Caterpillar cat dp40 k forklift lift trucks chassis and mast service repair manual sn：t19c 00011 and up

Caterpillar cat dp40 k forklift lift trucks chassis and mast service repair manual sn：t19c 00011 and up

• 1.
  Service Manual 99739-36100 For usewith G6 (GM4.3L), S6S Engine Service Manual GP40K, GP40KL, GP45K, GP50K; DP40K, DP40KL, DP45K, DP50K Chassis & Mast GP40K T29B-00011-up DP40K T19C-00011-up GP40KL T29B-50001-up DP40KL T19C-50001-up GP45K T29B-80001-up DP45K T19C-80001-up GP50K T33A-50001-up DP50K T28B-50001-up
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  FOREWORD This service manualis 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. Pub. No. 99739-36100 Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions: Indicates a specific potential hazard resulting in serious bodily injury or death. Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of, the machine. Indicates a condition that can cause damage to, or shorten service life of, the machine. NOTE CAUTION WARNING
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  HOW TO READTHIS MANUAL Disassembly diagram (example) Sequence 1. Cover [Bolt, Washer] (part name) 2. Output shaft (part name) Suggestion for disassembly (1) Output shaft removal 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) Unit: mm (in.) A 0.020 to 0.105 Clearance between (0.00079 to 0.00413) cylinder and piston 0.15 B (0.0059) A: Standard value B: Repair or service limit Disassembly sequence Each disassembly diagram is followed by Disassembly sequence and Suggestions for disassembly.
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  4. Lower theforks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly. 5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. 6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 7. To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments. 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot. The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product. 2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. 3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly. SAFETY WARNING The proper and safe lubrication and maintenance for this lift truck, recommended by Caterpillar, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance. WARNING Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death. WARNING
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  10. Always usetools that are in good condition and be sure you understand how to use them before performing any service work. 11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts. 12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck. 13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang “Do not Operate” tag in the Operator’s Compartment. 14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 15. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against 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. 18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly. 20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
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  GROUP INDEX Items GROUPINDEX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GENERAL INFORMATION COOLING SYSTEM ELECTRICAL SYSTEM POWER TRAIN CLUTCHES Model view, Truck models covered, Serial number locations, Dimensions, Technical data Fan removal and installation, Fan belt inspection and adjustment Console box, Chassis electrical devices, Lamp bulb specifications, Battery maintenance, Electrical system schematic Removal and installation Dry type clutch, Wet type clutch, Pressure plate assembly, Clutch booster, Clutch master cylinder, Clutch release cylinder, Adjustment MANUAL TRANSMISSION POWERSHIFT TRANSMISSION FRONT AXLE AND REDUCTION DIFFERENTIAL REAR AXLE BRAKE SYSTEM STEERING SYSTEM Description, Suggestions for removal and installation, Disassembly, Inspection and repair, Reassembly Torque converter, 1-speed transmission, Control valve, Automatic 2-speed transmission, Solenoid valve, Hydraulic control Front tires, Front axle, Reduction and differential Rear tires, Rear axle, Toe-in, Minimum turning radius Master cylinder, Wheel cylinders, Wheel brakes, Brake booster HYDRAULIC SYSTEM MASTS AND FORKS Steering gear, Power cylinder, Flow divider Hydraulic tank, Gear pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve Simplex mast, Duplex mast, Triplex mast SERVICE DATA OPTIONS Maintenance standards, Periodic service chart, Periodic replacement parts, Lubrication instructions, Special tools Radiator screen kit, Radiator plate-fin type kit, Elevated exhaust kit. Head lamp kit (installed on mast), Tail lamp upper relocate kit, etc.
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  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 1
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  Model View Truck ModelsCovered This Service Manual furnishes servicing and maintenance information for the following trucks: 1-1 GENERAL INFORMATION 103190 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 DP40K Manual T19C – 00011- up Mitsubishi S6S diesel engine Powershift DP40KL Manual T19C – 50001- up Mitsubishi S6S diesel engine Powershift DP45K Manual T19C – 80001- up Mitsubishi S6S diesel engine Powershift DP50K Powershift T28B – 50001- up Mitsubishi S6S diesel engine
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  Serial Number Locations 1-2 GENERALINFORMATION Name plate (Gasoline- and LP-Gas- engine models) Chassis serial number (Diesel-engine models) (Gasoline- and LP-Gas-engine models) (Diesel-engine models)Transmission serial numberMast serial number Engine serial number 202761A
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  1-3 GENERAL INFORMATION Chassis andMast 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.) 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”) Engine type GP: gasoline engine type DP: diesel engine type [Mast] 4 V 40 A 30
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  Dimensions 1-4 GENERAL INFORMATION G KC L B H A J E I P M F OND 202762A
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  1-5 GENERAL INFORMATION Ref. TruckModel GP40K GP40KL GP45K GP50K No. Item DP40K DP40KL DP45K DP50K A Maximum lift 3000 (118) B Free lift 150 (5.9) 160 (6.5) C Fork spread (outside) 300 to 1190 (12 to 47) D Fork length 1070 (42) 1220 (48) E Tilt angle (forward – backward) 6° – 12° F Overall length 4140 4190 4245 4525 (163.0) (165.0) (167.1) (178.2) Single tire 1415 (55.7) 1460 (57.5) G Overall width (outside of tires) Dual tire 1780 (70.1) 1965 (77.4) H Overall height (to top of mast lowered) 2170 (85.4) 2250 (88.6) I Overall height (to top of overhead guard) 2250 (88.6) J Overall height (mast extended) 4270 (168.1) 4290 (168.9) Single tire 1175 (46.3) K Tread (front) Dual tire 1310 (51.6) L Tread (rear) 1180 (46.5) M Wheelbase 2000 (78.7) 2150 (84.6) N Front overhang 557 (21.9) 562 (22.1) 582 (22.9) O Rear overhang 513 (20.2) 563 (22.2) 613 (24.1) 573 (22.6) P Underclearance (at frame) 252 (9.9) Unit: mm (in.)
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  Technical Data 1-6 GENERAL INFORMATION TruckModel GP40K GP40KL GP45K GP50K Item DP40K DP40KL DP45K DP50K Model code GP: T29B GP: T33A DP: T19C DP: T28B Type Standard Capacity/load center 4000/500 4000/600 4500/600 5000/600 kgf/mm (lbf/in.) (8000/20) (8000/24) (10000/24) (11000/24) Maximum lift mm (in.) 3000 (118) Lift speed (rate load) GP: 510 (100) GP: 440 (87) GP: 430 (85) mm/sec (fpm) DP: 500 (98) DP: 430 (85) DP: 420 (83) Lowering speed (rate load) 500 (98) mm/sec (fpm) Tilt angle (forward – backward) 6° – 12° Free lift mm (in.) 150 (5.9) 160 (6.5) 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) Minimum turning radius 2735 2775 2820 2965 mm (in.) (107.7) (109.3) (111) (116.7) 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) Front tires Single tire 8.25-15-12PR (I) 300-15-18PR (I) (size and inflation 800 (8.2) [116] 800 (8.2) [116] pressure) Dual tire 7.50-16-12PR (I) 8.25-15-12PR (I) kPa (kgf/cm2 ) [psi] 800 (8.2) [116] 800 (8.2) [116] Rear tires (size and inflation 7.00-12-12PR (I) 7.00-12-12PR (I) pressure) kPa (kgf/cm2 ) [psi] 800 (8.2) [116] 800 (8.2) [116] 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) GeneralPerformanceTiresTruckweight
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  1-7 GENERAL INFORMATION Truck Model GP40KGP40KL GP45K GP50K 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 Cylinder bore × stroke 101.6 × 88.39 mm (in.) (4.00 × 3.48) Displacement cc (cu in.) 4293 (262) Compression ratio 9.2 : 1 Rated output kW/rpm 68/2450 Rated torque 310 (31.0) [224]/1200 N·m (kgf·m) [lbf·ft]/rpm Minimum engine speed rpm 750 to 800 Maximum engine speed rpm 2600 to 2650 Dimensions (L × W × H) 710 × 620 × 740 mm (in.) (28.0 × 24.4 × 29.1) Weight kg (lb) 260 (573) Installation position Rear Ignition Spark Firing order 1 – 6 – 5 – 4 – 3 – 2 Initial ignition timing 0° Gasoline 8° L.P.G. BTDC deg Fuel tank capacity 115 (30) liter (U.S. gal) Engine(gasolineandLP-gas)
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  1-8 GENERAL INFORMATION Truck Model GP40KGP40KL GP45K GP50K Item Ignition Type Mold coil Manufacturer AC Delco Type Pointless Distributor Manufacturer AC Delco Type of spark Internal solid state circuit advance control Model #41-932 Manufacturer AC Delco Spark plug Size mm (in.) 14 (0.55) Gap mm (in.) 1.24 (0.0488) Type 1FZ Carburetor Manufacturer ASIAN Kogyo Co. Type Electromagnetic Fuel pump Manufacturer Jidosha Kiki Type × Number Cyclone with paper element × 1 Manufacturer Nippon Rokaki Type Pressure feed Oil pump Gear pump Oil filter Paper element Oil cooler Oil to water type Oil pan 4.2 (1.1) liter (U.S. gal) Refill Oil filter & cooler 0.8 (0.2) capacities liter (U.S. gal) Total 5.0 (1.3) liter (U.S. gal) EnginelubricationsystemFuelsystemIgnitionsystemAircleaner
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  1-9 GENERAL INFORMATION Truck Model GP40KGP40KL GP45K GP50K Item Type Forced circulation Radiator Corrugated fin with pressure type Refill capacity liter (U.S. gal) 11 (2.9) Water pump Centrifugal type driven by V-belt Thermostat Wax type Type × number 48D26L Voltage V 12 Capacity AH (5 Hr) 50 Type 3-phase AC Manufacturer MANDO Rated output V – A 12 – 50 Regulator Built-in IC type Type Electromagnetic Manufacturer Delco Remy Voltage – output V – kW 12 – 0.75 BatteryAlternatorCoolingsystemStarter
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  1-10 GENERAL INFORMATION Truck Model DP40KDP40KL DP45K DP50K 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 22 : 1 Rated output kW/rpm 62.5/2450 Maximum torque 250 (25.5) [184]/1600 N·m (kgf·m) [lbf·ft]/rpm Dimensions (L × W × H) 907.5 × 639 × 801 mm (in.) (35.7 × 25.2 × 31.5) Weight (service) kg (lb) 350 (771) Installation position Rear Intake Open BTDC deg 30° valves Close ABDC deg 50° Exhaust Open BBDC deg 74° valves Close ATDC deg 30° Intake valves Valve mm (in.) clearance 0.25 (0.0098) (at cold) Exhaust valves mm (in.) Ignition Compression Firing order 1 – 5 – 3 – 6 – 2 – 4 Ignition or injection timing 19° BTDC deg Engine(diesel)
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  1-11 GENERAL INFORMATION Truck Model DP40KDP40KL DP45K DP50K 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 Nippon Denso Fuel injection Plunger diam. 6.5 (0.256) pump mm (in.) Cam lift (one side) 6 (0.24) mm (in.) Type Throttle Fuel Spray holes diam. 1.0 (0.04) 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 Type × number Cyclone with paper element × 1 Air cleaner Manufacturer Nippon Rokaki Type Pressure feed Oil pump Trochoid type Oil filter Paper element type Refill Oil pan 11 (2.9) capacities liter Oil filter 1 (0.3) (U.S. gal) Total 12 (3.2) Engine(diesel)FuelsystemLubricationsystem
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  1-12 GENERAL INFORMATION Truck Model DP40KDP40KL DP45K DP50K Item Type Forced circulation Radiator Corrugated fin with pressure cap Refill capacity liter (U.S. gal) 10.35 (2.7) Water pump Centrifugal type driven by V-belt Thermostat Wax type Type × number 48D26R × 2 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 Mitsubishi Electric Corporation Voltage – output V – kW 24 – 5 Control Manufacturer Shin Dengen Kogyo timer Setting sec 5 to 7 Operating voltage 16 to 30 Stop V solenoid Rated current 11.3 (at 24 V) V Manufacturer Mitsubishi Electric Corporation Detector (magnetic Output mA 180 minimum pickup) Gap mm (in.) 0.7 ± 0.2 (0.028 ± 0.008) CoolingsystemBatteryAlternatorandregulatorStarterEnginestopdevice
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  1-13 GENERAL INFORMATION Truck Model GP40KGP40KL GP45K GP50K Item DP40K DP40KL DP45K DP50K Type Dry, single disc (OP: wet type) Clutch (DP40K thru Facing (OD × ID), 325 × 210 (12.8 × 8.3) DP45K) mm (in.) [wet: 325 × 225 (12.8 × 8.9)] Material DR-8 (wet: cork) Type 3-element, 1-stage, 2-phase Torque Manufacturer’s Okamura M15 converter model Stall torque ratio 3.2 Control and Hydraulic and column shift shift Powershift Forward 4.044 F1: 5.735 transmission F2: 3.239 Ratios Reverse 4.057 R1: 5.735 R2: 3.239 Type Synchro-mesh Shift Floor-shift Manual transmission Forward 1st 8.462 (DP40K thru ratio DP45K) 2nd 4.145 Reverse 1st 8.489 ratio 2nd 4.159 Type of gear Spiral bevel Reduction gear Gear ratio 4.857 Housing Banjo Type of gear – number Straight bevel – 2 Type of pinion – number Straight bevel – 4 Powertrain Differential
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  1-14 GENERAL INFORMATION Truck Model GP40KGP40KL GP45K GP50K Item DP40K DP40KL DP45K DP50K Type Recirculating ball-and-nut Gear ratio 20.0 Steering wheel diameter 380 (15) mm (in.) Type Semi-integral Power cylinder ID × 55 × 25 (2.17 × 0.98) rod diam. mm (in.) Power Effective stroke 275 (10.8) mm (in.) steering Relief pressure 8336 (85 ) [1209 ] kPa (kgf/cm2 ) [psi] Flow rate 17.5 ± 0.5 (4.6 ± 0.13) liter (U.S. gal)/min Front axle Full-floating tubular type Rear axle Elliott type Suspension Front Fixed type system Rear Center-pivot type Toe-in mm (in.) 0 Wheel Camber 1.0° alignment Caster 0° Kingpin inclination 5.0° Type Self-adjusting, duo-servo Drum diameter 317.5 (12.50) mm (in.) Lining (length × 351 × 60 × 6 − 2 Wheel width × thickness − brakes number) mm (in.) (13.8 × 2.4 × 0.2 − 2) Master cylinder 22.22 (0.8748) 25.4 (1.000) ID mm (in.) Wheel cylinder 28.58 (1.1252) 31.75 (1.2500) ID mm (in.) Parking Type Mechanical, mounted on wheels brake Brake booster Mastervac (vacuum suspended) Body Assembled-frame type + 71 0 + 5 0 + 490 0 BrakesystemTravelingsystemSteeringsystem 332 × 63 × 10 − 2 (13.1 × 2.5 × 0.4 − 2)
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  1-15 GENERAL INFORMATION Truck Model GP40KGP40KL GP45K GP50K Item DP40K DP40KL DP45K DP50K Type Gear Manufacturer Shimazu Hydraulic Manufacturer’s type SGP2B50L979 pump Rated discharge 110 (29.0)/2450 liter (U.S. gal)/rpm Drive line Universal joint Type KVS-120VPF-2 Control Manufacturer Kayaba valve Relief pressure 19123 (195 ) [2773 ] kPa (kgf/cm2 ) [psi] Flow Type Variable (Adjustable) regulator valve Regulated flow rate 100 (26.4) 115 (30.4) liter (U.S. gal)/min 65 70 Lift ID mm (in.) (2.56 ) (2.76 ) cylinders Stroke mm (in.) 1500 (59.06) 80 90 Tilt ID mm (in.) (3.15 ) (3.54 ) cylinders Stroke mm (in.) 185 (7.28) Hydraulic tank capacity L: 56.5 (14.9) liter (U.S. gal) N: 58.7 (15.5) H: 64.4 (17.0) + 0.004 0 + 0.004 0 + 0.1 0 + 0.1 0 + 0.004 0 + 0.004 0 + 0.1 0 + 0.1 0 + 71 0 + 5 0 + 490 0 Hydraulicsystem
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  Structure ................................................................................................... 2– 1 Removal and Installation ...................................................................... 2 – 2 Inspection and Adjustment ................................................................. 2 – 5 Fan Belt Condition .................................................................................... 2 – 5 Fan Belt Tension ....................................................................................... 2 – 5 Connecting Radiator Hoses ...................................................................... 2 – 5 Coolant ..................................................................................................... 2 – 6 Radiator Cap ............................................................................................ 2 – 6 COOLING SYSTEM 2
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  Structure 2-1 COOLING SYSTEM 8 32 1 4 5 6 208413 208411 208412 207009 1 Engine 2Universal joint 3 Gear pump 4 Fan belt 5 Cooling fan 6 Upper hose 7 Lower hose 8 Radiator 9 Oil cooler hoses 10 Tension pulley 1 5 10 3 2 8 6 9 7 9 8 7 6
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  Removal and Installation FanBelt Removal Start by: Remove the radiator cover. Suggestion for removal (1) Using a ratcheting wrench inserted in the gap between the weight and frame, loosen the tension pulley lock bolt by three or four turns. If the bolt is loosened insufficiently, the tension pulley will not be moved. (2) Move the tension pulley fully toward the fan, then remove the belt. 2-2 COOLING SYSTEM 2 (Only loosen.) 1 3 208414 Sequence 1 Universal joint 2 Tension pulley assembly, Bolt 3 Fan belt Tension pulley assembly Section A–A Tension pulley lock bolt A A 208415 NOTE Do not loosen the lock bolt to such an extent that the tension pulley would be removed.
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  Installation Perform installation byfollowing 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. Fan Assembly Removal Sequence 1 Fan cover 2 Fan assembly 3 Tension pulley assembly Start by: Remove the radiator cover. Suggestion for removal Remove the fan support bolts, detach the belt from the driven pulley, and then remove the fan assembly. Place the fan assembly with the fan support facing down and turn the fan to check for smooth rotation. Replace the bearing if it generates abnormal sound. 2-3 COOLING SYSTEM 3 1 2 208416
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  Installation Perform installation byfollowing 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
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  Inspection and Adjustment Fanbelt condition (1) Check the belt for contamination with oil, grease and/or dust. If the contamination is slight, remove it clean with rag or wiping paper. Do not use gasoline, oil or any other solvent to clean the belt. (2) During engine overhaul or belt tension adjustment, closely check the belt for condition. Replace the belt with a new one if it has any sort of damage. Fan belt tension Apply a force of 98 N (10 kgf) [22 lbf] perpendicularly to the belt at a point midway between the fan pulley and tension pulley. If necessary, adjust the tension by moving the tension pulley assembly such that the belt deflects 16 mm (0.63 in) when pressed with the above force. After adjustment, tighten the tension pulley assembly lock bolt firmly. Connecting Radiator Hoses When connecting the hoses to the radiator, fit their ends fully on the fittings and secure them with clamps. Tighten the clamp bolts to the torques indicated below. Make sure that each hose is correctly retained and prevented from disconnection by the flare of the fitting. Clamp bolt tightening torques 2-5 COOLING SYSTEM 3.92 to 5.88 N·m Upper and lower hoses (0.4 to 0.59 kgf·cm) [2.9 to 4.3 lbf·ft] 2.94 to 4.9 N Cooler hose (0.3 to 0.5 kgf) [2.2 to 3.6 lbf]
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  Coolant Fill the radiatorwith 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 Radiator Cap 2-6 COOLING SYSTEM Truck Model GP40K, GP40KL, DP40K, DP40KL, DP45K GP40K, DP40KL, GP45K, GP50K Manual transmission DP45K, DP50K Powershift transmission models Powershift transmission Item models models Engine 11 (2.9) 7.1 (1.9) 7.1 (1.9) Radiator 4.3 (1.1) 5.0 (1.3) 4.7 (1.2) Reserve tank (FULL level) 0.65 (0.17) 0.65 (0.17) 0.65 (0.17) Total quantity of coolant 17.2 (4.5) 14.0 (3.7) 14.7 (3.9) (including coolant in hoses) Oil cooler 0.62 (0.16) – 0.31 (0.08) Unit: liter (U.S. gal) 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]
• 30.
  Structure and Functions....................................................................... 3 – 1 Console Box ............................................................................................. 3 – 1 Chassis Electrical Devices ........................................................................ 3 – 3 Major Electrical Components ............................................................. 3 – 7 Starter Switch (with Anti-Restart Lock) ..................................................... 3 – 7 Lighting Switch ......................................................................................... 3 – 8 Turn Signal Switch .................................................................................... 3 – 8 Fuel Tank Unit ........................................................................................... 3 – 9 Neutral Switch .......................................................................................... 3 – 9 Fuse Box .................................................................................................. 3 – 10 Spare Terminals ........................................................................................ 3 – 10 Lamp Bulb Specifications .................................................................... 3 – 11 Battery Maintenance ............................................................................. 3 – 12 Disassembly and Reassembly ............................................................ 3 – 14 Console Box ............................................................................................. 3 – 14 Components in Console Box .................................................................... 3 – 15 Combination Meter ................................................................................... 3 – 16 Troubleshooting ...................................................................................... 3 – 17 Electrical Schematic .............................................................................. 3 – 23 ELECTRICAL SYSTEM 3
• 31.
  Structure and Functions ConsoleBox 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 3-1 ELECTRICAL SYSTEM 103195
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  OK Monitor 102794A 3-2 ELECTRICAL SYSTEM No.Indicator light OFF ON or flickering Remarks 1 Powershift transmission oil temp. indicator light Normal Overheating 2 Air cleaner element indicator light Normal Clogged Option 3 Brake fluid level indicator light Normal Low 4 Engine oil pressure indicator light Normal Low 5 Alternator not charging indicator light Normal Abnormal 6 Heater plug indicator Normal 7 Engine coolant level indicator light Normal Low Option Function How to check indicator light bulbs The bulbs are normal if all the indicator lights come ON when the starter switch key is turned to the (ON) position. (The indicator lights will go OFF when the engine starts.)
• 33.
  Chassis Electrical Devices Theelectrical system is divided into engine electrical system and chassis electrical system. Following are the components involved in the chassis electrical system: (1) Wire and fuses (2) Lighting system: Head lamps, working lamp and backup lamps (3) Signaling system: Turn signals, clearance lamps, tail/stop lamps, license plate lamp and horn (4) Instruments The circuit is a one-wire negative-ground system. 3-3 ELECTRICAL SYSTEM Solenoid valve ECU (Electronic control unit) Travel speed select switch Fuse box Travel speed sensor (pulse generator)Fusible linkHorn Pressure switch Backup buzzer Ground on body ECU power source Ground on body To rear combination lamps To rear combination lamps To front combination lamps To front combination lamps Fuel tank unit Starter relay Stop lamp switch Brake fluid level sensor T/C oil thermounit A To console box Spare terminal Spare terminal View A Power source 207548 Gasoline- and LP-Gas-engine models
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  3-4 ELECTRICAL SYSTEM 203782 Diesel-engine models
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  Sensors Each sensor sensesa 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 GP50K, optional for GP40K, GP40KL and GP45K) (5) Powershift transmission oil temperature sensor 3-5 ELECTRICAL SYSTEM Sender unit (powershift transmission oil temperature sensor) Dust indicator switch (option) Travel speed sensor (pulse generator) Brake fluid level sensor Coolant sensor (option) 207549 Gasoline- and LP-Gas-engine models
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  Travel speed sensor(standard for DP50K, optional for DP40K, DP40KL and DP45K) 3-6 ELECTRICAL SYSTEM 203783 Diesel-engine models
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  Major Electrical Components StarterSwitch (with Anti-Restart Lock) 3-7 ELECTRICAL SYSTEM (OFF) (ON) (START) B2 B1 M G1 G2 S 203561A Terminal B1, B2 G1 G2 M S Fuse box, Starter, neutral Component battery, Fuse box, switch (powershift Key alternator fuel-cut solenoid transmission position models) (OFF) (ON) (START) Connection chart Gasoline-engine models (12 V) Terminal B1, B2 G1 G2 M S Fuse box, Fuse box, fuel-cut Component glow plug relay, solenoid, glow Neutral switch, Key battery, plug timer, glow glow plug timer position alternator plug timer relay (OFF) (ON) (START) Diesel-engine models (24 V) 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. This switch has a built-in anti-restart lock, so the key cannot be turned from (ON) to (START) position while the engine is running. The gasoline- and diesel- engine models use the same starter switch. In the diesel-engine models, (ON) position of the switch is for energizing the glow plugs.
• 38.
  Lighting Switch Turn SignalSwitch 3-8 ELECTRICAL SYSTEM 8 (0.3) 8 (0.3) OFF 1st 2nd Stroke [Unit: mm (in.)] Knob position 206481 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 Connection chart L N R RF LF F 203573 Terminal F RF LF Lever Component Turn signal Turn signal Turn signal position relay (L) (RH) (LH) R (Right) N (Straight) L (Left) Cord color Green Yellow Black Connection chart 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. Insulation 1 M ohm or higher resistance (as measured by a 500 V megger) 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. Insulation 1 M ohm or higher resistance (as measured by a 500 V megger)
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  Fuel Tank Unit NeutralSwitch 3-9 ELECTRICAL SYSTEM To ground To fuel gauge 212.4mm (8.36in.) 141.4mm (5.57in.) E F 3/4 1/2 1/4 203574 Terminal E 1/4 1/2 3/4 F Item Standard resistance (ohm) 80 49.5 32 19 10 Tolerance (ohm) − ± 3 − + 1.0 − 0.5 + 12 + 2 Indication accuracy R N F a b c d e N (BR) B I (WL) R (BrB) B II (GW) 11 mm (0.43 in.) 18 mm (0.71 in.) 25mm (0.98in.) 206750 Position Battery Battery Neutral Reverse Forward Terminal I II N R F a b c d e Connection chart
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