Service Manual

MC/FC

Chassis, Mast & Options

GP40K
GP40KL
GP45K
GP50K

ET29C-00011-up
ET29C-50001-up
ET29C-80001-up
ET33B-50001-up

DP40K
DP40KL
DP45K
DP50K

For use with S6S and TB45 Engine Service Manual.

ET19C-00011-up
ET19C-50001-up
ET19C-80001-up
ET28B-50001-up

99739-65120

FOREWORD

This service manual is a guide for servicing Cat lift trucks. For your convenience the
instructions are grouped by systems as a ready reference.
The long productive life of your lift truck(s) depends on regular and proper servicing
servicing consistent with what you will learn by reading this service manual. Read the
respective sections of this manual carefully and familiarize yourself with all of the components
before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks with
serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to change
specifications or design without notice and without incurring obligation.
GP40K, GP40KL, GP45K, and GP50K are powered by TB45 gasoline engine.
DP40K, DP40KL, DP45K, and DP50K are powered by S6S diesel engine.

Safety Related Signs

The following safety related signs are used in this service
manual to emphasize important and critical instructions:

WARNING

CAUTION

NOTE

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.

Pub. No. 99739-65120

HOW TO READ THIS MANUAL

Disassembly diagram (example)

Each disassembly diagram is followed by

Disassembly sequence and Suggestions for
disassembly.

Disassembly sequence
Sequence
1. Cover, Bolt, Washer (part name)
2. Output shaft (part name)

Suggestion for disassembly

(1) Output shaft removal
Unit: mm (in.)
A

0.020 to 0.105
(0.00079 to 0.00413)

0.15
(0.0059)

Clearance between
cylinder and piston

A: Standard value

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)

B: Repair or service limit

WARNING

SAFETY

WARNING

WARNING

The proper and safe lubrication and

maintenance for this lift truck, recommended
by Cat Lift Trucks, are outlined in the
OPERATION & MAINTENANCE MANUAL for
these trucks.

Do not operate this truck before you read

and understand the instructions in the
OPERATION & MAINTENANCE MANUAL.
Improper truck operation is dangerous and
could result in injury or death.

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.

4. Lower the forks 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.

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.

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.

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.

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.

10. Always use tools 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 Operators
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.

GROUP INDEX
GROUP INDEX

Items

GENERAL INFORMATION

Model View, Truck Models Covered, Serial Number Locations, Chassis

and Mast Model Identification, Dimensions, Technical Data

COOLING SYSTEM

Structure, Removal and Installation, Inspection and Adjustment

ELECTRICAL SYSTEM

Structure and Functions, Disassembly and Reassembly, Major Electrical

Components, Lamp Bulb Specifications, Battery Maintenance, FC
(Finger-Tip-Control System), Troubleshooting, Electrical Schematics

POWER TRAIN

Removal and Installation

POWERSHIFT TRANSMISSIONS

1-Speed Transmission (GP40K, GP40KL, GP45K, DP40K, DP40KL,

DP45K), Structure and Functions, Removal and Installation, Torque
Converter, Transmission, Control Valve, Adjustment, Automatic 2-Speed
Transmission (GP50K, DP50K), Transmission, Selector Valve,
Adjustment, Troubleshooting, Service Data

FRONT AXLE AND

REDUCTION DIFFERENTIAL

Structure and Function, Removal and Installation, Axle Shafts and Hubs,
Reduction Differential, Troubleshooting, Service Data

REAR AXLE

Structure, Removal and Installation, Rear Axle Assembly, Steering

Cylinder, Adjustment, Troubleshooting, Service Data

BRAKE SYSTEM

Structure and Functions, Master Cylinder, Wheel Cylinders, Wheel

Brakes, Inspection and Adjustment, Troubleshooting, Service Data

STEERING SYSTEM

Structure and Functions, Removal and Installation, Steering Valve,

Troubleshooting, Service Data

Structure and Functions, Removal and Installation, Hydraulic Pump

(Gear Pump), Lift Cylinders, Tilt Cylinders, Flow Regulator Valve,
Down Safety Valve, Inspection and Adjustment, Testing,
Troubleshooting, Service Data MC Control Valve, FC Control Valve

10

MASTS AND FORKS

Structure, Removal and Installation, Disassembly and Reassembly,

Inspection and Adjustment, Troubleshooting, Service Data

11

SERVICE DATA

Tightening Torque for Standard Bolts and Nuts, Maintenance Schedule,

Parts To Be Changed Periodically, Location of Periodic Replacement
Parts, Lubrication Instructions, Special Tools

12

OPTIONS

Radiator Screen Kit, Radiator Plate-Fin Type Kit, Elevated Exhaust Kit,
Anti-corrosion Radiator Kit, Front Axle Breather Kit, Pre-cleaner Kit, etc.

13

HYDRAULIC SYSTEM

GENERAL INFORMATION
1
Model View ................................................................................................
Truck Models Covered ...........................................................................
Serial Number Locations .......................................................................
Chassis and Mast Model Identification .............................................
Dimensions ...............................................................................................
Technical Data ..........................................................................................

11
11
12
13
14
16

GENERAL INFORMATION

Model View

103235

Truck Models Covered

This Service Manual furnishes servicing and maintenance
information for the following trucks:
Truck model

Model code Serial number

Engine mounted

GP40K

ET29C 00011- up

TB45 gasoline engine

GP40KL

ET29C 50001- up

TB45 gasoline engine

GP45K

ET29C 80001- up

TB45 gasoline engine

GP50K

ET33B 50001- up

TB45 gasoline engine

DP40K

ET19C 00011- up

S6S diesel engine

DP40KL

ET19C 50001- up

S6S diesel engine

DP45K

ET19C 80001- up

S6S diesel engine

DP50K

ET28B 50001- up

S6S diesel engine

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

Generation designator

Maximum capacity/Load center

40: 4000 kg (8000 lb)/500 mm (24 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

40

33

Maximum lifting height

[33 stands for 3300 mm (130 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

E
J

H
B

202762A

1-4

GENERAL INFORMATION

Unit: mm (in.)
Ref.
No. Item

Truck Model

Maximum lift

Free lift

Fork spread (outside)

Fork length

Tilt angle (forward backward)

Overall length

Overall width (outside of tires)

GP40K
DP40K

150 (5.9)

6 10
4290
(168.9)

Overall height (to top of mast lowered)

Overall height (to top of overhead guard)

Overall height (mast extended)

Tread (front)

Wheelbase

Front overhang

Rear overhang

Underclearance (at frame)

160 (6.5)

1220 (48)

GP50K
DP50K

300 to 1190 (12 to 47)

4340
(170.9)

1415 (55.7)

Dual tire

Tread (rear)

GP45K
DP45K

3300 (130)

Single tire

GP40KL
DP40KL

4395
(173.0)

4525
(178.2)

1460 (57.5)
1780 (70.1)

1965 (77.4)

2320 (91.5)

2400 (94.5)
2250 (88.6)

4570 (180)

4590 (180.5)

Single tire

1175 (46.5)

Dual tire

1445 (56.9)
1180 (46.5)
2000 (78.5)
557 (21.9)
513 (20.6)

563 (22.6)

2150 (84.5)
562 (22.1)

582 (22.9)

613 (24.4)

573 (22.6)

252 (9.9)

1-5

GENERAL INFORMATION

Technical Data
Truck Model
Item

GP40K
DP40K

GP40KL
DP40KL

GP45K
DP45K

GP: ET29C
DP: ET19C

Model code
Type

General

Maximum lift

4000/500
(8000/24)

4000/600
(9000/24)

mm (in.)

Lift speed (rate load)

mm/sec (fpm)

GP: 510 (100)

DP: 520 (103)

GP: 440 (87)

DP: 450 (89)
500 (100)

Tilt angle (forward backward)

6 10

mm (in.)

Minimum turning radius

mm (in.)

5000/600
(11000/24)

3300 (130)

Travel speed of
Forward
powershift
transmission models
km/h (mph) Reverse
Performance

4500/600
(10000/24)

Lowering speed (rate load)

mm/sec (fpm)

Free lift

2735
(107.5)

150 (5.9)

160 (6.5)

19.5 (12)

23.5 (14.6)

19.5 (12)

23.5 (14.6)

2775
(109.5)

Inside

2820
(111)

2965
(116.5)

83

Steering angle
Outside
Minimum
Single tire
intersecting aisle
mm (in.) Dual tire
Front tires
(size and inflation
pressure)

Tires

GP: ET33B
DP: ET28B
Standard

Capacity/load center
kgf/mm (lbf/in.)

kPa (kgf/cm2) [psi]

5633
2390 (94)

2430 (96)

2450 (96.5)

2510 (99)

2570 (101)

2590 (102)

2620 (103)

2670 (105)

8.25-15-14PR (I)
785 (8.0) [114]

Single tire

7.50-16-12PR (I)
800 (8.2) [116]

Dual tire

Rear tires (size and inflation

pressure)
kPa (kgf/cm2) [psi]
Truck weight

GP50K
DP50K

7.00-12-12PR (I)
700 (7.0) [100]

8.25-15-12PR (I)
800 (8.2) [116]
7.00-12-12PR (I)
850 (8.5) [120]

Single drive tire (unloaded)

GP: 5570 (12300)
kg (lb) DP: 5710 (12600)

GP: 5970 (13150)

DP: 6120 (13500)

GP: 6530 (14400)

DP: 6680 (14750)

GP: 7050 (15500)

DP: 7160 (15800)

Dual drive tire (unloaded)

GP: 5700 (12550)
kg (lb) DP: 5900 (13000)

GP: 6050 (13350)

DP: 6250 (13750)

GP: 6610 (14550)

DP: 6820 (15050)

GP: 7130 (15700)

DP: 7320 (16150)

1-6

GENERAL INFORMATION

Truck Model
GP40K

GP40KL

GP45K

Item
Engine model

TB45

Type

Gasoline

Cooling system

Water cooled

No. of cylinders arrangement

6 in-line

No. of strokes

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.)

99.5 96.0
(3.92 3.78)

cc (cu in.)

4500 (275)

Compression ratio
Rated output

9.2 : 1
kW/rpm

72/2450

Rated torque
Nm (kgfm) [lbfft]/rpm

280 (28.5) [207]/1200

Minimum engine speed

rpm

650 to 700

Maximum engine speed

rpm

2450

Dimensions (L W H)
mm (in.)
Weight

907 647.5 781

(35.7 25.5 30.7)

kg (lb)

290 (639)

Installation position

Rear

Ignition

Spark

Firing order

153624

Initial ignition timing

BTDC deg

10 1

Fuel tank capacity

liter (U.S. gal.)

115 (30)

1-7

GP50K

GENERAL INFORMATION

Truck Model
GP40K

GP40KL

GP45K

Item
Ignition coil type

Mold

Distributor

Pointless

Type of spark
advance control

Internal solid state circuit

Model

BPR4ES
mm (in.)

Gap

mm (in.)

0.8 to 0.9 (0.031 to 0.035)

Fuel
system

Spark plug Size

Fuel pump type

Electromagnetic

Air
cleaner

Ignition system

Type

Type Number

Cyclone with paper element 1

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)

7.3 (1.93)

Oil filter & cooler

liter (U.S. gal)

0.3 (0.08)

Total
liter (U.S. gal)

7.6 (2.01)

Cooling system

Type

Forced circulation

Radiator
Refill capacity

Corrugated fin with pressure type

liter (U.S. gal.)

11.2 (2.96)

Water pump

Centrifugal type driven by V-belt

Thermostat

Wax type

1-8

GP50K

GENERAL INFORMATION

Truck Model
GP40K

GP40KL

GP45K

Item
Battery

Type number
Voltage

Starter

Alternator

Capacity

55D26R
V

12

AH (5 Hr)

50

Type
Rated output

3-phase AC
VA

12 50

Regulator

Built-in IC type

Type

Electromagnetic

Voltage output

V kW

12 0.75

1-9

GP50K

GENERAL INFORMATION

Truck Model
DP40K

DP40KL

DP45K

Item
Engine model

S6S

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
Nm (kgfm) [lbfft]/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

153624

Ignition or injection timing

BTDC deg

19

1-10

DP50K

GENERAL INFORMATION

Truck Model
DP40K

DP40KL

DP45K

Engine (diesel)

Item
Fuel tank capacity
liter (U.S. gal.)

115 (30)

No-load minimum speed

rpm

650 to 700

No-load maximum speed

rpm

2600 to 2650

Type

Fuel system

Fuel
injection
pump

Fuel
injection
nozzles

Glow plugs

Bosch

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

Fuel pump type

Plunger

Lubrication system

Air cleaner Type number

Cyclone with paper element 1

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

BUYNOW

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

24

Capacity

Ah

50

Alternator type

3-phase AC

Capacity

VA

24 35

Voltage/current regulator

Built-in IC type

Type

Electromagnetic

Voltage output
Control
timer

Engine stop device

48D26R 2

Stop
solenoid

Detector
(magnetic
pickup)

V kW

24 5

sec

5 to 7

Setting

Operating voltage
V
Rated current
(at 24 V)
Output
Gap

16 to 30

11.3

V
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

Torque
converter

DR-8 (wet: cork)

Type

3-element, 1-stage, 2-phase

Model

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

GENERAL INFORMATION

Truck Model
Item

GP40K
DP40K

GP40KL
DP40KL

Type

GP45K
DP45K

Recirculating ball-and-nut

Gear ratio

20.0

Steering system

Steering wheel diameter

mm (in.)

380 (15)

Type

Power
steering

Semi-integral

Power cylinder ID
rod diam. mm (in.)

55 25 (2.17 0.98)

Effective stroke
mm (in.)

275 (10.8)

Relief pressure
kPa (kgf/cm2) [psi]

8336

Traveling system

Flow rate
liter (U.S. gal)/min

+ 490
0

(85

) [1209

+ 71
0

Full-floating tubular type

Rear axle

Elliott type

Suspension Front
system
Rear

Fixed type

Toe-in

Center-pivot type
mm (in.)

Camber

1.0

Caster

0
5.0

Type

Self-adjusting, duo-servo

Drum diameter
mm (in.)
Wheel
brakes

Parking
brake

17.5 0.5 (4.6 0.13)

Kingpin inclination

Brake system

+5
0

Front axle

Wheel
alignment

GP50K
DP50K

317.5 (12.50)

Lining (length
width thickness
number) mm (in.)

351 60 6 2
(13.8 2.4 0.2 2)

332 63 10 2
(13.1 2.5 0.4 2)

Master cylinder
ID
mm (in.)

22.22 (0.8748)

25.4 (1.000)

Wheel cylinder
ID
mm (in.)

28.58 (1.1252)

31.75 (1.2500)

Type

Mechanical, mounted on wheels

Brake booster

Mastervac (vacuum suspended)

Body

Assembled-frame type

1-14

GENERAL INFORMATION

Truck Model
Item

GP40K
DP40K

GP40KL
DP40KL

Type

Hydraulic system

Flow
regulator
valve

Lift
cylinders

Tilt
cylinders

GP50K
DP50K

Gear

Hydraulic Rated discharge

pump
liter (U.S. gal)/rpm

Control
valve

GP45K
DP45K

110 (29.0)/2450

Drive line

Universal joint

Type

KVS-120VPF-2

Relief pressure
MPa (kgf/cm2) [psi]

19.1 (195) [2773]

Type

Variable (Adjustable)

Regulated flow rate

liter (U.S. gal)/min
ID

mm (in.)

Stroke

mm (in.)

ID

mm (in.)

Stroke

mm (in.)

100 (26.4)
65
(2.56

115 (30.4)

+ 0.1
0
+ 0.004
0

70
(2.76

+ 0.1
0
+ 0.004
0

1500 (59.06)
80 + 00.1
(3.15 + 00.004 )

90 + 00.1
(3.54 + 00.004 )
185 (7.28)
L: 56.5 (14.9)
N: 58.7 (15.5)
H: 64.4 (17.0)

Hydraulic tank capacity

liter (U.S. gal)

1-15

COOLING SYSTEM
Structure ....................................................................................................
Removal and Installation ......................................................................
Inspection and Adjustment ..................................................................

25

Fan Belt Condition .....................................................................................

25

Fan Belt Tension ........................................................................................

25

Connecting Radiator Hoses .......................................................................

25

Coolant ......................................................................................................

26

Radiator Cap .............................................................................................

26

21
22

COOLING SYSTEM

Structure

1
6
5
8
5
4

10

2
3
2

3
207009

208411

9
7
7

9
208412

1
2
3
4
5

208413

Engine
Universal joint
Gear pump
Fan belt
Cooling fan

6
7
8
9
10

2-1

Upper hose
Lower hose
Radiator
Oil cooler hoses
Tension pulley

COOLING SYSTEM

Removal and Installation

Fan Belt Removal

3
1
2
(Only loosen.)

208414

Sequence
1
2
3

Universal joint
Tension pulley assembly, Bolt
Fan belt

Start by:

Remove the radiator cover.

Suggestion for removal

Tension pulley assembly

(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 move.

NOTE
Do not loosen the lock bolt to such an extent that the
tension pulley would be removed.
(2) Move the tension pulley fully toward the fan, then
remove the belt.

Tension pulley lock bolt

Section AA

2-2

208415

COOLING SYSTEM

Installation
Perform installation by following 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

1
3
2

208416

Sequence
1
2
3

Fan cover
Fan assembly
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

Installation
Perform installation by following 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

Inspection and Adjustment

Fan Belt Condition
(1) Check the belt for contamination with oil, grease
and/or dust. When the contamination is slight, clean
the belt with a rag or paper towel. Do not use gasoline,
oil or any other solvent to clean the belt.
(2) During engine overhaul or belt tension adjustment,
closely check the condition of the belt. 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

Upper and lower hoses

Cooler hose

3.92 to 5.88 Nm
(0.4 to 0.59 kgfcm)
[2.9 to 4.3 lbfft]
2.94 to 4.9 N
(0.3 to 0.5 kgf)
[2.2 to 3.6 lbf]

2-5

COOLING SYSTEM

Coolant
Fill the radiator with 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

Unit: liter (U.S. gal.)

Truck Model
Item
Engine

GP40K, GP40KL,
GP45K, GP50K

DP40K, DP40KL,
DP45K, DP50K

11.2 (2.96)

7.1 (1.9)

3.4 (0.9)

4.7 (1.2)

Reserve tank (FULL level)

0.65 (0.17)

0.65 (0.17)

Total quantity of coolant

(including coolant in hoses)

15.3 (4.04)

14.7 (3.9)

Oil cooler

0.62 (0.16)

0.31 (0.08)

Radiator

Radiator Cap
Opening pressure

Vacuum valve

90 15 kPa
(0.92 0.15 kgf/cm2)
[13.1 2.2 psi]
0 to 5 kPa
(0 to 0.05 kgf/cm2)
[0 to 0.73 psi]

2-6

ELECTRICAL SYSTEM
Structure and Functions ....................................................................... 3 1
Console Box ............................................................................................. 3 1
Electrical Components Mounted on Body ................................................. 3 4

Disassembly and Reassembly ............................................................ 3 5

Console Box .............................................................................................. 3 5
Components in Console Box...................................................................... 3 7
Combination Meter .................................................................................... 3 8

Major Electrical Components ............................................................. 3 9

Starter Switch (with Anti-Restart Lock) ..................................................... 3 9
Lighting Switch .......................................................................................... 3 10
Turn Signal Switch ..................................................................................... 3 10
Fuel Tank Unit ............................................................................................ 3 11
Fuse Box .................................................................................................. 3 12
Spare Terminals ........................................................................................ 3 12

Lamp Bulb Specifications .................................................................... 3 13

Battery Maintenance ............................................................................. 3 14
FC (Finger-Tip-Control System) ......................................................... 3 16
Nomenclature ........................................................................................... 3 16
Maintenance Precautions ......................................................................... 3 17
Description ................................................................................................ 3 18
Operating Principles ................................................................................. 3 19
How to Set Controller ................................................................................ 3 27

Troubleshooting ...................................................................................... 3 30
Starter System .......................................................................................... 3 30
Gauges ..................................................................................................... 3 30
Lighting System ........................................................................................ 3 31
Alarm Unit ................................................................................................. 3 31
Battery ...................................................................................................... 3 32

FC (Finger-Tip-Control System) ................................................................ 3 33

1. Preparatory steps .............................................................................. 3 33
2. Connecting the GSE to the controller ................................................ 3 35
3. Troubleshooting cases as examples .................................................. 3 36
4. How to move the mast in an emergency ............................................ 3 48
5. How to clean harness connectors and system components .............. 3 52
6. Troubleshooting guide for solenoid control valves .............................. 3 53
7. Troubles Conceivable for Each Component ....................................... 3 53

Electrical Schematics ........................................................................... 3 55

ELECTRICAL SYSTEM

Structure and Functions

Console Box
1
2
3
4
5
6
7
8
9

Engine coolant temperature gauge

Travel speed select switch
Fuel gauge (for diesel-engine models)
Service hourmeter
OK monitor
Starter switch
Lighting switch
Fuse box
Auto-light switch (for FC models)

103249

3-1

ELECTRICAL SYSTEM

OK Monitor

103239

Function

No.

Indicator light

OFF

ON or flickering

Remarks

Powershift transmission oil temp. indicator light

Normal

Overheating

Air cleaner element indicator light

Normal

Clogged

Brake fluid level indicator light

Normal

Low

Engine oil pressure indicator light

Normal

Low

Alternator not charging indicator light

Normal

Abnormal

Heater plug indicator

Normal

LP-Gas residual pressure alarm lamp

Normal

Drain water

Option

System indicator light

Normal

Abnormal

FC models

Engine coolant level indicator light

Normal

Low

Option

Option

Diesel-engine
models

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
position. (The indicator lights will go OFF when the engine starts.)

Truck Model

Indicator light No.

MC diesel-engine model

1, 2, 3, 4, 5, 6

MC LPG-engine model

1, 2, 3, 4, 5

FC diesel-engine model

1, 2, 3, 4, 5, 6, 8

FC LPG-engine model

1, 3, 4, 5, 8

3-2

(ON)

ELECTRICAL SYSTEM

Sub Panel
The sub panel is mounted at the right front pillar of the
head guard.

104794

1st speed mode/automatic mode selector switch

(For 5 Ton Model as standard and others as
optional)
Automatic mode
(1st speed

2nd speed)

1st speed mode

Select the 1st speed mode for operating in the

speed-limit area [14 km/h (8.7 mph) max.],
climbing or traction.
104789

104575

Driving interlock indicator lamp

Flickers if the operator leaves the seat with the
direction lever in the forward or reverse position
while the engine is running.

Neutral indicator lamp

Glows when the direction lever is placed in
Neutral (N) position.

ECM warning light (GASOLINE)

(IF EQUIPPED)
Glow when ECM (engine control module) is
abnormal.
Consult your Cat lift truck dealer.

3-3

ELECTRICAL SYSTEM

Electrical Components Mounted on Body

208773

1
2
3
4
5
6

Main harness
Fusible link (R.H.)
Fusible link (L.H.)
Fuse
Fuse
Power relay (FC model)

7
8
A:
B:

3-4

System harness
Harness (tilt earth)
To forward/reverse lever
To turn signal switch

ELECTRICAL SYSTEM

Disassembly and Reassembly

Console Box

208774

Disassembly

Reassembly

1. Disconnect the electrical wires at connectors 1.

To reassemble the console box, follow the reverse of

disassembly procedure.

(Disconnect the choke cable on the engine side.)

2. Remove four screws 2 securing the cover.
3. Remove six screws 3 and separate the front and
rear panels.
4. Remove four screws 4 securing the instrument
panel.

NOTE
To replace the instrument panel bulbs, remove
screws 3 and 4.

3-5

ELECTRICAL SYSTEM

Console Box

208789

Disassembly

Reassembly

1. Remove two screws 1 securing the cover. (Use a

flat-tip screwdriver)

To reassemble the console box, follow the reverse of

disassembly sequence.

2. Remove six screws 2 and separate the front and

rear panels.
3. Remove four screws 3 securing the instrument
panel.

NOTE
To replace the instrument panel bulbs, remove
screws 2 and 3.

3-6

ELECTRICAL SYSTEM

Components in Console Box

9
6
5

4
3
2
7

208556

1
2
3
4
5

Power relay
Power relay (diesel-engine models)
Turn signal relay
Glow plug relay (diesel-engine models)
Glow plug timer (diesel-engine models)

6
7
8
9

3-7

Lighting switch
Starter switch
Fuses
Travel speed select switch

ELECTRICAL SYSTEM

Combination Meter
Disassembly

2
3
4

7
8
9
206480

Sequence
1
2
3
4
5

Instrument panel
Dial
Engine coolant temperature gauge
Service hourmeter
Fuel gauge (diesel-engine models)

6
7
8
9

Meter case
Printed circuit plate
Bulb
Socket

CAUTION

Be careful not to damage the printed circuit

plate when disassembling the combination
meter.

Reassembly

Bulb replacement

To reassemble the combination meter, follow the

reverse of disassembly sequence.

For bulb replacement, remove the socket from the

printed circuit plate by turning it to the left. For
configuration of the indicator lights, refer to the
preceding section OK Monitor.
3-8