caterpillar GP40K, GP40KL, GP45K, GP50K, DP40K, DP40KL, DP45K, DP50K Lift Trucks Service Manual PDF

This service manual is a guide for servicing Cat® lift trucks.
Service manual contains repair and maintenance information, service instructions, schematics and circuits for caterpillar lift trucks GP40K, GP40KL, GP45K, GP50K, DP40K, DP40KL, DP45K, DP50K.
This manual helps to remove all the existing problems and faults.
This service manual represents detailed description of service and maintenance procedures, special instructions, technical specifications.
Service manual comes in PDF format, includes 420 pages. All pages are printable. We recommend to use Adobe PDF Reader, to be sure all images / graphics will display correctly.

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

GROUP INDEX:

• 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
• HYDRAULIC SYSTEM
  • 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
• MASTS AND FORKS
  • Structure,
  • Removal and Installation,
  • Disassembly and Reassembly,
  • Inspection and Adjustment,
  • Troubleshooting,
  • Service Data
• 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
• OPTIONS
  • Radiator Screen Kit,
  • Radiator Plate-Fin Type Kit,
  • Elevated Exhaust Kit,
  • Anti-corrosion Radiator Kit,
  • Front Axle Breather Kit,
  • Pre-cleaner Kit