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

Removal and installation

Power train 4
Dry type clutch, Wet type clutch, Pressure plate assembly, Clutch booster,
Clutches
Clutch master cylinder, Clutch release cylinder, Adjustment 5
Description, Suggestions for removal and installation, Disassembly,
Manual transmission
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

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
Hydraulic system
Down safety valve 12

Masts and forks Dual-stage panoramic mast 13

Troubleshooting 14
Maintenance standards, Periodic service chart, Periodic replacement parts,
Service data
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
1
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
 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 Transmission serial number Diesel engine serial number

8
 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

202765 202766
Manual transmission models Powershift transmission models

1 Engine 7 Lower hose

2 Universal joint 8 Radiator
3 Gear pump 9 Oil cooler
4 Fan belt 10 Cooler hoses
5 Cooling fan 11 Tension pulley
6 Upper hose

21
COOLING SYSTEM

REMOVAL AND INSTALLATION

Fan Belt Removal

1. Method by removing radiator

203825

Removal sequence

1 Drain cock 5 Radiator

2 Cap 6 Universal joint
3 Hose 7 Tension pulley bolt
4 Hose 8 Belt
Start by:

(1) remove the radiator cover.

(2) remove the engine cover and gas

springs.

22
 COOLING SYSTEM

Suggestions for removal and installation

(1) Make sure coolant temperature is low

before opening the drain cock.

(2) Using tensioner wrench A

(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 203460
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.

(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
1 Muffler 4 Radiator
2 Fan assembly 5 Belt
3 Universal joint

Start by:

(1) remove the radiator cover.

(2) remove the counterweight mounting

bolts. Attach a hoist to the
counterweight and lift it off.

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
Tension
(1) Place the belt over the driven pulley Pulley
bolt
(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 203828

drive and driven pulleys through the
space between fan blades to make
sure the tension pulley moves freely,
then tighten the tension pulley bolt.

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 grille from the

counterweight.

(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 203465

the tension spring. Tighten the
tension pulley bolt.

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 trucks have the access

hole:
203767

27
 ELECTRICAL SYSTEM

DESCRIPTION

Console box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chassis electrical devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

MAJOR ELECTRICAL COMPONENTS

Starter switch (with anti-restart lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Lighting switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3
Buckup light switch (manual transmission models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel tank unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Neutral switch (powershift transmission models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Spare terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

LIGHT BULB SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DISASSEMBLY AND REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Console box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Components in console box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Combination meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

ELECTRICAL SYSTEM SCHEMATIC (GASOLINE MODELS). . . . . . . . . . . . . . . . . . . . . . . . . 49

 ELECTRICAL SYSTEM

DESCRIPTION

Console Box

1 Engine coolant temperature gauge

2 Choke control
3 Fuel gauge
4 Service hour meter
5 OK monitor
6 Starter switch
7 Light switch
8 Fuse box
9 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

Electronic Power
source
control unit

Solenoid valve

Backup light switch (for manual

tranmission models)
(Backup lights for powershift
transmission models are controlled
by neutral switch located under
Fuse box
dashboard.)

Horn Fusible link Travel speed sensor (pulse generator)

Backup
buzzer
Sender unit (powershift
transmission oil
temperature sensor) Ground
on body

Spare terminal

Fuel tank unit

Brake fluid
lever sensor Stop light Ground on body
switch

The electrical system is divided into engine (4) Instruments

electrical system and chassis electrical system. The circuit is a one-wire negative-ground system.
Following are the components involved in the
chassis electrical 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 Brake fluid level Coolant sensor (option)

(pulse generator) sensor

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 the diesel models, I (ON) position of the switch is
key cannot be turned from I (ON) to (START) for energizing the glow plugs.
position while the engine is running. The gasoline
and diesel models use the same starter switch. In

203561A

35
ELECTRICAL SYSTEM

Lighting Switch

206481

Turn Signal Switch

203573

36
 ELECTRICAL SYSTEM

Backup Light Switch (Manual Transmission Models)

ON OFF Shift rail

4 mm [0.16 in.] 2 mm (for FORWARD Backup light switch
[0.08 in.] and REVERSE)

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 20°C [68°F]. 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 45°C [ 113°F].

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 Terminal R

the engine is running.
Terminal B
(3) Do not ground the terminal L.
2027721
(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
 ELECTRICAL SYSTEM

DISASSEMBLY AND REASSEMBLY

Console Box

206422

Disassembly Reassembly

1. Disconnect the electrical wires at connectors 1. To reassemble the console box, follow the reverse
(In the gasoline models, disconnect the choke of disassembly procedure.
cable on the engine side.)

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 Power relay 5 Glow plug timer (diesel models)

2 Power relay 6 Light switch
3 Turn signal relay 7 Starter switch
4 Glow plug relay (diesel models) 8 Fuses

44
 ELECTRICAL SYSTEM

Combination Meter
Disassembly

206480

Sequence

1 Instrument panel 6 Meter case

2 Dial 7 Printed circuit
3 Engine coolant temperature gauge 8 Bulb
4 Service hour meter 9 Socket
5 Fuel gauge

CAUTION
Be careful not to damage the printed circuit
when disassembling the combination meter.
Bulb replacement
Reassembly
For bulb replacement, remove the socket from the
To reassemble the combination meter, follow the printed circuit by turning it to the left. For
reverse of disassembly procedure. configuration of the indicator lights, refer to “OK
Monitor.”

45
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