: 5.735 R2: 3.239
Power train
Ratios
Manual transmission (DP40K thru DP45K)
Type
Synchro-mesh
Shift
Floor-shift
Forward ratio
Reverse ratio
1st
8.462
2nd
4.145
1st
8.489
2nd
4.159
Type of gear
Spiral bevel
Reduction gear
Differential
Gear ratio
4.857
Housing
Banjo
Type of gear – number
Straight bevel – 2
Type of pinion – number
Straight bevel – 4
1-13