Caterpillar GP40N-55N, DP40NB-55NB Chassis and Mast Service Manual 99739-6B100
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Caterpillar GP40N-55N, DP40NB-55NB Chassis and Mast Service Manual 99739-6B100

$50.00

  • Type Of Manual: Service Manual
  • Manual ID: 99739-6B100
  • Number of Pages: 780
  • Size: 93.7MB
  • Format: PDF
Category:

Product details

  • Model List:

    • GP40N, GP45N, GP50CN, GP50N, GP55N, DP40NB, DP45NB, DP50CNB, DP50NB, DP55NB
  • 1. FRONT COVER
  • 2. FOREWORD
  • 2.1. Safety
  • 2.2. General Hazard Information When Servicing the Engine
  • 2.3. High Pressure Fuel Lines
  • 2.4. Symbols and Abbreviations
  • 2.5. Units
  • 3. Chapter 1 GENERAL INFORMATION
  • 3.1. Model View
  • 3.2. Applicable Truck Model
  • 3.3. Serial Number Locations
  • 3.4. Dimensions
  • 3.5. Specifications
  • 3.6. Performance
  • 4. Chapter 2 COOLING SYSTEM
  • 4.1. Specifications
  • 4.2. Structure
  • 4.3. Removing Fan Belt
  • 4.4. Inspecting Fan Belt
  • 4.5. Installing Fan Belt
  • 4.6. Inspecting Radiator
  • 4.7. Connecting Hoses
  • 4.8. Coolant
  • 4.9. Troubleshooting
  • 5. Chapter 3 ELECTRICAL SYSTEM
  • 5.1. Chassis Electrical Components and Wiring Outline
  • 5.2. Console Box
  • 5.3. Main Electrical Components
  • 5.4. Battery and Maintenance
  • 5.5. Meter Panel
  • 5.6. Wire Color
  • 5.7. Troubleshooting
  • 5.8. CIRCUIT DIAGRAM FOR LPG MODELS
  • 6. Chapter 4 CONTROLLER
  • 6.1. Outline
  • 6.2. Main Functions of Controllers
  • 6.3. Service Tool
  • 6.4. Mast Interlock System
  • 6.5. Driving Interlock System
  • 6.6. Seat Belt Warning Icon
  • 6.7. Parking Brake Warning Alarm and Warning Icon
  • 6.8. Harness Codes
  • 6.9. Truck Status Display and Troubleshooting
  • 7. Chapter 5 POWER TRAIN
  • 7.1. Removal and Installation (MC Model)
  • 7.2. Removing and Installing Power Train (FC Model)
  • 7.3. Service Data
  • 8. Chapter 6 POWERSHIFT TRANSMISSION
  • 8.1. Structure
  • 8.2. Removing Engine and Transmission
  • 8.3. Installation of Engine and Transmission
  • 8.4. Disassembling Transmission External Parts
  • 8.5. Assembling Transmission External Parts
  • 8.6. Disassembling Torque Converter
  • 8.7. Inspecting and Repairing Torque Converter
  • 8.8. Assembling Torque Converter
  • 8.9. Disassembling Transmission
  • 8.10. Inspecting and Repairing Transmission
  • 8.11. Assembling Transmission
  • 8.12. Disassembling F2 Clutch Pack Assembly
  • 8.13. Assembling F2 Clutch Pack Assembly
  • 8.14. Disassembling F1 Clutch Pack Assembly
  • 8.15. Inspecting and Repairing F1 Clutch Pack Assembly
  • 8.16. Assembling F1 Clutch Pack Assembly
  • 8.17. Disassembling R1 Clutch Pack Assembly
  • 8.18. Inspecting and Repairing R1 Clutch Pack Assembly
  • 8.19. Assembling R1 Clutch Pack Assembly
  • 8.20. Disassembling Parking Brake Assembly
  • 8.21. Inspecting and Repairing Parking Brake Assembly
  • 8.22. Assembling Parking Brake Assembly
  • 8.23. Disassembling Gear Pump Assembly
  • 8.24. Inspecting and Repairing Gear Pump Assembly
  • 8.25. Assembling Gear Pump Assembly
  • 8.26. Disassembling Control Valve
  • 8.27. Inspecting and Repairing Control Valve
  • 8.28. Assembling Control Valve
  • 8.29. Disassembling Main Regulator Valve
  • 8.30. Inspecting and Repairing Main Regulator Valve
  • 8.31. Assembling Main Regulator Valve
  • 8.32. Inspecting and Repairing Main Regulator Valve
  • 8.33. Adjusting Brake Inching Pedal
  • 8.34. Adjusting Inching Cable
  • 8.35. Troubleshooting
  • 8.36. Service Data
  • 9. Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 9.1. Specifications
  • 9.2. Structure
  • 9.3. Removing Front Wheel
  • 9.4. Removing Brake Shoe and Lining
  • 9.5. Removing Front Axle Assembly (Dry Brakes)
  • 9.6. Removing Each Assembly (Dry Brakes)
  • 9.7. Disassembling and Assembling Tube Assembly and Final Reduction (Dry Brakes)
  • 9.8. Removing Front Axle Assembly (Wet Disc Brakes)
  • 9.9. Removing Each Assembly (Wet Disc Brakes)
  • 9.10. Disassembling and Assembling Tube Assembly and Final Reduction (Wet Disc Brakes)
  • 9.11. Disassembling and Assembling Reduction Differential
  • 9.12. Troubleshooting
  • 10. Chapter 8 REAR AXLE
  • 10.1. Structure of Rear Axle
  • 10.2. Removing and Installing Rear Wheel and Rear Axle Assembly
  • 10.3. Disassembling and Assembling Wheel Hub
  • 10.4. Disassembling and Assembling Knuckle (Kingpin)
  • 10.5. Disassembling and Assembling Steering Cylinder
  • 10.6. Disassembling and Assembling Tie Rod
  • 10.7. Troubleshooting
  • 10.8. Service Data
  • 11. Chapter 9 BRAKE SYSTEM
  • 11.1. Structure of Brake System
  • 11.2. Structure of Wet Disc Brakes
  • 11.3. Disassembling and Assembling Wheel Brake
  • 11.4. Disassembling and Assembling Wheel Cylinder
  • 11.5. Disassembling and Assembling Parking Brake Valve
  • 11.6. Disassembling and Assembling Wet Disc Brake Assembly (Option)
  • 11.7. Disassembling and Assembling Parking Brake Valve (Wet Disc Brakes)
  • 11.8. Disassembling and Assembling Automatic Deceleration Valve (Wet Disc Brake Option)
  • 11.9. Inspecting and Adjusting Brake System
  • 11.10. Troubleshooting
  • 11.11. Service Data
  • 12. Chapter 10 STEERING SYSTEM
  • 12.1. Structure and Functions
  • 12.2. Disassembling and Assembling Pipes and Hoses
  • 12.3. Disassembling Steering Wheel and Steering Valve
  • 12.4. Installing Steering Wheel and Steering Valve
  • 12.5. Removing Steering Valve
  • 12.6. Installing Steering Valve
  • 12.7. Disassembling Tilt Lock Lever
  • 12.8. Assembling Tilt Lock Lever
  • 12.9. Disassembling Steering Valve
  • 12.10. Assembling Steering Valve
  • 12.11. Troubleshooting
  • 12.12. Service Data
  • 13. Chapter 11 HYDRAULIC SYSTEM
  • 13.1. Structure and Functions
  • 13.2. Removing Hydraulic Pump
  • 13.3. Installing Hydraulic Pump
  • 13.4. Disassembling Hydraulic Pump
  • 13.5. Inspecting and Repairing Hydraulic Pump
  • 13.6. Assembling Hydraulic Pump
  • 13.7. Removing Lift Cylinders (Simplex Mast)
  • 13.8. Installing Lift Cylinders (Simplex Mast)
  • 13.9. Removing Lift Cylinders (Duplex and Triplex Masts)
  • 13.10. Installing Lift Cylinders (Duplex and Triplex Masts)
  • 13.11. Disassembling Lift Cylinder (Second Cylinder for Simplex Mast and Triplex Mast)
  • 13.12. Inspecting Lift Cylinder (Second Cylinder for Simplex Mast and Triplex Mast)
  • 13.13. Assembling Lift Cylinders (Second Cylinder for Simplex Mast and Triplex Mast)
  • 13.14. Disassembling Lift Cylinder (Second Cylinder for Duplex Mast)
  • 13.15. Inspecting Lift Cylinder (Second Cylinder for Duplex Mast)
  • 13.16. Assembling Lift Cylinder (Second Cylinder for Duplex Mast)
  • 13.17. Disassembling Lift Cylinder (First Cylinder for Duplex and Triplex Masts)
  • 13.18. Inspecting Lift Cylinder (First Cylinder for Duplex and Triplex Masts)
  • 13.19. Assembling Lift Cylinders (First Cylinder for Duplex and Triplex Masts)
  • 13.20. Removing Tilt Cylinders
  • 13.21. Installing Tilt Cylinders
  • 13.22. Disassembling Tilt Cylinder
  • 13.23. Inspecting Tilt Cylinder
  • 13.24. Assembling Tilt Cylinder
  • 13.25. Disassembling Flow Regulator Valve (For Models With FC Control Valve)
  • 13.26. Inspecting Flow Regulator Valve (For Models With FC Control Valve)
  • 13.27. Assembling Flow Regulator Valve (For Models With FC Control Valve)
  • 13.28. Piping
  • 13.29. Removing Suction Strainer and Return Filter
  • 13.30. Inspecting Suction Strainer and Return Filter
  • 13.31. Installing Suction Strainer and Return Filter
  • 13.32. Inspection and Adjustment
  • 13.33. Troubleshooting
  • 13.34. Service Data
  • 13.35. Outline of MC Control Valve
  • 13.36. MC Control Valve Function
  • 13.37. Precautions for Handling MC Control Valve
  • 13.38. Structure and Function of FC Control Valve
  • 13.39. Removing FC Control Valve
  • 13.40. Installing FC Control Valve
  • 13.41. Disassembling FC Control Valve
  • 13.42. Assembling FC Control Valve
  • 13.43. Disassembling Inlet Valve Assembly
  • 13.44. Disassembling Tilt Section
  • 13.45. Disassembling Attachment Section
  • 13.46. Disassembling End Cover Plate
  • 13.47. Cleaning
  • 13.48. Inspecting End Plate
  • 13.49. Assembling Inlet Valve Assembly (Part 1)
  • 13.50. Assembling Inlet Valve Assembly (Part 2)
  • 13.51. Assembling Inlet Valve Assembly (Part 3)
  • 13.52. Assembling Electromagnetic Proportional Pressure Control Valve and Load Pressure Unload Solenoid Valve
  • 13.53. Assembling Tilt Section
  • 13.54. Assembling Attachment Section
  • 13.55. Assembling End Cover Section
  • 14. Chapter 12 MAST AND FORKS
  • 14.1. Simplex Mast
  • 14.2. Duplex Mast
  • 14.3. Triplex Mast
  • 15. Chapter 13 SERVICE DATA
  • 15.1. Maintenance Schedule
  • 15.2. Tightening Torques for Standard Bolts and Nuts
  • 15.3. Parts to Be Replaced Periodically
  • 15.4. Lubrication Schedule
  • 15.5. Special Tools
  • 16. Chapter 14 HOW TO READ CIRCUIT DIAGRAMS
  • 16.1. Description of Circuit Diagrams
  • 16.2. How to Read Circuit Diagrams
  • 16.3. How to Read Connector Diagrams
  • 16.4. Abbreviation
  • 17. Chapter 15 CIRCUIT DIAGRAM FOR DIESEL MODELS
  • 17.1. Circuit Diagram for LPG Models
  • 18. BACK COVER
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