Caterpillar Cat DP40L Forklift Lift Trucks Service Repair Manual SN4CP-10001 and up

99739-84100

GP40, GPL40; DP40, DPL40, DP45, DP50 Chassis & Mast

For use with: 6G72 Gasoline, S6S Diesel Engine Service Manual

FOREWORD This service manual is a guide to servicing of Caterpillar Lift Trucks. The instructions are grouped by systems to serve the convenience of your ready reference.

Long productive life of your lift trucks depends to a great extent on correct servicing—the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing.

Caterpillar reserves the right to change specifications or design without notice and without incurring obligation.

The gasoline models (GP40/GPL40) are powered by Caterpillar 6G72-32FD gasoline engine. The diesel models (DP40/DPL40/DP45/DP50) are powered

by Caterpillar S6S diesel engine.

Pub.No. 99739-84100

GROUP INDEX

Group

Items involved

General

Serial number locations, Dimensions, Technical data

1

Cooling system

Fan removal and installation, Fan belt adjustment

2

Electrical system

Console box, Chassis electrical devices, Care of the battery, Schematic

3

Power train

Removal and installation

4

Clutches

Dry type clutch, Wet type clutch, Pressure plate assembly, Clutch booster, Clutch master cylinder, Clutch release cylinder, Adjustment

5

Manual transmission

Description, Suggestions for removal and installation, Disassembly, Inspection and repair, Reassembly

6

Powershift transmission

Torque converter, 1-speed transmission, Control valve, Automatic 2-speed transmission

7

Front axle and reduction differential

Front tires, Front axle, Reduction and differential

8

Rear axle

Rear axle, Rear tires

9

Brake system

Master cylinder, Wheel brakes, Brake booster

10

Steering system

Steering gear, Power cylinder, Flow divider

11

Hydraulic system

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

12

Masts and forks

Dual-stage panoramic mast

13

Troubleshooting Service data

14 Maintenance standards, Periodic service chart, Periodic replacement parts, Lubrication instructions, Special tools, Inspection guide

15

HOW TO READ THIS MANUAL Disassembly diagram (example)

Each disassembly diagram is followed

by Disassembly sequence and Suggestions for disassembly.

Disassembly sequence

Cover [bolt, washer] (part name) Output shaft (part name) Suggestion for disassembly (1) Output shaft removal

Reassembly diagram (example) Suggestions for installation or assembly of item marked with * are given on the page which follows.

202760

Reassembly sequence

(The same index numbering as that for disassembly is used.)

3

GENERAL INFORMATION

MODEL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

TRUCK MODELS COVERED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

1

GENERAL INFORMATION

MODEL VIEW

100507

TRUCK MODELS COVERED This Service Manual furnishes servicing and maintenance information for the following trucks:

7

GENERAL INFORMATION

SERIAL NUMBER LOCATIONS Nameplate

Chassis serial number

Gasoline engine serial number

206747

Mast serial number 8

Transmission serial number

Diesel engine serial number

GENERAL INFORMATION

DIMENSIONS

202762

9

GENERAL INFORMATION Unit mm [in.]

10

GENERAL INFORMATION

TECHNICAL DATA

11

GENERAL INFORMATION

12

GENERAL INFORMATION

13

GENERAL INFORMATION

14

GENERAL INFORMATION

15

GENERAL INFORMATION

16

GENERAL INFORMATION

17

COOLING SYSTEM

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

INSPECTION AND ADJUSTMENT Fan belt inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Fan belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

2

COOLING SYSTEM

DESCRIPTION

203823

203824

202766

202765

Manual transmission models

1 2 3 4 5 6

Engine Universal joint Gear pump Fan belt Cooling fan Upper hose

Powershift transmission models

7 8 9 10 11

Lower hose Radiator Oil cooler Cooler hoses Tension pulley

21

COOLING SYSTEM

REMOVAL AND INSTALLATION Fan Belt Removal 1. Method by removing radiator

203825

Removal sequence 1 Drain cock 2 Cap 3 Hose 4 Hose Start by: (1) remove the radiator cover.

(2) remove the engine cover and gas springs.

22

5 Radiator 6 Universal joint 7 Tension pulley bolt 8 Belt

COOLING SYSTEM

Suggestions for removal and installation (1) Make sure coolant temperature is low before opening the drain cock. tensioner wrench A (2) Using (91268-04500) through the space between the counterweight and frame (home base plate), loosen the tension pulley bolt.

To loosen this bolt, move tensioner wrench A in the direction of arrow 15 to 20 times. The pulley will not move unless its bolt is not loosened enough. Over-loosening of the bolt, however, would cause the pulley to come off. If the pulley comes off, the counterweight has to be removed for installation of the pulley.

203460

(3) Force the pulley all the way toward the fan and remove fan belt.

Installation

203826

To install, follow the reverse of removal procedure and do the following steps: (1) Turn the fan by hand to make sure it rotates smoothly. If its bearing is noisy, replace it.

(2) After putting the belt on the drive and driven pulleys, push it midway between the pulleys to make sure the tension pulley moves freely. Then, tighten the pulley bolt.

(3) When installing the hoses to the radiator, push each hose over the flared portion of the hose connector of radiator and clamp it there securely.

(4) Pour antifreeze coolant into the radiator and start the engine. Run the engine and check for any abnormal noise. Check the coolant level in the reserve tank.

23

COOLING SYSTEM

2. Method by removing counterweight

203827

Removal sequence 4 Radiator 5 Belt

1 Muffler 2 Fan assembly 3 Universal joint Start by: (1) remove the radiator cover.

(2) remove the counterweight bolts.

Attach a hoist counterweight and lift it off.

mounting to the

NOTE Check the weight of counterweight in attaching the hoist.

24

COOLING SYSTEM

Suggestions for removal and installation (1) Unscrew the fan support bolts. Slide the belt from the driven pulley, then remove the fan assembly. Lay the fan assembly on the bench with the fan support down. Turn the fan by hand to check the bearing. Replace the bearing if it is noisy.

(2) Remove two bolts at the bottom of radiator. Loosen two bolts at the top of radiator.

Only loosen

(3) Force the radiator toward the engine and slide the belt from the tension pulley, letting it fall onto the universal joint.

203463

Installation To install, follow the reverse of removal procedure and do the following steps: Fan assembly installation (1) Place the belt over the driven pulley (fan assembly) and tighten one bolt only until snug at the bottom of fan support. Loosen the tension pulley bolt. Move the top of fan support to the mounting boss (frame) and bolt it there.

(2) Push the belt midway between the drive and driven pulleys through the space between fan blades to make sure the tension pulley moves freely, then tighten the tension pulley bolt.

Tension Pulley bolt

203828

25

COOLING SYSTEM

INSPECTION AND ADJUSTMENT Fan Belt Inspection (1) Check to make sure the belt is free of oil, grease or other foreign matter.

Replace the belt if necessary. A slightly dirty belt can be re-used by cleaning with cloth or paper. Do not attempt to clean the belt with gasoline or the like.

(2) At the time of overhauling the engine or adjusting the belt tension, closely check the belt and replace it if defective.

Fan Belt Adjustment (1) Trucks with standard muffler Remove the counterweight.

grille

from

the

(2) Using ratchet wrench B with extension through the vent in the counterweight, loosen the tension pulley bolt 3 to 4 turns.

(3) The belt will be properly tightened by the tension spring.

Tighten the tension pulley bolt.

203465

2. Trucks with non-standard muffler (1) Remove the radiator cover.

(2) Using tensioner wrench A through the space between the counterweight and frame (home base plate):, loosen the tension pulley bolt 3 to 4 turns.

NOTE Refer to the topics, 1. Method by removing radiator, Fan Belt Removal.

203826

26

COOLING SYSTEM

(3) The belt will be automatically tightened. Tighten the pulley bolt.

(4) Install the radiator cover.

3.

Trucks having an access hole on left rear side

(1)

Remove the cover from the access hole.

(2)

Using ratchet wrench C through the access hole, loosen the tension pulley bolt 3 to 4 turns.

(3)

The belt will be properly tightened by the tension spring. Tighten the tension pulley bolt.

The following hole:

trucks

have

the

access 203767

27

ELECTRICAL SYSTEM

DESCRIPTION Console box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis electrical devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 33

MAJOR ELECTRICAL COMPONENTS Starter switch (with anti-restart lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lighting switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Buckup light switch (manual transmission models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Neutral switch (powershift transmission models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 36 36 37 37 38 39 39

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

40

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

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

Console box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components in console box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combination meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 44 45 47

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

49

3

ELECTRICAL SYSTEM

DESCRIPTION Console Box 1 2 3 4 5 6 7 8 9

Engine coolant temperature gauge Choke control Fuel gauge Service hour meter OK monitor Starter switch Light switch Fuse box Speed selector switch

102389A

31

ELECTRICAL SYSTEM

OK monitor

102392

How to check indicator light bulbs The bulbs are normal if the indicator lights 1, 2, 6 and 7 come ON when the starter switch key is turned to | (ON) position. (The indicator lights will go OFF when the engine starts.)

32

ELECTRICAL SYSTEM

Chassis Electrical Devices 1ST SPEED/AUTO selector switch Power source

Electronic control unit Solenoid valve Backup light switch (for manual tranmission models) (Backup lights for powershift transmission models are controlled by neutral switch located under dashboard.)

Horn

Fusible link

Fuse box Travel speed sensor (pulse generator)

Backup buzzer

Sender unit (powershift transmission oil temperature sensor)

Ground on body

Spare terminal

Brake fluid lever sensor

Fuel tank unit Ground on body Stop light switch

The electrical system is divided into engine electrical system and chassis electrical system.

Following are the components involved in the chassis electrical system:

(4) Instruments The circuit is a one-wire negative-ground system.

(1) Wire and fuses (2) Lighting system: Head lights, working light and backup lights (3) Signaling system: Turn signals, clearance lights, tail/stop lights, license plate light and horn

33

ELECTRICAL SYSTEM

Sensors

Sender unit (powershift transmission oil temperature sensor)

Dust indicator switch (option)

Travel speed sensor (pulse generator)

Brake fluid level sensor

Coolant sensor (option)

206749

The gasoline and diesel models use the following sensors. Each sensor senses a change in physical quantity and converts that change into a useful input signal for the OK monitor built in the console box.

(1) Brake fluid level sensor (2) Coolant sensor (option) (3) Dust indicator switch (option) (4) Travel speed sensor (standard for DP50, optional for GP40/GPL40 and DP40/DPL40/DP45) (5) Powershift transmission oil temperature sensor 34

ELECTRICAL SYSTEM

MAJOR ELECTRICAL COMPONENTS Starter Switch (with Anti-Restart Lock) This switch has a built-in anti-restart lock, so the key cannot be turned from I (ON) to (START) position while the engine is running. The gasoline and diesel models use the same starter switch. In

the diesel models, I (ON) position of the switch is for energizing the glow plugs.

203561A

35

ELECTRICAL SYSTEM

Lighting Switch

206481

Turn Signal Switch

203573

36

ELECTRICAL SYSTEM

Backup Light Switch (Manual Transmission Models)

ON

OFF Shift rail (for FORWARD 2 mm [0.08 in.] and REVERSE)

4 mm [0.16 in.]

Backup light switch

Transmission case

M 12 x 1.75

200013 203576

Fuel Tank Unit

To fuel gauge To ground

Indication accuracy

203574

37

ELECTRICAL SYSTEM

Neutral Switch (Powershift Transmission Models)

Connection chart

N (BR)

R (BrB)

BI (WL)

BII (GW) 206750

38

ELECTRICAL SYSTEM

Fuse Box

102607

Spare Terminals The spare terminal cord extends from the fuse box in the console box. (Another spare terminal is located on the chassis-side main harness.)

Cord color: Lg (yellowish green) Removing the console box rear panel will expose this spare terminal which is fastened to the harness protector with vinyl tape.

Spare Terminal

206424

39

ELECTRICAL SYSTEM

LIGHT BULB SPECIFICATIONS

206751

40

ELECTRICAL SYSTEM

BATTERY MAINTENANCE 1. State of charge and electrolyte specific gravity adjustment

2. Specific gravity reading and state of charge To check the battery for state of charge, take hydrometer readings on its electrolyte. The battery may be fully charged if the S.G. reading is 1.280 to 1.265 at 20째C [68째F]. The state of charge can be told from the way the electrolyte level goes down to expose the cell plates. If addition of distilled water is necessary every month or so, the battery is overcharged. If addition is not required for more than 3 months, it is likely that the battery is inadequately charged.

(4) When connecting the cables to the battery, begin with the cable for the positive (+) terminal. When disconnecting them from the battery, begin with the cable for the negative (-) terminal.

CAUTION Be sure to turn OFF the starter switch and light switch before disconnecting or connecting the battery cables to prevent the IC regulator from suffering damage.

3. Charging precautions (1) In slow charging, the charging current should be about 1/10 the capacity of the battery to be charged.

(2) In quick charging, the battery capacity in ampere should not be exceeded.

(3) During charging, adjust the charging current to prevent the elFectrolyte temperature from rising beyond 45째C [ 113째F].

41

ELECTRICAL SYSTEM

Precautions for servicing charging system (with alternator) The alternator is equipped with a built-in IC (integrated circuit) voltage regulator. When servicing the charging system, pay attention to the following precautions: (1) Do not reverse the polarity of the battery.

Terminal L

(2) Do not disconnect the battery terminal while the engine is running.

(3) Do not ground the terminal L. (4) Do not short the terminals L and R. (5) Do not direct a blast of steam cleaner to the alternator. Remember, a blast of steam will damage the IC regulator.

42

Terminal R

Terminal B 2027721

ELECTRICAL SYSTEM

DISASSEMBLY AND REASSEMBLY Console Box

206422

Reassembly

Disassembly 1. Disconnect the electrical wires at connectors 1.

(In the gasoline models, disconnect the choke cable on the engine side.)

To reassemble the console box, follow the reverse of disassembly procedure.

2. Remove screws 2 (four) securing the cover.

3. Remove screws 3 (six) and separate the front and rear panels.

4. Remove screws 4 (four) securing the instrument panel.

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

43

ELECTRICAL SYSTEM

Components in Console Box

206423

1 2 3 4

44

Power relay Power relay Turn signal relay Glow plug relay (diesel models)

5 6 7 8

Glow plug timer (diesel models) Light switch Starter switch Fuses

ELECTRICAL SYSTEM

Combination Meter Disassembly

206480

Sequence 1 2 3 4 5

Instrument panel Dial Engine coolant temperature gauge Service hour meter Fuel gauge

6 7 8 9

Meter case Printed circuit Bulb Socket

CAUTION Be careful not to damage the printed circuit when disassembling the combination meter.

Bulb replacement Reassembly To reassemble the combination meter, follow the reverse of disassembly procedure.

For bulb replacement, remove the socket from the printed circuit by turning it to the left. For configuration of the indicator lights, refer to “OK Monitor.�

45

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