Service Manual
99739-36100
For use with G6 (GM4.3L), S6S Engine Service Manual
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
GP40K, GP40KL, GP45K, GP50K; DP40K, DP40KL, DP45K, DP50K Chassis & Mast
GENERAL INFORMATION
Modelview,Truckmodelscovered,Serialnumberlocations, Dimensions,Technicaldata
COOLING SYSTEM
Fanremovalandinstallation,Fanbeltinspectionandadjustment
ELECTRICAL SYSTEM
POWER TRAIN
CLUTCHES
MANUAL TRANSMISSION
POWERSHIFT TRANSMISSION
FRONT AXLE AND REDUCTION DIFFERENTIAL
REAR AXLE
BRAKE SYSTEM
STEERING SYSTEM
HYDRAULIC SYSTEM
MASTS AND FORKS
SERVICE DATA OPTIONS
Consolebox,Chassiselectricaldevices,Lampbulbspecifications, Batterymaintenance,Electricalsystemschematic
Removalandinstallation
Drytypeclutch,Wettypeclutch,Pressureplateassembly,Clutchbooster, Clutchmastercylinder,Clutchreleasecylinder,Adjustment
Description,Suggestionsforremovalandinstallation,Disassembly, Inspectionandrepair,Reassembly
Torqueconverter,1-speedtransmission,Controlvalve, Automatic2-speedtransmission,Solenoidvalve,Hydrauliccontrol
Fronttires,Frontaxle,Reductionanddifferential
Reartires,Rearaxle,Toe-in,Minimumturningradius
Mastercylinder,Wheelcylinders,Wheelbrakes,Brakebooster
Steeringgear,Powercylinder,Flowdivider
Hydraulictank,Gearpump,Controlvalve,Liftandtiltcylinders, Flowregulatorvalve,Downsafetyvalve
Simplexmast,Duplexmast,Triplexmast
Maintenancestandards,Periodicservicechart,Periodicreplacement parts,Lubricationinstructions,Specialtools
Radiatorscreenkit,Radiatorplate-fintypekit,Elevatedexhaustkit. Headlampkit(installedonmast),Taillampupperrelocatekit,etc.
GROUP INDEX Items GROUP INDEX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
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
Model View
103190
Truck Models Covered
ThisServiceManualfurnishesservicingandmaintenance informationforthefollowingtrucks:
TruckmodelTransmissionModelcode–SerialnumberEnginemounted
GP40KPowershiftT29B–00011-upG6(GM4.3L)gasolineengine
GP40KLPowershiftT29B–50001-upG6(GM4.3L)gasolineengine
GP45KPowershiftT29B–80001-upG6(GM4.3L)gasolineengine
GP50KPowershiftT33A–50001-upG6(GM4.3L)gasolineengine
DP40K Manual T19C–00011-upMitsubishiS6Sdieselengine Powershift
DP40KL Manual T19C–50001-upMitsubishiS6Sdieselengine Powershift
DP45K Manual T19C–80001-upMitsubishiS6Sdieselengine Powershift
DP50KPowershiftT28B–50001-upMitsubishiS6Sdieselengine
1-1 GENERAL INFORMATION
GENERAL INFORMATION
Serial Number Locations
Name plate
Chassis serial number
(Gasoline- and LP-Gasengine models)
(Diesel-engine models)
(Gasoline- and LP-Gas-engine models)
(Diesel-engine models)
1-2
Transmission serial number Mast serial number Engine serial number 202761A
Chassis and Mast Model Identification
[Chassis]
GP40K
Generationdesignator
Maximumcapacity/Loadcenter
40:4000kg(8000lb)/500mm(20in.)
40L:4000kg(8000lb)/600mm(24in.)
45:4500kg(10000lb)/600mm(24in.)
50:5000kg(11000lb)/600mm(24in.)
Enginetype
GP:gasolineenginetype
DP:dieselenginetype [Mast] 4V40A30
Maximumliftingheight [“30”standsfor3000mm(118in.)]
Orderoftheminorchange (“A”fortheoriginal,“B”forthefirstchange,“C”for thesecondchange,andsoon)
Applicabletruckmodeldesignation
40:4tonclass
40L:4tonclass
45:4.5tonclass
50:5tonclass
Kindofmast
V:simplexmast
F:duplexmast
M:triplexmast
Majorchange (“2”fortheoriginal,“3”forthefirstchange,andso onupto“9”)
1-3 GENERAL INFORMATION
1-4 GENERAL INFORMATION GKC L B H A J E I P M F O N D 202762A
Dimensions
Unit:mm(in.)
Ref.TruckModelGP40KGP40KLGP45KGP50K No.ItemDP40KDP40KLDP45KDP50K
A Maximumlift3000(118)
B Freelift150(5.9)160(6.5)
C Forkspread(outside)300to1190(12to47)
D Forklength1070(42)1220(48)
E Tiltangle(forward–backward)6°–12°
F Overalllength4140419042454525
Singletire1415(55.7)1460(57.5)
G Overallwidth(outsideoftires)
Dualtire1780(70.1)1965(77.4)
H Overallheight(totopofmastlowered)2170(85.4)2250(88.6)
I Overallheight(totopofoverheadguard)2250(88.6)
J Overallheight(mastextended)4270(168.1)4290(168.9)
Singletire1175(46.3)
K Tread(front) Dualtire1310(51.6)
L Tread(rear)1180(46.5)
M Wheelbase2000(78.7)2150(84.6)
N Frontoverhang557(21.9)562(22.1)582(22.9)
O Rearoverhang513(20.2)563(22.2)613(24.1)573(22.6)
P Underclearance(atframe)252(9.9)
1-5
GENERAL INFORMATION
(163.0)(165.0)(167.1)(178.2)
GENERAL INFORMATION
Technical Data
TruckModelGP40KGP40KLGP45KGP50K
ItemDP40KDP40KLDP45KDP50K
ModelcodeGP:T29BGP:T33A DP:T19CDP:T28B
TypeStandard
Capacity/loadcenter4000/5004000/6004500/6005000/600 kgf/mm(lbf/in.)(8000/20)(8000/24)(10000/24)(11000/24)
Maximumliftmm(in.)3000(118)
Liftspeed(rateload)GP:510(100)GP:440(87)GP:430(85) mm/sec(fpm)DP:500(98)DP:430(85)DP:420(83)
Loweringspeed(rateload)500(98) mm/sec(fpm)
Tiltangle(forward–backward)6°–12°
MinimumSingletire2360(92.9)2400(94.5)2450(96.5)2510(98.8) intersectingaisle
mm(in.)Dualtire2490(98)2520(99.2)2570(101.2)2740(107.9)
FronttiresSingletire8.25-15-12PR(I)300-15-18PR(I) (sizeandinflation800(8.2)[116]800(8.2)[116] pressure)
kPaDualtire7.50-16-12PR(I)8.25-15-12PR(I) (kgf/cm2)[psi]800(8.2)[116]800(8.2)[116]
Reartires(sizeandinflation7.00-12-12PR(I)7.00-12-12PR(I) pressure)kPa(kgf/cm2)[psi]800(8.2)[116]800(8.2)[116]
Singledrivetire(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)
Dualdrivetire(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)
1-6
Freeliftmm(in.)150(5.9)160(6.5) TravelspeedofForward19.5(12.1)19.5(12.1)19.5(12.1)23.5(14.6) powershift transmissionmodels km/h(mph)Reverse19.5(12.1)23.5(14.6) Minimumturningradius2735277528202965 mm(in.)(107.7)(109.3)(111)(116.7) Inside83° Steeringangle Outside56°33’
General Performance Tires Truck weight
Engine (gasoline and LP-gas)
EnginemodelG6(GM4.3L)
ManufacturerGeneralMotors
TypeGasoline
CoolingsystemWatercooled
No.ofcylinders–arrangement6–90°V
No.ofstrokes4
TypeofcombustionchamberSemi-spherical
ValvearrangementOverhead
TypeofcylinderlinersIntegral
Cylinderbore × stroke101.6 × 88.39 mm(in.)(4.00 × 3.48)
Displacementcc(cuin.)4293(262)
Compressionratio9.2:1
RatedoutputkW/rpm68/2450
Ratedtorque310(31.0)[224]/1200 N·m(kgf·m)[lbf·ft]/rpm
Minimumenginespeedrpm750to800
Maximumenginespeedrpm2600to2650
Dimensions(L × W × H)710 × 620 × 740 mm(in.)(28.0 × 24.4 × 29.1)
Weightkg(lb)260(573)
InstallationpositionRear
IgnitionSpark
Firingorder1–6–5–4–3–2
Initialignitiontiming0°Gasoline8°L.P.G. BTDCdeg
Fueltankcapacity115(30) liter(U.S.gal)
1-7
INFORMATION
GENERAL
TruckModel GP40KGP40KLGP45KGP50K Item
GENERAL INFORMATION
Item
TruckModel GP40KGP40KLGP45KGP50K
IgnitionTypeMold coilManufacturerACDelco
TypePointless
DistributorManufacturerACDelco
TypeofsparkInternalsolidstatecircuit advancecontrol
Model#41-932
ManufacturerACDelco
Sparkplug
Sizemm(in.)14(0.55)
Gapmm(in.)1.24(0.0488)
Type1FZ
Carburetor
ManufacturerASIANKogyoCo.
TypeElectromagnetic
Fuelpump
ManufacturerJidoshaKiki
Type × NumberCyclonewithpaperelement × 1
ManufacturerNipponRokaki
TypePressurefeed
OilpumpGearpump
OilfilterPaperelement
OilcoolerOiltowatertype Oilpan4.2(1.1) liter(U.S.gal)
RefillOilfilter&cooler0.8(0.2) capacitiesliter(U.S.gal)
Total5.0(1.3) liter(U.S.gal)
1-8
Engine lubrication systemFuel systemIgnition system Air cleaner
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Item
Battery AlternatorCooling system Starter
TruckModel GP40KGP40KLGP45KGP50K
TypeForcedcirculation
RadiatorCorrugatedfinwithpressuretype
Refillcapacityliter(U.S.gal)11(2.9)
WaterpumpCentrifugaltypedrivenbyV-belt
ThermostatWaxtype
Type × number48D26L
VoltageV12
CapacityAH(5Hr)50
Type3-phaseAC
ManufacturerMANDO
RatedoutputV–A12–50
RegulatorBuilt-inICtype
TypeElectromagnetic
ManufacturerDelcoRemy
Voltage–outputV–kW12–0.75
1-9 GENERAL INFORMATION
GENERAL INFORMATION
TruckModel
DP40KDP40KLDP45KDP50K
Item
EnginemodelS6S
ManufacturerMitsubishiHeavyIndustries,Ltd.
TypeWater-cooled,4-strokecycle
No.ofcylinders–arrangement6–in-line
TypeofcombustionchambersSwirl
ValvearrangementOverhead
TypeofcylinderlinersDry
Bore × strokemm(in.)94 × 120(3.70 × 4.72)
Displacementcc(cuin.)4996(305)
Compressionratio22:1
RatedoutputkW/rpm62.5/2450
Maximumtorque250(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)
InstallationpositionRear
IntakeOpenBTDCdeg30°
valvesCloseABDCdeg50°
ExhaustOpenBBDCdeg74°
valvesCloseATDCdeg30°
Intakevalves
Valvemm(in.)
clearance0.25(0.0098) (atcold)Exhaustvalves mm(in.)
IgnitionCompression
Firingorder1–5–3–6–2–4
Ignitionorinjectiontiming19°
BTDCdeg
1-10
Engine (diesel)
