Caterpillar GP40N, GP45N, GP50CN, GP50N, GP55N, DP40NB, DP45NB, DP50CNB, DP50NB, DP55NB Forklift Service Manual
814 pages · Publication 99739-6B110
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- Models
- GP40N, GP45N, GP50CN, GP50N, GP55N, DP40NB, DP45NB, DP50CNB, DP50NB, DP55NB
- Serial coverage
- CT40A-00011-99999
- CT29E-50001-79999
- CT29E-80001-99999
- CT33D-50001-79999
- CT33D-80001-99999
- CT12D-00011-99999
- CT19F-50001-79999
- CT19F-80001-99999
- CT28E-50001-79999
- CT28E-80001-99999
- Manual type
- Service Manual
- Pages
- 814
- Publication
- 99739-6B110
- Condition
- Brand new
What's inside
From the manual's own table of contents: 478 topics. See sample pages (PDF, 571 KB)
- Model View
- Applicable Truck Model
- Serial Number Locations
- Dimensions
- Specifications
- Performance
- Structure
- Removing Fan Belt
- Preparation
- Removal Sequence
- Suggestions for Removal
- Inspecting Fan Belt
- Installing Fan Belt
- Suggestions for Installation
- Inspecting Radiator
- Radiator
- Expansion Tank (Diesel Model Only)
- Radiator Rubber Mount (Rubber Cushion)
- Pressure Cap (Diesel Model)
- Radiator Cap (LPG Model)
- Connecting Hoses
- Coolant
- Draining Coolant
- Refilling Coolant
Show all 478 topics
- Checking Coolant Level
- Troubleshooting
- Chassis Electrical Components and Wiring Outline
- Diesel Model
- LPG Model
- Electrical Components and Location of Each System
- Console Box
- Outline of Console Box
- Removing Meter Panel
- Installing Meter Panel
- Main Electrical Components
- Meter Panel
- Key Switch (Anti-Restart Switch)
- Light Switch and Turn Signal Switch
- Direction (FNR) Switch
- Horn
- Fuel Tank Unit
- Stop Light Switch
- Thermosensor (Engine Coolant Temperature)
- Thermosensor (T/C Oil)
- Parking Brake Switch
- Fuse Box (Diesel Model)
- Fuse Box (LPG Model)
- Relay Box Location (Diesel Model)
- Relay Box Location (LPG Model)
- List of Lights
- Battery and Maintenance
- Battery Specific Gravity Condition and Adjustment
- Relationship Between Electrolyte Specific Gravity and State of Charge 3-33
- Precautions for Battery Charging
- Meter Panel Layout
- Basic Display
- Basic Operation
- When Several Warnings Occur Simultaneously
- Warning Symbol
- Warning Icons
- Optional Functions
- Optional Functions to Use With Wet Disc Brakes (WDB)
- Hour Meter
- Wire Color
- List of Wire Color Codes
- Engine Startup Problem
- Gauge Related Problem
- Light Related Problems
- Warning Device Problem
- Battery Related Problem
- CIRCUIT DIAGRAM FOR LPG MODELS
- Outline
- Main Functions of Controllers
- VCM (Vehicle Control Module)
- Model)
- OCM (Optional Control Module)
- Input/Output Units
- Gateway Controller (Diesel Model Only)
- GSE Connector
- Service Tool
- Service Tool Menus
- Toolbox
- Mast Interlock System
- Function
- Checking Mast Interlock System of VCM Controller
- Active Test Inspection Procedure (LPG Model Only)
- Driving Interlock System
- Controller Function
- Checking Driving Interlock Function
- Seat Belt Warning Icon
- Functions of Seat Belt Warning Icon
- Checking Seat Belt Warning Icon
- Parking Brake Warning Alarm and Warning Icon
- Checking the Operation of Parking Brake Warning Alarm/Icon
- Parking Brake Warning Alarm
- Position
- Harness Codes
- VCM (Diesel Model)
- VCM (LPG Model)
- Input Unit and Output Unit (FC Models, Type A)
- ECM (Diesel Model)
- ECM (LPG Model)
- Meter Panel (Diesel Model)
- Meter Panel (LPG Model)
- Seat Switch
- Direction Lever Switch
- Vehicle Speed Sensor
- T/M Solenoid
- Unload Solenoid
- Lift Lock Solenoid
- Warning Alarm
- Warning Alarm Relay
- Warning Alarm Circuit
- Parking Brake Solenoid
- Truck Status Display and Troubleshooting
- Truck Status Display
- Diagnosis Table (F Code)
- LED Blink Pattern
- Diagnostic Codes and Troubleshooting
- Removal and Installation (MC Model)
- Engine and Transmission Assembly
- Overhead Guard, Covers, and Air Cleaner Element (Diesel Model)
- Overhead Guard, Covers, and Air Cleaner Element (LPG Model)
- Removing Engine and Transmission Related Parts (Diesel Model)
- Removing Engine and Transmission Related Parts (LPG Model)
- Removing Driving Control Related Parts
- Removing Pipes, Hoses, and Radiator (Diesel Model)
- Removing Pipes, Hoses, and Radiator (LPG Model)
- Removing Engine and Transmission Assembly
- Installing Engine and Transmission (Diesel Model)
- Installing Engine and Transmission (LPG Model)
- Removing and Installing Power Train (FC Model)
- Suggestions for Removing Engine Cover and Seat
- Frame)
- Suggestions for Removing Wet Disc Brakes
- Service Data
- Transmission
- Power Flow
- Torque Converter (Diesel Model)
- Torque Converter (LPG Model)
- Powershift Transmission Control
- Control Valve
- Main Regulator Valve
- Description of Parking Brake Actuation
- Emergency Release Method of Parking Brake
- Schematic Diagram of Powershift Transmission Hydraulic System
- Schematic Diagram of Powershift Transmission Hydraulic Pressure
- External View of Powershift Transmission
- Removing Engine and Transmission
- Installation of Engine and Transmission
- Suggestions for Coupling to the Engine (Diesel Model)
- Suggestions for Coupling to the Engine (LPG Model)
- Disassembling Transmission External Parts
- Disassembly Sequence
- Assembling Transmission External Parts
- Assembly
- Disassembling Torque Converter
- Suggestions for Disassembly
- Inspecting and Repairing Torque Converter
- Pilot Boss (Diesel Model Only)
- Assembling Torque Converter
- Assembly Sequence
- Suggestions for Assembly
- Disassembling Transmission
- Inspecting and Repairing Transmission
- Assembling Transmission
- Disassembling F2 Clutch Pack Assembly
- Inspecting and Repairing F2 Clutch Pack Assembly
- Assembling F2 Clutch Pack Assembly
- Disassembling F1 Clutch Pack Assembly
- Inspecting and Repairing F1 Clutch Pack Assembly
- Assembling F1 Clutch Pack Assembly
- Disassembling R1 Clutch Pack Assembly
- Inspecting and Repairing R1 Clutch Pack Assembly
- Assembling R1 Clutch Pack Assembly
- Disassembling Parking Brake Assembly
- Inspecting and Repairing Parking Brake Assembly
- Assembling Parking Brake Assembly
- Disassembling Gear Pump Assembly
- Inspecting and Repairing Gear Pump Assembly
- Assembling Gear Pump Assembly
- Disassembling Control Valve
- Inspecting and Repairing Control Valve
- Assembling Control Valve
- Disassembling Main Regulator Valve
- Inspecting and Repairing Main Regulator Valve
- Assembling Main Regulator Valve
- Measuring Oil Pressure
- Adjusting Brake Inching Pedal
- Adjusting Inching Cable
- Pump Boss
- Pilot Boss
- Flexible Plate
- Clutches
- R1 Clutch Shaft, F1 Clutch Shaft, and F2 Clutch Shaft
- Stator Shaft
- Gear Backlash
- Parking Brake
- Gear Pump
- Control Valve
- Main Regulator Valve
- Dry Brakes
- Wet Disc Brakes
- Removing Front Wheel
- Removal
- Installation
- Removing Brake Shoe and Lining
- Inspecting and Adjusting Brake Shoe and Lining After Removal
- Installing Brake Shoe and Lining
- Removing Front Axle Assembly (Dry Brakes)
- Removing Each Assembly (Dry Brakes)
- (Dry Brakes)
- Disassembly
- Suggestions for Disassembly (Final Reduction)
- Suggestions for Disassembly (Tube Assembly)
- Inspection and Repair
- Removing Front Axle Assembly (Wet Disc Brakes)
- Removing Each Assembly (Wet Disc Brakes)
- (Wet Disc Brakes)
- Inspection and Repair Using Wear Gauge (Wet Disc Brakes)
- Air Leak Test
- Disassembling and Assembling Reduction Differential
- Adjustment
- Structure of Rear Axle
- Main Components
- Specifications for Wheel Alignment and Steering Angle
- Main Components of Wheel Hub Section
- Main Components of Kingpin
- Main Components of Tie Rod Section
- Main components of Steering Cylinder
- Removing and Installing Rear Wheel and Rear Axle Assembly
- Removing Rear wheels
- Removing Rear Wheel and Rear Axle Assembly
- Installing Rear Wheel
- Installing Rear Axle Assembly
- Disassembling and Assembling Wheel Hub
- Disassembling Wheel Hub
- Assembling and Adjusting Wheel Hub
- Disassembling and Assembling Knuckle (Kingpin)
- Removing Kingpin
- Disassembling and Assembling Steering Cylinder
- Removing Cylinder
- Installing Cylinder
- Disassembling Steering Cylinder
- Disassembling and Assembling Tie Rod
- Structure of Brake System
- Wheel Brake
- Parking Brake Valve
- Structure of Wet Disc Brakes
- Wet Disc Brake Assembly
- Parking Brake Valve (Wet Disc Brakes)
- Auto Deceleration Valve (Wet Disc Brake Option)
- Disassembling and Assembling Wheel Brake
- Disassembling Wheel Brake (4.0 to 4.5 Ton Class)
- Disassembling Wheel Brake (5.0C to 5.5 Ton Class)
- Assembling Wheel Brake (4.0 to 4.5 Ton Class)
- Assembling Wheel Brake (5.0C to 5.5 Ton Classes)
- Disassembling and Assembling Wheel Cylinder
- Disassembling Wheel Cylinder (4.0 to 4.5 Ton Class)
- Disassembling Wheel Cylinder (5.0C to 5.5 Ton Classes)
- Inspecting and Repairing Wheel Cylinder After Disassembly
- Assembling Wheel Cylinder
- Disassembling and Assembling Parking Brake Valve
- Disassembling Parking Brake
- Assembling Parking Brake
- Disassembling and Assembling Wet Disc Brake Assembly (Option) 9-28
- Disassembling Wet Disc Brake Assembly
- Inspecting and Repairing Wet Disc Brake Assembly After Disassembly 9-32
- Assembling Wet Disc Brake Assembly
- Disassembling Parking Brake Valve (Wet Disc Brakes)
- Assembling Parking Brake Valve (Wet Disc Brakes)
- (Wet Disc Brake Option)
- Inspecting and Adjusting Brake System
- Operation Test of Automatic Adjuster
- Manual Adjustment
- Adjusting Brake Pedal
- Bleeding Wheel Brake
- Bleeding Parking Brake
- Replacing and Refilling Brake Oil
- Flushing and Bleeding Wet Disc Brakes
- Braking Performance Test
- Measuring Oil Pressure (Wet Disc Brakes)
- Parking Brake Emergency Release
- Structure and Functions
- General
- Steering Valve
- Steering Column
- Disassembling and Assembling Pipes and Hoses
- Suggestions for Disassembly and Assembly
- Disassembling Steering Wheel and Steering Valve
- Installing Steering Wheel and Steering Valve
- Inspection After Installation
- Removing Steering Valve
- Installing Steering Valve
- Disassembling Tilt Lock Lever
- Assembling Tilt Lock Lever
- Disassembling Steering Valve
- Inspection After Disassembly
- Assembling Steering Valve
- Hydraulic Lines Diagram (With MC Control Valve)
- Hydraulic Lines Diagram (With FC Control Valve)
- Hydraulic Lines Diagram (Wet Disc Brakes)
- Hydraulic tank
- Hydraulic Pump (Gear Pump)
- MC Control Valve
- FC Control Valve (Type A)
- FC Control Valve (Type B)
- Flow Regulator Valve (For Models Equipped With FC Control Valve)
- Down Safety Valve
- Lift Cylinder (Second Lift Cylinder for Simplex Mast and Triplex Mast) . 11-10
- Lift Cylinder (First Lift Cylinder for Duplex and Triplex Masts)
- Lift Cylinder (Second Lift Cylinder for Duplex Mast)
- Tilt Cylinder
- Removing Hydraulic Pump
- Installing Hydraulic Pump
- Disassembling Hydraulic Pump
- Inspecting and Repairing Hydraulic Pump
- Assembling Hydraulic Pump
- Test Operation
- Removing Lift Cylinders (Simplex Mast)
- Installing Lift Cylinders (Simplex Mast)
- Removing Lift Cylinders (Duplex and Triplex Masts)
- Installing Lift Cylinders (Duplex and Triplex Masts)
- (Second Lift Cylinder for Simplex Mast and Triplex Mast)
- Disassembling Lift Cylinder (Second Lift Cylinder for Duplex Mast) 11-31
- Disassembly Sequence (4.0 to 4.5 Ton)
- Disassembly Sequence (5.0C to 5.5 Ton)
- Assembling Lift Cylinder (Second Lift Cylinder for Duplex Mast) .11-33
- Suggestions for Assembly (4.0 to 4.5 Ton class)
- Suggestions for Assembly (5.0C to 5.5 Ton class)
- (First Lift Cylinder for Duplex and Triplex Masts)
- Removing Tilt Cylinders
- Installing Tilt Cylinders
- Disassembling Tilt Cylinder
- Inspecting Tilt Cylinder
- Assembling Tilt Cylinder
- Piping
- MC Valve Piping
- FC Valve Piping
- Removing Suction Strainer and Return Filter
- Inspecting Suction Strainer and Return Filter
- Installing Suction Strainer and Return Filter
- Inspection and Adjustment
- Inspecting and Adjusting Hydraulic Tank
- Inspecting Control Valve
- Second Cylinder for Simplex and Triplex Masts
- Second Cylinder for Duplex Mast
- First Cylinder for Duplex and Triplex Masts
- Outline of MC Control Valve
- Hydraulic Line of MC Control Valve
- Component Names of MC Control Valve
- MC Control Valve Function
- Priority Valve Function
- Unload Solenoid Valve Function
- Lift Section Function
- Tilt Section Function
- Attachment Section Function
- Pressure Control Valve Function
- Precautions for Handling MC Control Valve
- Transportation
- Miscellaneous
- Structure and Function of FC Control Valve
- FC Hydraulic System Line
- Valves Function in Hydraulic System
- Bleed-off Valve
- Lift Valve
- Tilt Valve
- Attachment Valve
- Pressure Valve)
- Removing FC Control Valve
- Installing FC Control Valve
- Disassembling FC Control Valve
- Assembling FC Control Valve
- Disassembling Inlet Valve Assembly
- Disassembling Tilt Section
- Disassembling Attachment Section
- Disassembling End Cover Plate
- Cleaning
- Inspecting End Plate
- General Precautions During Assembly
- Assembling Inlet Valve Assembly (Part 1)
- Assembling Inlet Valve Assembly (Part 2)
- Assembling Inlet Valve Assembly (Part 3)
- and Load Pressure Unload Solenoid Valve
- Assembling Tilt Section
- Assembling Attachment Section
- Assembling End Cover Section
- Simplex Mast
- Mast System
- Removal Sequence of Mast and Lift Bracket Assembly
- Suggestions for Removing Mast and Lift Bracket Assembly
- Suggestions for Installing Mast and Lift Bracket Assembly
- Disassembly Sequence of Mast and Lift Bracket
- Suggestions for Disassembling Mast and Lift Bracket
- Inspecting Mast and Lift Bracket
- Assembly Sequence of Lift Bracket Roller
- Adjusting Lift Bracket Clearance
- Installing Outer/Inner Mast Rollers
- Installing Mast Strips
- Installing Lift Cylinders
- Connecting Chains
- Installing Hydraulic Lines
- Lift Truck
- Inspecting Forks
- Inspecting and Adjusting Chain Tension
- Checking Chain Elongation
- Adjusting Clearance Between Lift Bracket Roller and Inner Mast
- Mast Roller Clearance Adjustment
- Inspecting and Adjusting Mast Strip Clearance
- Mast Tilt Angle Adjustment
- Inspecting and Adjusting Right and Left Lift Cylinder Stroke
- Duplex Mast
- Preparation for Disassembling Mast and Lift Bracket
- Lift Bracket Clearance Adjustment
- Installing Second Lift Cylinder
- Installing First Lift Cylinder
- Mast Strip Clearance Inspection and Adjustment
- Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke
- Triplex Mast
- Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke
- Maintenance Schedule
- Tightening Torques for Standard Bolts and Nuts
- Metric Fine Thread
- Metric Coarse Thread
- Periodic Inspection Parts
- Periodic Replacement Parts
- Periodic Replacement Parts (Wet Disc Brake)
- Safety Critical Parts
- Lubrication Schedule
- Lubrication Chart
- Fuel and Lubricant Specifications
- Adjustment Value and Oil Capacity
- Special Tools
- Special Service Tools (MC and FC models)
- Special Service Tools (For FC models)
- Special Service Tools (For Powershift Transmission)
- Radiator Screen Kit
- Semi Under Net Kit
- Large Capacity Radiator Kit
- Low Coolant Indicator Kit (Diesel Model)
- Low Coolant Indicator Kit (LPG Model)
- Strobe Light Kit
- Revolving Light Kit
- Rear Working Light Kit
- Mast LED Head Light Kit
- Armrest FNR Control Kit
- LPG Warning Kit (LPG Model Only)
- Utility Tray Kit (MC Model Only)
- Fire Extinguisher Kit
- High Overhead Guard Kit
- Low Overhead Guard Kit
- Backup Handle Kit
- Counterweight Hook Kit
- Drawbar Pin Kit
- Torque Converter Cooler Filter Kit
- Hydraulic Oil Cooler Kit
- Dual Air Cleaner Element Kit
- Pre-Cleaner Kit
- Dust Proof Breather Kit (Front Axle)
- Dust Proof Breather Kit (Hydraulic Tank)
- Dust Proof Suction Strainer Kit
- Universal Joint Cover Kit
- Description of Circuit Diagrams
- Circuit Diagrams
- Connector Diagrams
- How to Read Circuit Diagrams
- Symbols
- Sheet Symbol
- Connecting Lines
- Equipment
- Relay Contactor and Coil
- Connectors
- Indication of Connecting Line
- Indication of GND (Earth)
- Indication of Another Specification
- How to Read Connector Diagrams
- Abbreviation
- Circuit Diagram for Diesel Models
Inside this manual
Real pages from this service manual (814 pages). Open the sample pages (PDF, 570 KB)
- Troubleshooting, page 107: CHAPTER 3 ELECTRICAL SYSTEM
- Diagram, page 251: CHAPTER 6 POWERSHIFT TRANSMISSION
- Specifications, page 767: CHAPTER 15 HOW TO READ CIRCUIT DIAGRAMS
- Color page, page 136: CHAPTER 4 CONTROLLER
- Color page, page 189: CHAPTER 4 CONTROLLER
- Foldout diagram, page 113: 8(MCFA:5)W/G
Other manuals for this machine
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This manual: Service Manual 99739-6B110$89.83
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 814 pages
Quantity one is the manual described above.
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Other editions and similar models
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