99739-84100
GP40, GPL40; DP40, DPL40, DP45, DP50 Chassis & Mast
For use with: 6G72 Gasoline, S6S Diesel Engine Service Manual
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 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. 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
GROUP INDEX
Group
Items involved
General
Serial number locations, Dimensions, Technical data
1
Cooling system
Fan removal and installation, Fan belt adjustment
2
Electrical system
Console box, Chassis electrical devices, Care of the battery, 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
7
Front axle and reduction differential
Front tires, Front axle, Reduction and differential
8
Rear axle
Rear axle, Rear tires
9
Brake system
Master cylinder, Wheel brakes, Brake booster
10
Steering system
Steering gear, Power cylinder, Flow divider
11
Hydraulic system
Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve
12
Masts and forks
Dual-stage panoramic mast
13
Troubleshooting Service data
14 Maintenance standards, Periodic service chart, Periodic replacement parts, Lubrication instructions, Special tools, Inspection guide
15
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.)
3
GENERAL INFORMATION
MODEL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
TRUCK MODELS COVERED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
1
GENERAL INFORMATION
MODEL VIEW
100507
TRUCK MODELS COVERED This Service Manual furnishes servicing and maintenance information for the following trucks:
7
GENERAL INFORMATION
SERIAL NUMBER LOCATIONS Nameplate
Chassis serial number
Gasoline engine serial number
206747
Mast serial number 8
Transmission serial number
Diesel engine serial number
GENERAL INFORMATION
DIMENSIONS
202762
9
GENERAL INFORMATION Unit mm [in.]
10
GENERAL INFORMATION
TECHNICAL DATA
11
GENERAL INFORMATION
12
GENERAL INFORMATION
13
GENERAL INFORMATION
14
GENERAL INFORMATION
15
GENERAL INFORMATION
16
GENERAL INFORMATION
17
COOLING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
INSPECTION AND ADJUSTMENT Fan belt inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
Fan belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
2
COOLING SYSTEM
DESCRIPTION
203823
203824
202766
202765
Manual transmission models
1 2 3 4 5 6
Engine Universal joint Gear pump Fan belt Cooling fan Upper hose
Powershift transmission models
7 8 9 10 11
Lower hose Radiator Oil cooler Cooler hoses Tension pulley
21
COOLING SYSTEM
REMOVAL AND INSTALLATION Fan Belt Removal 1. Method by removing radiator
203825
Removal sequence 1 Drain cock 2 Cap 3 Hose 4 Hose Start by: (1) remove the radiator cover. (2) remove the engine cover and gas springs.
22
5 Radiator 6 Universal joint 7 Tension pulley bolt 8 Belt
COOLING SYSTEM
Suggestions for removal and installation (1) Make sure coolant temperature is low before opening the drain cock. tensioner wrench A (2) Using (91268-04500) through the space between the counterweight and 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 come off. If the pulley comes off, the counterweight has to be removed for installation of the pulley.
203460
(3) Force the pulley all the way toward the fan and remove fan belt.
Installation
203826
To install, follow the reverse of removal procedure and do the following steps: (1) Turn the fan by hand to make sure it rotates smoothly. If its bearing is noisy, replace it. (2) 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. (3) 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. (4) 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. 23
COOLING SYSTEM
2. Method by removing counterweight
203827
Removal sequence 4 Radiator 5 Belt
1 Muffler 2 Fan assembly 3 Universal joint Start by: (1) remove the radiator cover. (2) remove the counterweight bolts. Attach a hoist counterweight and lift it off.
mounting to the
NOTE Check the weight of counterweight in attaching the hoist.
24
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 assembly on the bench with the fan support down. Turn the fan by hand to check the bearing. Replace the bearing if it is noisy. (2) Remove two bolts at the bottom of radiator. Loosen two bolts at the top of radiator.
Only loosen
(3) Force the radiator toward the engine 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 (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. (2) Push the belt midway between the drive and driven pulleys through the space between fan blades to make sure the tension pulley moves freely, then tighten the tension pulley bolt.
Tension Pulley bolt
203828
25
COOLING SYSTEM
INSPECTION AND ADJUSTMENT Fan Belt Inspection (1) Check to make sure the belt is free of oil, grease or other foreign matter. Replace the belt if 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 counterweight.
grille
from
the
(2) Using ratchet wrench B with extension through the vent in the counterweight, 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.
203465
2. Trucks with non-standard muffler (1) Remove the radiator cover. (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. 203826
26
COOLING SYSTEM
(3) The belt will be automatically tightened. Tighten the pulley bolt. (4) Install the radiator cover. 3.
Trucks having an access hole on left rear side
(1)
Remove the cover from the access hole.
(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.
The following hole:
trucks
have
the
access 203767
27
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
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
3
ELECTRICAL SYSTEM
DESCRIPTION Console Box 1 2 3 4 5 6 7 8 9
Engine coolant temperature gauge Choke control Fuel gauge Service hour meter OK monitor Starter switch Light switch Fuse box Speed selector switch
102389A
31
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.)
32
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.)
Horn
Fusible link
Fuse box Travel speed sensor (pulse generator)
Backup buzzer
Sender unit (powershift transmission oil temperature sensor)
Ground on body
Spare terminal
Brake fluid lever sensor
Fuel tank unit 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.
(1) Wire and fuses (2) Lighting system: Head lights, working light and backup lights (3) Signaling system: Turn signals, clearance lights, tail/stop lights, license plate light and horn
33
ELECTRICAL SYSTEM
Sensors
Sender unit (powershift transmission oil temperature sensor)
Dust indicator switch (option)
Travel speed sensor (pulse generator)
Brake fluid level sensor
Coolant sensor (option)
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. (1) Brake fluid level sensor (2) Coolant sensor (option) (3) Dust indicator switch (option) (4) Travel speed sensor (standard for DP50, optional for GP40/GPL40 and DP40/DPL40/DP45) (5) Powershift transmission oil temperature sensor 34
ELECTRICAL SYSTEM
MAJOR ELECTRICAL COMPONENTS Starter Switch (with Anti-Restart Lock) 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
the diesel models, I (ON) position of the switch is for energizing the glow plugs.
203561A
35
ELECTRICAL SYSTEM
Lighting Switch
206481
Turn Signal Switch
203573
36
ELECTRICAL SYSTEM
Backup Light Switch (Manual Transmission Models)
ON
OFF Shift rail (for FORWARD 2 mm [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
ELECTRICAL SYSTEM
Neutral Switch (Powershift Transmission Models)
Connection chart
N (BR)
R (BrB)
BI (WL)
BII (GW) 206750
38
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
ELECTRICAL SYSTEM
LIGHT BULB SPECIFICATIONS
206751
40
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 20째C [68째F]. 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.
3. 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 elFectrolyte temperature from rising beyond 45째C [ 113째F].
41
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: (1) Do not reverse the polarity of the battery.
Terminal L
(2) Do not disconnect the battery terminal while the engine is running. (3) Do not ground the terminal L. (4) Do not short the terminals L and R. (5) Do not direct a blast of steam cleaner to the alternator. Remember, a blast of steam will damage the IC regulator.
42
Terminal R
Terminal B 2027721
ELECTRICAL SYSTEM
DISASSEMBLY AND REASSEMBLY Console Box
206422
Reassembly
Disassembly 1. Disconnect the electrical wires at connectors 1. (In the gasoline models, disconnect the choke cable on the engine side.)
To reassemble the console box, follow the reverse of disassembly procedure.
2. Remove screws 2 (four) securing the cover. 3. Remove screws 3 (six) and separate the front and rear panels. 4. Remove screws 4 (four) securing the instrument panel. NOTE To replace the instrument panel bulbs, remove screws 3 and 4.
43
ELECTRICAL SYSTEM
Components in Console Box
206423
1 2 3 4
44
Power relay Power relay Turn signal relay Glow plug relay (diesel models)
5 6 7 8
Glow plug timer (diesel models) Light switch Starter switch Fuses
ELECTRICAL SYSTEM
Combination Meter Disassembly
206480
Sequence 1 2 3 4 5
Instrument panel Dial Engine coolant temperature gauge Service hour meter Fuel gauge
6 7 8 9
Meter case Printed circuit Bulb Socket
CAUTION Be careful not to damage the printed circuit when disassembling the combination meter. Bulb replacement Reassembly To reassemble the combination meter, follow the reverse of disassembly procedure.
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.� 45
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