Page 1

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


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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


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

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CATERPILLAR CAT DP40K FORKLIFT LIFT TRUCKS CHASSIS AND MAST Service Repair Manual SN:T19C-00011 and  

CATERPILLAR CAT DP40K FORKLIFT LIFT TRUCKS CHASSIS AND MAST Service Repair Manual SN:T19C-00011 and  

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